Zenith C-30HDG manual 30HDG Pump HOW IT Works, Pumping Cylinder

Page 27

The C-30HDG concrete pump has one main pumping piston which is valved by means of two ball checks. (A inlet, and B outlet.)

The secondary piston is used as a compensator piston to smooth out the pulsations of a single piston action.Note:The compensator will not start operating until material is pumped into the line and back pressure develops.

The compensator spring, which is installed on the compensator piston rod, deflects with each piston stroke.This“spring cushion”, in conjunction with the cam profile, produces and uninterrupted smooth flow of material under average pumping conditions.

The pumping cylinder (Figure 10) retracts drawing the material past the ball (A) and filling the cylinder.The compensator piston is pumping the material out to the nozzle and causing ball (B) to seat preventing the material from returning to the pumping cylinder intake.

C-30HDG PUMP — HOW IT WORKS

An automatic, centrifugal clutch is installed to engage and disengage the pumping action without stopping or starting the engine.The centrifugal clutch is set at 1100 R.P.M.The engine idle speed is approximately 875 R.P.M.; therefore, the clutch is completely disengaged at idle.The throttle settings while pumping should always maintain an engine R.P.M.high enough to prevent the clutch from slipping and burning the clutch lining.

The return spring which is installed on the rocker arm, is installed to eliminate shock and stress between the cam roller and the cam weldment when the pump is in operation. If the return spring is removed or replaced for any reason, maintain the backing plate dimension of 3” as shown on Figure 3, to produce the proper pre-loading of the spring for a smooth performance.

