Zenith Chainsaw C 30HDG User Manual

OPERATION AND PARTS MANUAL  
SERIES  
MODEL C-30HDG  
CONCRETE PUMP  
(ZENITH 416 GASOLINE ENGINE)  
Revision #6 (04/02/12)  
To find the latest revision of this  
publication, visit our website at:  
www.multiquip.com  
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.  
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C-30HDG PUMP — PROPOSITION 65WARNING  
PAGE 2 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)  
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C-30HDG PUMP — SILICOSIS/RESPIRATORYWARNINGS  
WARNING WARNING  
SILICOSIS WARNING  
RESPIRATORY HAZARDS  
Grinding/cutting/drilling of masonry, concrete, metal and  
other materials with silica in their composition may give  
off dust or mists containing crystalline silica. Silica is a  
basic component of sand, quartz, brick clay, granite and  
numerous other minerals and rocks. Repeated and/or  
substantial inhalation of airborne crystalline silica can  
cause serious or fatal respiratory diseases, including  
silicosis. In addition, California and some other  
authorities have listed respirable crystalline silica as a  
substance known to cause cancer. When cutting such  
materials, always follow the respiratory precautions  
mentioned above.  
Grinding/cutting/drilling of masonry, concrete, metal and  
other materials can generate dust, mists and fumes  
containing chemicals known to cause serious or fatal  
injury or illness, such as respiratory disease, cancer,  
birth defects or other reproductive harm. If you are  
unfamiliar with the risks associated with the particular  
process and/or material being cut or the composition of  
the tool being used, review the material safety data  
sheet and/or consult your employer, the material  
manufacturer/supplier, governmental agencies such as  
OSHA and NIOSH and other sources on hazardous  
materials. California and some other authorities, for  
instance, have published lists of substances known to  
cause cancer, reproductive toxicity, or other harmful  
effects.  
Control dust, mist and fumes at the source where  
possible. In this regard use good work practices and  
follow the recommendations of the manufacturers or  
suppliers, OSHA/NIOSH, and occupational and trade  
associations. Water should be used for dust  
suppression when wet cutting is feasible. When the  
hazards from inhalation of dust, mists and fumes cannot  
be eliminated, the operator and any bystanders should  
always wear a respirator approved by NIOSH/MSHA for  
the materials being used.  
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 3  
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TABLE OF CONTENTS  
COMPONENT DRAWINGS  
MAYCO C-30HDG (ZENITH)  
CONCRETE PUMP  
Nameplate and Decals....................................... 70-71  
Compensator Piston Rod Assembly .................. 72-73  
Connecting Rod - Drive Side Assembly ............. 74-75  
Rocker Assembly ............................................... 76-77  
Countershaft Assembly ...................................... 78-79  
Crankshaft Assembly ......................................... 80-81  
Manifold Assembly ............................................. 82-83  
Frame Assembly ................................................ 84-85  
Axle Assembly .................................................... 86-87  
Muffler, Air filter And Stop Switch Assembly ...... 88-89  
Clutch Assy ........................................................ 90-91  
Engine Mounting Brackets Assembly ................ 92-93  
Radiator, Mounting Bracket And Hoses Assy .... 94-95  
Control Box Assembly ........................................ 96-97  
Battery Assembly ............................................... 98-99  
Fuel Tank Assembly ....................................... 100-101  
Hopper Assy................................................... 102-103  
Hood Assembly .............................................. 104-105  
Lubrication Panel Assembly ........................... 106-107  
Remote Control Cable Assembly................... 107-108  
Proposition 65 Warning ..............................................2  
Silicosis/Respiratory Warnings ...................................3  
Table of Contents .......................................................4  
Parts Ordering Procedures ........................................5  
Pump Specifications...................................................6  
Engine Specifications .................................................6  
Pump Dimensions ......................................................7  
Safety Message Alert Symbols .............................. 8-9  
Rules For Safe Operation .................................. 10-12  
Towing Guidelines .............................................. 14-15  
Trailer Safety Guidelines .................................... 16-18  
Operation And Safety Decals ...................................20  
Important Hand Signals ...........................................21  
Pump Components ............................................ 22-23  
Control Box Components .........................................24  
Engine Components ................................................25  
General Information .................................................26  
How It Works ...................................................... 27-28  
Operating Information ........................................ 29-33  
Inspection........................................................... 34-36  
Startup ............................................................... 36-37  
Shutdown Procedures..............................................37  
Maintenance (Pump) ......................................... 38-47  
Engine Troubleshooting...................................... 48-49  
Engine Fault Codes ............................................. 50-53  
Wiring Diagram (Zenith Wiring Harness) ........... 54-55  
Wiring Diagram ........................................................56  
Pin Connections ......................................................57  
Wiring Diagram (Tail Lights).....................................58  
Appendix —  
Terms and Conditions Of Sale — Parts .................109  
Mayco Pump Warranty ...........................................110  
Slump Test Procedure........................................60  
Concrete Mix Information............................. 61-63  
Recommended Shotcrete System ............... 64-65  
Recommended Shotcrete Accessories........ 66-67  
Explanation of Codes in Remarks Column ..............68  
Suggested Spare Parts ............................................69  
Specification and part number are subject  
to change without notice.  
