Zenith C-30HDG manual 30HDG Pump Inspection, Before Starting, Engine Oil Check

Page 34

CAUTION - General Saftey Guidelines

NEVER operate the pump in a confined area or enclosed area structure that does not provide ample free flow of air.

ALWAYS wear approved eye and hearing protection before operating the pump .

NEVER operate the pumps's engine with the engine hood removed.The possibility exists of hands, long hair, and clothing becoming entangled with the V-belt, causing injury and bodily harm.

NEVER place hands or feet inside the hopper.ALWAYS make while the engine is running. ALWAYS shut-down the engine before performing any kind of maintenance service on the pump.

Before Starting

1.Read safety instructions at the beginning of this manual.

2.Removing any dirt and dust that might have accumulated around the engine cooling air inlet, fuel injection system.

3.Check the air filter for dirt and dust. Ifairfilteris dirty, replace air filter with a new one as required.

4.Check fuel injection system for external dirt and dust.Clean with dry compressed air.

5.Check fastening nuts and bolts for tightness.

6.ConnectBattery

7.Make sure hopper is free of dirt and foreign debris (large objects over 2-inches)

8.Make sure radiator is filled with proper amount of anti-freeze water solution (50/50).

9.Make sure all hose lines are in good condition and are working properly.

Reference manufacturer engine manual for specific servicing instructions.

C-30HDG PUMP — INSPECTION

Engine Oil Check

1.To check the engine oil level, place the pump on secure level ground with the engine stopped.

2.Remove the dipstick from its holder (Figure 13) and wipe it clean.

Figure 13. Engine Oil Dipstick (Removal)

3.Check the engine oil level as shown on the dipstick (Figure 14).

Figure 14. Engine Oil Dipstick

4.Iftheengineoillevelislow,addoilthroughtheengineoilfiller hole (Figure 15) with the recommended oil type (Table 3). Maximum oil capacity is 3.9 quarts (3.7 liters).

