Zenith C-30HDG - Manuals

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 5 PARTS ORDERING PROCEDURES www .multiquip .com Ordering parts has never been easier! Choose from three easy options: WE ACCEPT ALL MAJOR CREDIT CARDS! When ordering parts, please supply: R Dealer Account Number R Dealer Nam...

PAGE 6 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — PUMP SPECIFICATIONS Table 1. C-30HDG Pump Specifications Pump Type Reciprocating Piston Pumping Rate Up to 25 cu. yds. per hour* Vertical Pumping Height Up to 150 ft. (45.73 m) Horizontal Pumping Distance 40...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 7 C-30HDG PUMP — PUMP DIMENSIONS Figure 1. C-30HDG Concrete Pump Dimensions

PAGE 8 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — SAFETY MESSAGE ALERT SYMBOLS Safety precautions should be followed at all times when operatingthis equipment. Failure to read and understand the SafetyMessages and Operating Instructions could result in inju...

PAGE 10 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — RULES FOR SAFE OPERATION The following safety guidelines should always be used whenoperating the Mayco C-30HDG Concrete Pump: General Safety ■ DO NOT operate or service this equipment before reading this en...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 13 NOTES

PAGE 14 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — TOWING GUIDELINES To reduce the possibility of an accident while transporting thepump on public roads, always make sure that the trailer and thetowing vehicle are in good operating condition and both unitsa...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 15 C-30HDG PUMP — TOWING GUIDELINES Figure 2. Towing Applications Figure 2 shown below illustrates the typical towing applicationthat should be used when towing the pump.

PAGE 16 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — TRAILER SAFETY GUIDELINES This section is intended to provide the user with trailer serviceand maintenance information. Remember periodic inspection ofthe trailer will ensure safe towing of the equipment an...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 17 Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical componentsof the trailer. When specifying or replacing the trailer wheels it isimportant the wheels, tires, and axle are properly matched. C-30HDG P...

PAGE 18 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only the fastenersmatched to the cone angle of the wheel. Proper procedure forattachme...

PAGE 20 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — OPERATION AND SAFETY DECALS Figure 5. Operation and Safety Decals Figure 5 display's the operation and safety decals as they appear on the concrete pump, should any of these decals becomedamaged or unreadab...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 21 C-30HDG PUMP — IMPORTANT HAND SIGNALS Figure 6. Operation Hand Signals Figure 6 display's the basic hand signals commonly used in concrete pumping operations.

PAGE 22 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — PUMP COMPONENTS Figure 7. Major Pump Components

PAGE 24 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — CONTROL BOX COMPONENTS Figure 8. Pump Control Box Components Figure 8 illustrates the location of the major components for theC-30HDG Control Box. The function of each component isdescribed below: 1 . Throt...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 25 C-30HDG PUMP — ENGINE COMPONENTS Figure 9. Zenith 416 Basic Engine Components Figure 9 illustrates the location of the basic components for theZenith 416, 1.6 liter gasoline engine..The function of eachcomponent is descri...

PAGE 26 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — GENERAL INFORMATION The following operating principles and operating suggestionsshould prove helpful in the successful operation of your concretepump. Your new “small line” concrete pump has been designedto...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 27 C-30HDG PUMP — HOW IT WORKS The C-30HDG concrete pump has one main pumping pistonwhich is valved by means of two ball checks. ( A inlet, and B outlet.) The secondary piston is used as a compensator piston to smoothout the...

PAGE 28 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) Figure 12 shows the relationship between the return spring, the compensator spring and the rocker arm to maintain a smoothperformance. DO NOT tighten the bolt (Item 1) completely, the rod end must be able to move. The ret...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 29 C-30HDG PUMP — OPERATING INFORMATION OPERATING SUGGESTIONS 1. A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves through-out the job. 2. Before concrete is dischar...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 31 6. If a blockage occurs in a hose, “walk the hose” until you find the point of trouble. The hose will be soft immediately past theblockage. If this happens at the start, disconnect the hose atthe first coupling past the b...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 33 C-30HDG PUMP — OPERATING INFORMATION Cam Roller If the cam roller does not ride on the cam profile smoothly, it maybe caused by insufficient line back-pressure; e.g., a wet mix withonly 50 feet of hose. Add more hose as n...

PAGE 34 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — INSPECTION Figure 13. Engine Oil Dipstick (Removal) 3. Check the engine oil level as shown on the dipstick (Figure 14). 4. If the engine oil level is low, add oil through the engine oil filler hole (Figure ...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 35 Gasoline Check 1. Remove the gasoline cap located on top of fuel tank. 2. Handle Fuel in a safety container. If the container does not have a spout use a funnel. 3. Visually inspect to see if fuel level is low. If fuel is...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 37 C-30HDG PUMP — STARTUP/SHUTDOWN PROCEDURES Figure 22. Ignition Switch 3. Insert the ignition key into the ignition switch (Figure 22), turn the key to the ON position, then to the START position, release the key when the ...