PAGE 4 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)  
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PARTS ORDERING PROCEDURES  
Ordering parts has never been easier!  
Choose from three easy options:  
Effective:  
January 1st, 2006  
Best Deal!  
Order via Internet (Dealers Only):  
Order parts on-line using Multiquip’s SmartEquip website!  
If you have an MQ Account, to obtain a Username  
and Password, E-mail us at: parts@multiquip.  
com.  
N View Parts Diagrams  
N Order Parts  
N Print Specification Information  
To obtain an MQ Account, contact your  
District Sales Manager for more information.  
Use the internet and qualify for a 5% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
Goto www.multiquip.com and click on  
to log in and save!  
Order Parts  
Note: Discounts Are Subject To Change  
Fax your order in and qualify for a 2% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
Order via Fax (Dealers Only):  
All customers are welcome to order parts via Fax.  
Domestic (US) Customers dial:  
1-800-6-PARTS-7 (800-672-7877)  
Note: Discounts Are Subject To Change  
Domestic (US) Dealers Call:  
Order via Phone:  
1-800-427-1244  
Non-Dealer Customers:  
International Customers should contact  
their local Multiquip Representatives for  
Parts Ordering information.  
Contact your local Multiquip Dealer for  
parts or call 800-427-1244 for help in  
locating a dealer near you.  
When ordering parts, please supply:  
R
Dealer Account Number  
R
Specify Preferred Method of Shipment:  
R
R
R
R
R
Dealer Name and Address  
UPS/Fed Ex  
DHL  
Truck  
N
N
Priority One  
Ground  
Shipping Address (if different than billing address)  
Return Fax Number  
N Next Day  
Second/Third Day  
Applicable Model Number  
N
Quantity, Part Number and Description of Each Part  
NOTICE  
All orders are treated as Standard Orders and will  
ship the same day if received prior to 3PM PST.  
WE ACCEPT ALL MAJOR CREDIT CARDS!  
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 5  
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C-30HDG PUMP — PUMP SPECIFICATIONS  
Table 1. C-30HDG Pump Specifications  
Reciprocating Piston  
Pump Type  
Pumping Rate  
Up to 25 cu. yds. per hour*  
Vertical Pumping Height  
Horizontal Pumping Distance  
Max. Concrete Piston Face Pressure  
Maximum Aggregate Size  
Hopper Capacity  
Up to 150 ft. (45.73 m)  
400 - 500 ft. (122 - 152 m)*  
500 PSI  
1/2 in. minus (12.7 mm)  
6 cu. ft. etc.  
2" or 2-1/2"  
(50.8 or 63.5 mm)"  
Material Hose  
Weight  
2,950 lbs. (1,338 Kg)  
7 Gallons (26.5 Liters)  
125 ft. cable Standard  
Lube oil Box  
Remote Control  
7.35" x 14"  
(187 x 356 mm)  
Tire Size  
* Volume output will vary depending on mix design, slump, line size used  
and job site conditions.  
TABLE 2. ENGINE SPECIFICATIONS  
Model  
ZENITH 416 ENGINE  
4 stroke, overhead valve, single cylinde  
horizontal shaft gasoline engine  
Type  
2.99 x 3.23 in.  
(76 x 82 mm)  
Bore X Stroke  
Compression Ratio  
Displacement  
10:1  
97.6 cu. (1,599 cc)  
Continuous Output  
Fuel Tank Capacity  
Fuel Type  
61 H.P. @3600 R.P.M.  
Approx. 11 U.S. Gallons (42 liters)  
Unleaded Gasoline  
Engine  
Lube Oil Capacity  
3.9 qts. (3.7 liters)  
Engine Speed  
Full Load  
2650 rpm 100 (No Load 2750 rpm +/- 50)  
(Load 2750 rpm +/- 100)  
Engine Speed  
Full Idle  
875 rpm 100  
Air Cleaner  
Air Horn Type  
SAE 10W-30 (Oil Grade)  
SG or SF (Service Class)  
Engine Lubrication  
Starting Method  
Spark Plug  
Electric Start  
B4ES  
0.8 - 0.9 in.  
(0.031-0.035 mm)  
Spark Plug Gap  
20.10 x 22.50 x 25.80 in.  
(509.9 x 527.5 x 654.5 mm)  
Dimension (L x W x H)  
Dry Net Weight  
178 lbs (126.3 Kg.)  