Figure 10. Pumping Cylinder

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 27

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Contents Model C-30HDG 30HDG Pump Proposition 65WARNING Silicosis Warning 30HDG Pump SILICOSIS/RESPIRATORYWARNINGSTable of Contents Parts Ordering Procedures Best Deal! Order via Internet Dealers OnlyOrder via Fax Dealers Only 30HDG Pump Specifications 30HDG Pump Pump Specifications30HDG Concrete Pump Dimensions 30HDG Pump Pump Dimensions30HDG Pump Safety Message Alert Symbols Structure that does not provide ample free flow airYou can be injured if you do not follow directions 30HDG Pump Safety Message Alert Symbols Always wear approved respiratory protectionAlways wear approved eye and hearing protection General Safety High Temperatures Allow the engine30HDG Pump Rules for Safe Operation Do not use worn out hoses or couplings inspect daily 30HDG Pump Rules for Safe OperationMaintenance Safety LiftingEmergencies Page Recommended Maintenance 30HDG Pump -TOWING GuidelinesPumpTrailer Vehicle Connection Towing Applications 30HDG Pump -TOWING GuidelinesTrailer Safety Precautions 30HDG Pump -TRAILER Safety GuidelinesTorsion Bar Suspension 30HDG Pump -TRAILER Safety GuidelinesTires/Wheels/Lug Nuts TiresWear/InflationNEVER! use an pneumatic air gun to tighten wheel lug nuts 30HDG Pump -TRAILER Safety GuidelinesLug Nut Torque Requirements Start all wheel lug nuts by handPage Operation and Safety Decals 30HDG Pump Operation and Safety DecalsOperation Hand Signals 30HDG Pump Important Hand SignalsMajor Pump Components 30HDG Pump Pump Components30HDG Pump Pump Components Pump Control Box Components 30HDG Pump Control BOX ComponentsZenith 416 Basic Engine Components 30HDG Pump Engine Components30HDG Pump General Information Pump Mix GuidelinesSample Design Mix 3000 Psi 3/8 in. Slump 4- 5 Pumping Cylinder 30HDG Pump HOW IT WorksPumping Pistons 30HDG Pump HOW IT WorksOperating Suggestions 30HDG Pump Operating InformationMbvr air entraining, acts as a lubricant 30HDG Pump Operating InformationNew Pumps Pumping TipsClearing a Mix from the System Stop the pump. Switch OFF the engineAvoiding Setting of the Mix in the System Clearing a Plugged ManifoldPulsation Down-Hill PumpingVerticalPumping ValveSeats30HDG Pump Operating Information Cam RollerSnap-Joint Engine Oil Check Read safety instructions at the beginning of this manual30HDG Pump Inspection Before Starting30HDG Pump Inspection Gasoline CheckLubrication Box Belt Deflection 30HDG Pump INSPECTION/STARTUPChecking Engine Coolant Level If cooling water is dirty, flush the cooling system30HDG Pump STARTUP/SHUTDOWN Procedures Remote Control OperationRadio Remote Control Operation Always carry extra Orings 30HDG Pump Maintenance PumpPreventive Maintenance General Clean-up ProcedurePiston Cup Wear 30HDG Pump Maintenance PumpSponge Clean-out Procedure Never use compressed air to clean out the linesCrankshaft and Cam Assembly Procedure 30HDG Pump Maintenance PumpFollowing procedure will assist you in replacing the lining Bearing/Cam Bushing Installation Bearing InstallationDetent Holes Detent Hole 3 Installation30HDG Pump Maintenance Pump Installation and Drive Alignment Roller Chain ApplicationWorking Loads Chain-Link Cross Section Drive Chain LubricationChain-Link Pin Removal Installation Of CoversidesInstallation of Spring Locks and Cotter-Pins Assembling and Disassembling Drive ChainEngine Troubleshooting 30HDG Pump EnginetroubleshootingEngine oil level too full? Correct engine oil level? 30HDG Pump EnginetroubleshootingFuel tank empty? Replace fuel filter Fuel filter clogged? Unions a required30HDG Pump Engine Fault Codes Malfunction Indicator Diagnostic SystemExample GCP ECU Fault Code List for ZZP 416 Engine 30HDG Pump Engine Fault CodesFuel LPG or NG run-out longer than expected AUX 5V Analog Input 3 low Zenith Fuel Injection System Wiring Diagram 30HDG Pump -WIRING Diagram Zenith Wiring Harness30HDNI Pump -WIRING Diagram Zenith Wiring Harness Wiring Diagram 30HDG Pump -WIRING DiagramZPP 416, 420 & 640 Customer 16-PIN Connections 30HDG Pump PIN ConnectionsTrailerTail Lights Wiring Diagram 30HDG Pump -WIRING Diagram Tail LightsPage Slump Test 2/3 Full Appendix C-30HDNI C-30HDNI Slumptest ProcedureAppendix C-30HDG Concrete MIX Information Appendix C-30HDG Concrete MIX Information 2749 27082775 2685Recommended Shotcrete System Appendix Recommended Shotcrete SystemGeneral recommendations Recommended Shotcrete Accessories Appendix Recommended Shotcrete AccessoriesAppendix Recommended Shotcrete Accessories Xxxxx only Not Used on Explanation of Code in Remarks ColumnUnits 30HDG Pump Suggested Spare Parts30HDG Pump Nameplate and Decals 30HDG Pump Nameplate and Decals Compensator Piston ROD Assy 30HDG Pump Compensator Piston ROD AssyBearing CUP Spring ReturnPiston Guide Assy FittingConnecting ROD Drive Side Assy 30HDG Pump Connecting ROD Drive Side AssyPiston ROD Assy Rocker Assy 30HDG Pump Rocker AssyBolt 1-14X2 HEX Head Connecting RODShaft Rocker ARM Journal BlockCountershaft Assy 30HDG Pump COUNTER-SHAFT Assy30HDG Pump COUNTER-SHAFT Assy Crankshaft Assy 30HDG Pump Crankshaft Assy30HDG Pump Crankshaft Assy Bearing BlockLock Washer 3/4 Manifold Assy 30HDG Pump Manifold Assy30HDG Pump Manifold Assy Frame Assy 30HDG Pump Frame AssyWasher Thick Frame AssemblyAXLE, Assembly Jack STAND, RearAxle Assy 30HDG Pump Axle AssyOuter Bearing CAP 14 Chrome Includes Items WDust Cover Castle NUTMUFFLER, AIR Filter and Stop Switch Assy 30HDG Pump MUFFLER, AIR FILTER, and Stop Switch AssyFILTER, AIR PRECLEANER, AIR Filter ZE1 ELEMENT, AIR FilterGland Connector Stop SWITCH, Engine CoverClutch Assy 30HDG Pump Clutch AssyWASHER, Flat 1/2 Special Rotor AssemblyClutch Housing W/LINING WASHER, Lock 1/2Engine Mounting Brackets Assy 30HDG Pump Engine Mounting Brackets AssyBRACKET, ECU Mount Support BRACKET, RightSupport BRACKET, Left SPACER, 20 OD X 11 ID X 32 LongRADIATOR, Bracket and Hoses Assy 30HDG Pump RADIATOR, Mounting Bracket and Hoses AssyPart Name Control BOX Assy 30HDG Pump Control BOX AssyIgnition Switch KEY SWITCH, Throttle ControlIgnition Switch CONNECTOR, PlasticBattery Assy 30HDG Pump Battery AssyBATTERY, 12 Volt CABLE, Positive BatteryBOX, Battery CABLE, Negative BatteryFuel Tank Assy 30HDG Pump Fueltank AssyIncludes Item HOSE, Fuel 5/16CLAMP, Hose FILTER, FuelHopper Assy 30HDG Pump Hopper AssyHopper PIN, HairWasher 5/8 Flat Hood Assy 30HDG Pump Hood AssyNUT 1/2-13 Heavy HEX RivetLatch KIT BUMPER, RubberLubrication Panel Assy 30HDG Pump Lubrication Panel Assy1FT=1PC FITTING, Grease 1/8 NPTStraight Fitting 1/8 NPT Coupling W/NUT 1/8 NPTRemote Control Cable Assy 30HDG Pump Remote Control Cable AssyJunction BOX SWITCH, MicroGuard Switch Aluminum CONNECTOR, 3/16 RingFreight Policy Terms and Conditions of Sale PartsMechanical Drive Models Mayco PumpwarrantyHERE’S HOW to GET Help

C-30HDG specifications

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