PAGE 40 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — MAINTENANCE (PUMP) Crankshaft and Cam Assembly Procedure 1. Set bearing block (P/N EM14303) into hydraulic press. Place bearing cup into bearing block and press in evenly. Bearingcup should be aligned equal...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 41 Clutch Lining Replacement(For P/N EM14320 Clutch Assembly Only) The normal lining thickness measures 3/16 of an inch. If theclutch starts to slip or make an usual noise, it may be necessaryto replace the lining. Please no...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 43 C-30HDG PUMP — MAINTENANCE (PUMP) Detent Hole (3) Installation 1. After the bearing assembly has been is installed , remove the three “dog type” allen head set screws (B) to allow detents tobe drilled. See Figure 25 below...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 45 C-30HDG PUMP — MAINTENANCE (PUMP) Roller Chain Application A properly selected, installed and maintained drive chain (Figure 27) is an extremely versatile means of power transmission.It is possible, however, to greatly re...

PAGE 46 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) The clearance between pin and bushings is very small(Figure 30), on the order of .003 to .005 inches. A lubricant mustbe thin enough to flow into the chain. SAE 30 weight oil is aboutright for room temperature. Lighter oi...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 47 Assembling and Disassembling Drive Chain The components of the drive chain are hardened parts. Strikingthese parts may cause metal chips to break off from the chainor the tools used resulting in personal injury. During al...

PAGE 48 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — ENGINE TROUBLESHOOTING For more detail troubleshooting methods, refer to Zenith Operation and Maintenance manual supplied with yourpump. G N I T O O H S E L B U O R T E N I G N E . 6 E L B A T N O T P M Y S...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 49 C-30HDG PUMP — ENGINE TROUBLESHOOTING For more detail troubleshooting methods, refer to Zenith Operation and Maintenance manual supplied with your pump. ) D E U N I T N O C ( G N I T O O H S E L B U O R T E N I G N E . 6 ...

PAGE 50 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — ENGINE FAULT CODES Malfunction Indicator Diagnostic System T h e M a y c o C - 3 0 H D G c o n c r e t e p u m p f e a t u r e s a n e n g i n e m a l f u n c t i o n i n d i c a t o r l a m p f o u n d o n...

PAGE 54 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) Figure 38. Zenith Fuel Injection System Wiring Diagram C-30HDG PUMP — WIRING DIAGRAM (ZENITH WIRING HARNESS)

PAGE 56 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — WIRING DIAGRAM Figure 39. Wiring Diagram

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 57 ZPP 416, 420 & 640 CUSTOMER 16-PIN CONNECTIONS Rev: 2 Date 02/17/2007 IGN. (12 VDC HOT IN RUN & CRANKING) ALTERNATOR CHARGING TROUBLE INDICATOR LAMP GASOLINE FUEL PUMP GROUND GASOLINE FUEL PUMP +12VDC STARTER REQU...

PAGE 58 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — WIRING DIAGRAM (TAIL LIGHTS) Figure 40. Trailer Tail Lights Wiring Diagram

PAGE 60 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) Figure 41-A. Slump Test (1/3 Full) Figure 41-C. Slump Test (Full-Overflow) Figure 41-B. Slump Test (2/3 Full) Figure 41-D. Slump Test (Removing Excess Concrete) Figure 41-E. Slump Test (Cone Invert) Figure 41-F. Slump Tes...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 61 APPENDIX — C-30HDG CONCRETE MIX INFORMATION The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to helpcreate a better understanding of the importance ...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 63 APPENDIX — C-30HDG CONCRETE MIX INFORMATION Consolidated Rock Products Co., Division of Tests3/8” Pea Gravel STANDARD PUMP MIXES (one-half inch minus) NOTE: All weights shown are one cubic yard with S.S.D. aggregates. CRP...

PAGE 64 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) APPENDIX — RECOMMENDED SHOTCRETE SYSTEM RECOMMENDED SHOTCRETE SYSTEM Figure 42. Shotcrete System MA YC0 C-3 0H DN 1-800-30-MA YCO 7 8 10 3 3 2 1 9 10 11 13 14 15 1/2 STANDARD AIR HOSE AIR COMPRESSOR (125 TO 250 CFM) 3/4 S...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 65 APPENDIX — RECOMMENDED SHOTCRETE SYSTEM General recommendations ■ If the site will permit, use steel pipe from the pumpto the pool perimeter. It will reduce line pressureswhich is highly recommended. ■ The vibrator on the...

PAGE 66 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES Use a 1-3/8" rubber nozzle tip for a wide spray pattern. Use a 1-1/4" rubber nozzle tip for a narrow spray pattern. DO NOT INSTALL THE...

PAGE 68 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. SAMPLE PARTS LIST NO. PART N...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 69 C-30HDG CONCRETE PUMP W/ ZENITH FUEL INJECTION SYSTEM 1 Units QTY. P/N DESCRIPTION 6 ....... EM14904 ...................... PISTON CUP KITS4 ....... EM18804 ...................... 4 1/2" STEEL BALL4 ....... EM14818 .....

