Model C-30HDG
30HDG Pump Proposition 65WARNING
Silicosis Warning
30HDG Pump SILICOSIS/RESPIRATORYWARNINGS
Table of Contents
Parts Ordering Procedures
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Order via Fax Dealers Only
30HDG Pump Specifications
30HDG Pump Pump Specifications
30HDG Concrete Pump Dimensions
30HDG Pump Pump Dimensions
30HDG Pump Safety Message Alert Symbols
Structure that does not provide ample free flow air
You can be injured if you do not follow directions
30HDG Pump Safety Message Alert Symbols
Always wear approved respiratory protection
Always wear approved eye and hearing protection
General Safety
High Temperatures Allow the engine
30HDG Pump Rules for Safe Operation
Do not use worn out hoses or couplings inspect daily
30HDG Pump Rules for Safe Operation
Maintenance Safety
Lifting
Emergencies
Page
Recommended Maintenance
30HDG Pump -TOWING Guidelines
PumpTrailer Vehicle Connection
Towing Applications
30HDG Pump -TOWING Guidelines
Trailer Safety Precautions
30HDG Pump -TRAILER Safety Guidelines
Torsion Bar Suspension
30HDG Pump -TRAILER Safety Guidelines
Tires/Wheels/Lug Nuts
TiresWear/Inflation
NEVER! use an pneumatic air gun to tighten wheel lug nuts
30HDG Pump -TRAILER Safety Guidelines
Lug Nut Torque Requirements
Start all wheel lug nuts by hand
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Operation and Safety Decals
30HDG Pump Operation and Safety Decals
Operation Hand Signals
30HDG Pump Important Hand Signals
Major Pump Components
30HDG Pump Pump Components
30HDG Pump Pump Components
Pump Control Box Components
30HDG Pump Control BOX Components
Zenith 416 Basic Engine Components
30HDG Pump Engine Components
30HDG Pump General Information
Pump Mix Guidelines
Sample Design Mix 3000 Psi 3/8 in. Slump 4- 5
Pumping Cylinder
30HDG Pump HOW IT Works
Pumping Pistons
30HDG Pump HOW IT Works
Operating Suggestions
30HDG Pump Operating Information
Mbvr air entraining, acts as a lubricant
30HDG Pump Operating Information
New Pumps
Pumping Tips
Clearing a Mix from the System
Stop the pump. Switch OFF the engine
Avoiding Setting of the Mix in the System
Clearing a Plugged Manifold
Pulsation
Down-Hill Pumping
VerticalPumping
ValveSeats
30HDG Pump Operating Information
Cam Roller
Snap-Joint
Engine Oil Check
Read safety instructions at the beginning of this manual
30HDG Pump Inspection
Before Starting
30HDG Pump Inspection
Gasoline Check
Lubrication Box
Belt Deflection
30HDG Pump INSPECTION/STARTUP
Checking Engine Coolant Level
If cooling water is dirty, flush the cooling system
30HDG Pump STARTUP/SHUTDOWN Procedures
Remote Control Operation
Radio Remote Control Operation
Always carry extra Orings
30HDG Pump Maintenance Pump
Preventive Maintenance
General Clean-up Procedure
Piston Cup Wear
30HDG Pump Maintenance Pump
Sponge Clean-out Procedure
Never use compressed air to clean out the lines
Crankshaft and Cam Assembly Procedure
30HDG Pump Maintenance Pump
Following procedure will assist you in replacing the lining
Bearing/Cam Bushing Installation
Bearing Installation
Detent Holes
Detent Hole 3 Installation
30HDG Pump Maintenance Pump
Installation and Drive Alignment
Roller Chain Application
Working Loads
Chain-Link Cross Section
Drive Chain Lubrication
Chain-Link Pin Removal
Installation Of Coversides
Installation of Spring Locks and Cotter-Pins
Assembling and Disassembling Drive Chain
Engine Troubleshooting
30HDG Pump Enginetroubleshooting
Engine oil level too full? Correct engine oil level?
30HDG Pump Enginetroubleshooting
Fuel tank empty? Replace fuel filter Fuel filter clogged?