PAGE 6 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)  
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C-30HDG PUMP — PUMP DIMENSIONS  
Figure 1. C-30HDG Concrete Pump Dimensions  
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 7  
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C-30HDG PUMP — SAFETY MESSAGE ALERT SYMBOLS  
HAZARD SYMBOLS  
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!  
Potential hazards associated with operation of the pump will be  
referenced with Hazard Symbols which appear throughout this  
manual, and will be referenced in conjunction with Safety  
Message Alert Symbols.Some examples are listed below:  
Safety precautions should be followed at all times when operating  
this equipment. Failure to read and understand the Safety  
Messages and Operating Instructions could result in injury to  
yourself and others.  
This Owner's Manual has been  
developed to provide complete  
WARNING - LETHAL EXHAUST GASES  
instructions for the safe and efficient  
operation of the Mayco Model  
C-30HDG Concrete Pump.  
Gasoline engine exhaust gases contain  
poisonous carbon monoxide. This gas is  
colorless and odorless, and can cause  
death if inhaled. NEVER operate this  
equipment in a confined area or enclosed  
structure that does not provide ample free flow air.  
Refer to the engine manufacturers instructions for data relative  
to its safe operation.  
Before using this pump, ensure that the operating individual  
has read and understands all instructions in this manual.  
WARNING - EXPLOSIVE FUEL  
SAFETY MESSAGE ALERT SYMBOLS  
Gasoline is extremely flammable, and its  
vapors can cause an explosion if ignited.  
DO NOT start the engine near spilled fuel  
or combustible fluids. DO NOT fill the fuel  
tank while the engine is running or hot.  
The three (3) Safety Messages shown below will inform you  
about potential hazards that could injure you or others.The Safety  
Messages specifically address the level of exposure to the  
operator, and are preceded by one of three words: DANGER,  
WARNING, or CAUTION.  
DO NOT overfill tank, since spilled fuel  
could ignite if it comes into contact with hot engine parts or  
sparks from the ignition system. Store fuel in approved  
containers, in well-ventilated areas and away from sparks and  
flames. NEVER use fuel as a cleaning agent.  
DANGER  
You WILL be KILLED or SERIOUSLY injured if you do  
not follow directions.  
WARNING - BURN HAZARDS  
Engine components can generate extreme  
heat. To prevent burns, DO NOT touch these  
areas while the engine is running or  
immediately after operations. NEVER operate  
the engine with heat shields or heat guards  
removed.  
WARNING  
You COULD be KILLED or SERIOUSLY injured if you  
do not follow directions.  
CAUTION  
You CAN be injured if you do not follow directions  
PAGE 8 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)  
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C-30HDG PUMP — SAFETY MESSAGE ALERT SYMBOLS  
WARNING - ROTATING PARTS  
CAUTION - RESPIRATORY HAZARDS  
NEVER operate equipment with covers,  
or guards removed. Keep fingers, hands,  
hair and clothing away from all moving  
parts to prevent injury.  
ALWAYS wear approved respiratory  
protection.  
CAUTION - ACCIDENTAL STARTING  
CAUTION - SIGHT AND HEARING HAZARDS  
ALWAYS place the Engine ON/OFF switch  
in the OFF position and remove the ignition  
key when the pump is not in use.  
ALWAYS wear approved eye and  
hearing protection.  
CAUTION - OVER-SPEED CONDITIONS  
CAUTION - EQUIPMENT DAMAGE MESSAGES  
NEVER tamper with the factory settings of  
the engine governor or settings. Personal  
injury and damage to the engine or  
equipment can result if operating in speed  
ranges above maximum allowable.  
Other important messages are provided throughout this manual  
to help prevent damage to your concrete pump, other property,  
or the surrounding environment.  
WARNING  
DO NOT operate at pressures exceeding the rating of the  
entire material delivery system.  
Use snap pins on all snap couplings.  
This pump, other property, or the surrounding  
environment could be damaged if you do not  
follow instructions.  
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 9  
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C-30HDG PUMP — RULES FOR SAFE OPERATION  
Whenever necessary, replace nameplate, operation and safety  
decals when they become difficult read.  
DANGER - ReadThis Manual!  
Failure to follow instructions in this manual may lead to serious  
injury or even death! This equipment is to be operated by  
trained and qualified personnel only! This equipment is for  
industrial use only.  
Manufacture does not assume responsibility for any accident  
due to equipment modifications.  
NEVER use accessories or attachments, which are not  
recommended by Multiquip for this equipment. Damage to the  
equipment and/or injury to user may result.  
The following safety guidelines should always be used when  
operating the Mayco C-30HDG Concrete Pump:  
NEVER touch the hot exhaust manifold, muffler or cylinder.  
Allow these parts to cool before servicing engine or  
concrete pump.  
General Safety  
DO NOT operate or service this equipment  
before reading this entire manual.  