PAGE 70 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — NAMEPLATE AND DECALS

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 71 C-30HDG PUMP — NAMEPLATE AND DECALS NAME PLATE AND DECALS NO PART NO PART NAME QTY. REMARKS 1 * DCL152 DECAL, CAUTION OIL LEVEL 1 2 * EM932 DECAL, CAUTION, MANIFOLD 1 3 * EM1028 DECAL, MULTIQUIP MAYCO 2 4 * 508594 DECAL, ...

PAGE 72 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) COMPENSATOR PISTON ROD ASSY. C-30HDG PUMP — COMPENSATOR PISTON ROD ASSY.

PAGE 76 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) ROCKER ASSY. C-30HDG PUMP — ROCKER ASSY. 17 16 15 13 12 27 7 25 44 5 8 9 10 11 6 3 7 7 10 20 31 24 23 8 24 23 22 21 30 28 7 1 35 27 45 14 7 31 7 7 A B C 3 4 2 19 NOTES: A. LONG STROKE SETTING. HIGHER VOLUME, LOWER PSI. B....

PAGE 88 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — MUFFLER, AIR FILTER, AND STOP SWITCH ASSY. MUFFLER, AIR FILTER AND STOP SWITCH ASSY. 102 184 184 112 446 448 107 206 202 204 208 104 106 460 102 104 103 195 140 136 236 132 133 135 137 208 204 212 212 210 1...

PAGE 92 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — ENGINE MOUNTING BRACKETS ASSY. ENGINE MOUNTING BRACKETS ASSY.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 93 C-30HDG PUMP — ENGINE MOUNTING BRACKETS ASSY. ENGINE MOUNTING BRACKETS ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM517379 SUPPORT BRACKET, RIGHT 1 2 EM517418 SUPPORT BRACKET, LEFT 1 3 20900059 SPACER, 20 OD X 11 ID X 32...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 95 RADIATOR, BRACKET AND HOSES ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 20800072 BRACKET, TOP MOUNT 1 2 21000161 BRACKET, TUBE SUPPORT 1 3 62410120 CONNECTOR, STRAIGHT 410 X 32 DIA 2 4 64700072 PLAIN WASHER, 10 MM 1 5 647...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 99 C-30HDG PUMP — BATTERY ASSY. BATTERY ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM515122 CABLE, POSITIVE BATTERY 1 2 EM506266 COVER, POSITIVE TERMINAL 1 3 10318 BOX, BATTERY 1 4 EM492541 NUT, HEX 5/16- 18 1 5 EM923023 WA...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 101 C-30HDG PUMP — FUEL TANK ASSY. FUEL TANK ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM517206 HOSE, FUEL 5/16 IN. 18" 2 EM506208 CLAMP, HOSE 1 3 ZPPC6304 FILTER, FUEL 1 5 EM491210 PLUG, 1/4 IN. 1 7 EM517433 FUEL TANK...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 103 C-30HDG PUMP — HOPPER ASSY. HOPPER ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM14159 HOPPER SCREEN 1 2 EM14141 HOPPER 1 3 EM925191 PIN, HAIR 2 4 EM104 BOLT, 5/8”-11X2” HEX HEAD 3 5 EM507599 WASHER 5/8” FLAT 3

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 105 C-30HDG PUMP — HOOD ASSY. HOOD ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 503723 RIVET 4 2 491010 LATCH KIT 2 3 EM516883 HOOD ASSY. 1 4 490937 BUMPER, RUBBER 2 5 EM406 NUT 1/2”-13 HEAVY HEX 2 6 EM124 BOLT 1/2” DIA-NC X4...

PAGE 106 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — LUBRICATION PANEL ASSY. POSITION LOCATION LENGTH OF LINES 1 .................................................... COMPENSATOR ROD ........................................................................ 28&...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 107 LUBRICATION PANEL ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 * EM916001 FITTING, GREASE 1/8" NPT 14 2 * EM505489 STRAIGHT FITTING 1/8" NPT 13 3 * 505534 COUPLING W/NUT 1/8' NPT 14 4 * EM505516 PLASTIC HOSE LINE ...

PAGE 108 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) C-30HDG PUMP — REMOTE CONTROL CABLE ASSY. REMOTE CONTROL CABLE ASSY. 3 4 2 5 9 8 7 6 1 1 I NCLUDED W ITH IT EM 1 . NO T ES: 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 109 C-30HDG PUMP — REMOTE CONTROL CABLE ASSY. REMOTE CONTROL CABLE ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 * EM16753 JUNCTION BOX 1 2 * EM16754 SWITCH, MICRO 1 3 * EM16756 GUARD SWITCH - ALUMINUM 1 4 * EM491897 CONNECTOR...

PAGE 110 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) PAYMENT TERMS Terms of payment for parts are net 30 days. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s re...

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 111 MAYCO PUMP WARRANTY MECHANICAL DRIVE MODELS MAYCO PUMP, hereinafter referred to as “Manufacturer’, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal u...

OPERATION AND PARTS MANUAL Your Local Dealer is: HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Office MQ Parts Department 18910 Wi lm i ngton A v e . C ars on, C A 90746 Cont a ct : mq@mult i qu i p.com T e l. (800) 421-1244 F a...