Zenith C-30HDG manual 30HDG Pump Maintenance Pump, Crankshaft and Cam Assembly Procedure

C-30HDG PUMP — MAINTENANCE (PUMP)

Crankshaft and Cam Assembly Procedure Ball and Seat Replacement Procedure

1.Setbearingblock(P/NEM14303)intohydraulicpress.Place bearing cup into bearing block and press in evenly.Bearing cupshouldbealignedequallyonbothsidesofbearingblock.

2.Set crankshaft into hydraulic press with the long end to- wards the top. Install spacer (P/N EM14322), O-ring (P/N EM14326) and bearing cone (P/N EM14325) onto crank- shaft. Place bearing block on crankshaft until the bearing cone is riding in the bearing cup.

3.Insert bearing cone spacer (P/N EM14323) onto crankshaft and inside bearing block. Install second bearing cone until it is seated inside bearing cup.

4.Place O-ring and spacer (P/N EM14302) on crankshaft. Set camweldmentontopofspacer.Installcrankshaftkeyandcam key on cam bushing (P/N EM14301).

5.Slide cam bushing down crankshaft and align the bushing, camandcrankshaft.Installsleeveovercrankshaftandalign with hydraulic press.Install cam bushing bolts loosely.Press bushing down onto bearing assembly.Leaving pressure on the bushing, tighten cam bolts evenly to 40-50 foot pounds.

6.Releasepressureonthebushing,reapplypressuretobush- ing and tighten bolts evenly to 40-50 foot pounds. Repeat procedure 3 to 4 times.

7.After bushing has been fitted tightly into cam, remove from hydraulic press. Remove one bolt at a time, using Loctite, installboltsandtorqueto65-70footpounds.Countersinkset screw hole and install dog point set screw and second set screw both with LoctiteTM.

8.Place cam bearing onto crankshaft keeping bearing loose.

Make sure the eccentric lock is facing toward the outside of the pumping unit.

9.Set crankshaft assembly into the pump box and align both bearing assemblies with the pump box mountings.

10.After crankshaft assembly is securely fastened to the pump box, place sprocket (P/N EM14307) onto the cam side of the crankshaft assembly. Install bushing (P/N EM14309) into sprocket. Align sprocket with sprocketon countershafts and tighten bolts.

11.Install chain P/N EM14308. To adjust, loosen locknuts on pusher bolts and tighten chain to approximately 1/2 in. slack in the chain. Once chain is adjusted properly, tighten down locknuts.

1.Remove 3”x 2” reducer and 3” elbow from the pump outlet. Remove exhaustgateandY-manifold(secondarymanifold). Check ball seat and ball stop pin for wear. If any wear is detected, the part should be replaced. Remove T-manifold (primarymanifold).Checkallpartsforwear.Removehopper and hopper seat and inspect.

2.Loosenthepistonnutsandremovethepistoncup assembly andcylinders.Inspectallpartsforwearandreplacepartswith excessive wear. Check oiler pump for proper operation.

3.Clean all parts thoroughly, removing all foreign material and concrete slurry.Once parts are clean, install concrete cylin- ders.PlaceoilerplateO-ringinplaceandcoatwithoil.Install smallO-ringonpistonrod.Runoilerlinethroughthecylinders and connect in the oiler fitting on the oiler plate.

4.Push oiler plate into cylinder.Install ring and felt holder, soak felt ring in oil, then install around felt holder in cylinder.Make sure the bronze ring is flat, then push it up flush with the ring and felt holder.

5.Coat piston cup with oil and push it into the cylinder. Install bushing into center of piston cup. Put small O-ring on rod, place face plate on rod and tighten down securely. Repeat these procedure on the opposite cylinder.

6.Thoroughly check T-manifold, ball stoppings and both steel balls for wear. Insert an O-ring in the top flange and in the leading edge of the manifold. Put the manifold onto the primarysideofthepumpandinstallboltsleavingthemloose.

7.CheckY-manifoldforwear,installallO-rings,ballstoppin,ball and seat. Align and install Y-manifold to T-manifold and cylinder assembly.TightenY-manifold bolts first before tight- eningT-manifoldbolts.Aftermanifoldsaretight,checkO-rings for slippage.

8.InsertseatintoframeholedirectlyabovetheT-manifold.The seatorificeshouldfitinsidetheframeitself,thentheseatsits on top of the orifice. On the dura-seat, set the big end of the seatintheframe.Theseat,orthesmallpartofthedura-seat, fits into the bottom of the hopper.

9.After tightening the manifold bolts and inserting the seats in place, set the hopper over the seat and align the bolt holes. Tighten bolts, check O-ring and seat for alignment.

10.Check exhaust gate for wear, install and align gate onto Y-manifold.Insert O-ring into exhaust gate flange and close gate. Lock down lever and adjust clamp arm.

11.Install3in.elbowand3x2in. reducer.Fillhopperhalffulland check for leaks.

PAGE 40 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)