Unions a required
30HDG Pump Engine Fault Codes
Malfunction Indicator Diagnostic System
Example
GCP ECU Fault Code List for ZZP 416 Engine
30HDG Pump Engine Fault Codes
Fuel 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 Harness
30HDNI Pump -WIRING Diagram Zenith Wiring Harness
Wiring Diagram
30HDG Pump -WIRING Diagram
ZPP 416, 420 & 640 Customer 16-PIN Connections
30HDG Pump PIN Connections
TrailerTail Lights Wiring Diagram
30HDG Pump -WIRING Diagram Tail Lights
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Slump Test 2/3 Full
Appendix C-30HDNI C-30HDNI Slumptest Procedure
Appendix C-30HDG Concrete MIX Information
Appendix C-30HDG Concrete MIX Information
2749
2708
2775
2685
Recommended Shotcrete System
Appendix Recommended Shotcrete System
General recommendations
Recommended Shotcrete Accessories
Appendix Recommended Shotcrete Accessories
Appendix Recommended Shotcrete Accessories
Xxxxx only Not Used on
Explanation of Code in Remarks Column
Units
30HDG Pump Suggested Spare Parts
30HDG Pump Nameplate and Decals
30HDG Pump Nameplate and Decals
Compensator Piston ROD Assy
30HDG Pump Compensator Piston ROD Assy
Bearing CUP
Spring Return
Piston Guide Assy
Fitting
Connecting ROD Drive Side Assy
30HDG Pump Connecting ROD Drive Side Assy
Piston ROD Assy
Rocker Assy
30HDG Pump Rocker Assy
Bolt 1-14X2 HEX Head
Connecting ROD
Shaft Rocker ARM
Journal Block
Countershaft Assy
30HDG Pump COUNTER-SHAFT Assy
30HDG Pump COUNTER-SHAFT Assy
Crankshaft Assy
30HDG Pump Crankshaft Assy
30HDG Pump Crankshaft Assy
Bearing Block
Lock Washer 3/4
Manifold Assy
30HDG Pump Manifold Assy
30HDG Pump Manifold Assy
Frame Assy
30HDG Pump Frame Assy
Washer Thick
Frame Assembly
AXLE, Assembly
Jack STAND, Rear
Axle Assy
30HDG Pump Axle Assy
Outer Bearing
CAP 14 Chrome Includes Items W
Dust Cover
Castle NUT
MUFFLER, AIR Filter and Stop Switch Assy
30HDG Pump MUFFLER, AIR FILTER, and Stop Switch Assy
FILTER, AIR
PRECLEANER, AIR Filter ZE1 ELEMENT, AIR Filter
Gland Connector
Stop SWITCH, Engine Cover
Clutch Assy
30HDG Pump Clutch Assy
WASHER, Flat 1/2 Special
Rotor Assembly
Clutch Housing W/LINING
WASHER, Lock 1/2
Engine Mounting Brackets Assy
30HDG Pump Engine Mounting Brackets Assy
BRACKET, ECU Mount
Support BRACKET, Right
Support BRACKET, Left
SPACER, 20 OD X 11 ID X 32 Long
RADIATOR, Bracket and Hoses Assy
30HDG Pump RADIATOR, Mounting Bracket and Hoses Assy
Part Name
Control BOX Assy
30HDG Pump Control BOX Assy
Ignition Switch KEY
SWITCH, Throttle Control
Ignition Switch
CONNECTOR, Plastic
Battery Assy
30HDG Pump Battery Assy
BATTERY, 12 Volt
CABLE, Positive Battery
BOX, Battery
CABLE, Negative Battery
Fuel Tank Assy
30HDG Pump Fueltank Assy
Includes Item
HOSE, Fuel 5/16
CLAMP, Hose
FILTER, Fuel
Hopper Assy
30HDG Pump Hopper Assy
Hopper
PIN, Hair
Washer 5/8 Flat
Hood Assy
30HDG Pump Hood Assy
NUT 1/2-13 Heavy HEX
Rivet
Latch KIT
BUMPER, Rubber
Lubrication Panel Assy
30HDG Pump Lubrication Panel Assy
1FT=1PC
FITTING, Grease 1/8 NPT
Straight Fitting 1/8 NPT
Coupling W/NUT 1/8 NPT
Remote Control Cable Assy
30HDG Pump Remote Control Cable Assy
Junction BOX
SWITCH, Micro
Guard Switch Aluminum
CONNECTOR, 3/16 Ring
Freight Policy
Terms and Conditions of Sale Parts
Mechanical Drive Models
Mayco Pumpwarranty
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