Figure 15. Engine Oil Filler Hole

PAGE 34 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

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Contents Model C-30HDG 30HDG Pump Proposition 65WARNING 30HDG Pump SILICOSIS/RESPIRATORYWARNINGS Silicosis WarningTable of Contents Best Deal! Order via Internet Dealers Only Parts Ordering ProceduresOrder via Fax Dealers Only 30HDG Pump Pump Specifications 30HDG Pump Specifications30HDG Pump Pump Dimensions 30HDG Concrete Pump DimensionsStructure that does not provide ample free flow air 30HDG Pump Safety Message Alert SymbolsYou can be injured if you do not follow directions Always wear approved respiratory protection 30HDG Pump Safety Message Alert SymbolsAlways wear approved eye and hearing protection High Temperatures Allow the engine General Safety30HDG Pump Rules for Safe Operation 30HDG Pump Rules for Safe Operation Do not use worn out hoses or couplings inspect dailyLifting Maintenance SafetyEmergencies Page 30HDG Pump -TOWING Guidelines Recommended MaintenancePumpTrailer Vehicle Connection 30HDG Pump -TOWING Guidelines Towing Applications30HDG Pump -TRAILER Safety Guidelines Trailer Safety PrecautionsTiresWear/Inflation 30HDG Pump -TRAILER Safety GuidelinesTires/Wheels/Lug Nuts Torsion Bar SuspensionStart all wheel lug nuts by hand 30HDG Pump -TRAILER Safety GuidelinesLug Nut Torque Requirements NEVER! use an pneumatic air gun to tighten wheel lug nutsPage 30HDG Pump Operation and Safety Decals Operation and Safety Decals30HDG Pump Important Hand Signals Operation Hand Signals30HDG Pump Pump Components Major Pump Components30HDG Pump Pump Components 30HDG Pump Control BOX Components Pump Control Box Components30HDG Pump Engine Components Zenith 416 Basic Engine ComponentsPump Mix Guidelines 30HDG Pump General InformationSample Design Mix 3000 Psi 3/8 in. Slump 4- 5 30HDG Pump HOW IT Works Pumping Cylinder30HDG Pump HOW IT Works Pumping Pistons30HDG Pump Operating Information Operating SuggestionsPumping Tips 30HDG Pump Operating InformationNew Pumps Mbvr air entraining, acts as a lubricant Clearing a Plugged Manifold Stop the pump. Switch OFF the engine Avoiding Setting of the Mix in the System Clearing a Mix from the SystemValveSeats Down-Hill PumpingVerticalPumping PulsationCam Roller 30HDG Pump Operating InformationSnap-Joint Before Starting Read safety instructions at the beginning of this manual30HDG Pump Inspection Engine Oil CheckGasoline Check 30HDG Pump InspectionLubrication Box If cooling water is dirty, flush the cooling system 30HDG Pump INSPECTION/STARTUPChecking Engine Coolant Level Belt DeflectionRemote Control Operation 30HDG Pump STARTUP/SHUTDOWN ProceduresRadio Remote Control Operation General Clean-up Procedure 30HDG Pump Maintenance PumpPreventive Maintenance Always carry extra OringsNever use compressed air to clean out the lines 30HDG Pump Maintenance PumpSponge Clean-out Procedure Piston Cup Wear30HDG Pump Maintenance Pump Crankshaft and Cam Assembly ProcedureFollowing procedure will assist you in replacing the lining Bearing Installation Bearing/Cam Bushing InstallationDetent Hole 3 Installation Detent Holes30HDG Pump Maintenance Pump Roller Chain Application Installation and Drive AlignmentWorking Loads Drive Chain Lubrication Chain-Link Cross SectionAssembling and Disassembling Drive Chain Installation Of CoversidesInstallation of Spring Locks and Cotter-Pins Chain-Link Pin Removal30HDG Pump Enginetroubleshooting Engine TroubleshootingUnions a required 30HDG Pump EnginetroubleshootingFuel tank empty? Replace fuel filter Fuel filter clogged? Engine oil level too full? Correct engine oil level?Malfunction Indicator Diagnostic System 30HDG Pump Engine Fault CodesExample 30HDG Pump Engine Fault Codes GCP ECU Fault Code List for ZZP 416 EngineFuel LPG or NG run-out longer than expected AUX 5V Analog Input 3 low 30HDG Pump -WIRING Diagram Zenith Wiring Harness Zenith Fuel Injection System Wiring Diagram30HDNI Pump -WIRING Diagram Zenith Wiring Harness 30HDG Pump -WIRING Diagram Wiring Diagram30HDG Pump PIN Connections ZPP 416, 420 & 640 Customer 16-PIN Connections30HDG Pump -WIRING Diagram Tail Lights TrailerTail Lights Wiring DiagramPage Appendix C-30HDNI C-30HDNI Slumptest Procedure Slump Test 2/3 FullAppendix C-30HDG Concrete MIX Information Appendix C-30HDG Concrete MIX Information 2685 27082775 2749Appendix Recommended Shotcrete System Recommended Shotcrete SystemGeneral recommendations Appendix Recommended Shotcrete Accessories Recommended Shotcrete AccessoriesAppendix Recommended Shotcrete Accessories Explanation of Code in Remarks Column Xxxxx only Not Used on30HDG Pump Suggested Spare Parts Units30HDG Pump Nameplate and Decals 30HDG Pump Nameplate and Decals 30HDG Pump Compensator Piston ROD Assy Compensator Piston ROD AssyFitting Spring ReturnPiston Guide Assy Bearing CUP30HDG Pump Connecting ROD Drive Side Assy Connecting ROD Drive Side AssyPiston ROD Assy 30HDG Pump Rocker Assy Rocker AssyJournal Block Connecting RODShaft Rocker ARM Bolt 1-14X2 HEX Head30HDG Pump COUNTER-SHAFT Assy Countershaft Assy30HDG Pump COUNTER-SHAFT Assy 30HDG Pump Crankshaft Assy Crankshaft AssyBearing Block 30HDG Pump Crankshaft AssyLock Washer 3/4 30HDG Pump Manifold Assy Manifold Assy30HDG Pump Manifold Assy 30HDG Pump Frame Assy Frame AssyJack STAND, Rear Frame AssemblyAXLE, Assembly Washer Thick30HDG Pump Axle Assy Axle AssyCastle NUT CAP 14 Chrome Includes Items WDust Cover Outer Bearing30HDG Pump MUFFLER, AIR FILTER, and Stop Switch Assy MUFFLER, AIR Filter and Stop Switch AssyStop SWITCH, Engine Cover PRECLEANER, AIR Filter ZE1 ELEMENT, AIR FilterGland Connector FILTER, AIR30HDG Pump Clutch Assy Clutch AssyWASHER, Lock 1/2 Rotor AssemblyClutch Housing W/LINING WASHER, Flat 1/2 Special30HDG Pump Engine Mounting Brackets Assy Engine Mounting Brackets AssySPACER, 20 OD X 11 ID X 32 Long Support BRACKET, RightSupport BRACKET, Left BRACKET, ECU Mount30HDG Pump RADIATOR, Mounting Bracket and Hoses Assy RADIATOR, Bracket and Hoses AssyPart Name 30HDG Pump Control BOX Assy Control BOX AssyCONNECTOR, Plastic SWITCH, Throttle ControlIgnition Switch Ignition Switch KEY30HDG Pump Battery Assy Battery AssyCABLE, Negative Battery CABLE, Positive BatteryBOX, Battery BATTERY, 12 Volt30HDG Pump Fueltank Assy Fuel Tank AssyFILTER, Fuel HOSE, Fuel 5/16CLAMP, Hose Includes Item30HDG Pump Hopper Assy Hopper AssyPIN, Hair HopperWasher 5/8 Flat 30HDG Pump Hood Assy Hood AssyBUMPER, Rubber RivetLatch KIT NUT 1/2-13 Heavy HEX30HDG Pump Lubrication Panel Assy Lubrication Panel AssyCoupling W/NUT 1/8 NPT FITTING, Grease 1/8 NPTStraight Fitting 1/8 NPT 1FT=1PC30HDG Pump Remote Control Cable Assy Remote Control Cable AssyCONNECTOR, 3/16 Ring SWITCH, MicroGuard Switch Aluminum Junction BOXTerms and Conditions of Sale Parts Freight PolicyMayco Pumpwarranty Mechanical Drive ModelsHERE’S HOW to GET Help