HighTemperatures – Allow the engine  
to cool before adding fuel or performing  
service and maintenance functions.  
Contact with hot! components can cause  
serious burns.  
ALWAYS read, understand, and follow  
procedures in Operator’s Manual before  
attempting to operate equipment.  
ALWAYS be sure the operator is familiar with proper safety  
precautions and operations techniques before using pump  
The engine section of this concrete pump requires an  
adequate free flow of cooling air.NEVER operate the concrete  
pump in any enclosed or narrow area where free flow of the  
air is restricted. If the air flow is  
restricted it will cause serious  
damage to the concrete pump  
or engine and may cause injury  
to people. Remember the  
concrete pump's engine gives  
off DEADLY carbon monoxide  
This equipment should not be operated by persons under 18  
years of age.  
ALWAYS read, understand and follow procedures in  
Operator’s Manual before attempting to operate equipment.  
ALWAYS be sure the operator is familiar with proper safety  
precautions and operations techniques before using pump  
NEVER operate this equipment without proper protective  
clothing, shatterproof glasses, steel-toed boots and other  
protective devices required by the job.  
gas.  
ALWAYS refuel in a well-ventilated area, away from sparks  
and open flames.  
ALWAYS use extreme caution when working with flammable  
liquids.When refueling, stop the engine and allow it to cool.  
DO NOT smoke around or near the machine. Fire or  
explosion could result from fuel vapors, or if fuel is spilled on  
a hot engine.  
NEVER operate this equipment when not feeling  
well due to fatigue, llness or taking medicine.  
NEVER operate this equipment under the  
influence of drugs or alcohol.  
NEVER operate the concrete pump in an  
explosive atmosphere or near  
combustible materials. An explosion or fire  
could result causing severe bodily harm  
or even death.  
Topping-off to filler port is dangerous, as it tends to spill fuel.  
ALWAYS wear proper respiratory (mask),  
hearing and eye protection equipment when  
operating the concrete pump.  
Stop the engine when leaving the concrete pump unattended.  
DO NOT leave the pump unattended. Use chock blocks if  
parking pump on a grade.  
Maintain this equipment in a safe operating condition at all  
times.  
PAGE 10 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)  
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C-30HDG PUMP — RULES FOR SAFE OPERATION  
CAUTION must always be observed while servicing this  
pump.Rotating parts can cause injury if contacted.  
A copy of this manual shall accompany the pump at all times.  
DO NOT use worn out hoses or couplings;inspect daily.  
ALWAYS stored the pump in a clean, dry location out of the  
reach of children.  
DO NOT disconnect the hose couplings or nozzle while they  
are under pressure. Relieve the pressure by manually  
swinging the clamp arm latch handle to the first open position  
at the exhaust cone outlet.  
ALWAYS use extreme care when operating near obstructions,  
on slippery surfaces, grades and side slopes.  
Unauthorized equipment modifications will void all  
warranties.  
The pump should NEVER be towed in excess of 45 MPH (or  
less depending on road conditions).  
Refer to the Engine Owner's Manual for engine technical  
questions or information.  
If hose lines are blocked for any reason, or if the lines are  
kinked when starting up or during pumping cycle, the pump  
pressure could straighten out the kink or force out the blockage.  
This rapid surge of material could cause the lines to move or  
whip in a manner that could cause injury to personnel.  
Before start-up, check the hopper and remove all obstructions.  
Keep all hands out of the hopper when the engine is running.  
DO NOT operate the pump with the hood open.  
Inspect the hose lines at all times  
Replace any worn or damaged pump components  
immediately.  
DO NOT tow the pump with the hopper full of material.  
DO NOT tow the pump with the hoses attached.  
ALWAYS turn the engine OFF before performing must be  
before performing maintenance.  
NEVER disconnect any emergency or safety devices.  
These devices are intended for operator safety.Disconnection  
of these devices can cause severe injury, bodily harm or even  
death! Disconnection of any of these devices will void all  
warranties.  
ALWAYS make sure pump is correctly secured to the trailer.  
Check all supports attaching the pump to the trailer and make  
sure they are tight.  
ALWAYS make sure that the pump's trailer is placed on solid  
level ground so that it cannot slide or shift around, endangering  
workers. Place blocks under the trailer's bumper to make it  
level (prevents tipping), and use a chocked block underneath  
the wheels to prevent rolling. Also keep the immediate area  
free of bystanders.  
ALWAYS make sure the delivery system used, pipe hose  
clamps ect., exceed the rated pressure of the pump. In addition  
the pumping system should be checked for worn components  
prior to start up. Use snap pins on all snap couplings.  
Before towing, check the hitch and secure the safety chain to  
the towing vehicle. Also check for proper tire pressure.  
Tow only with a vehicle and hitch rated to tow a 2,950 lbs.  
(1,338 Kg) load.  
If pump is equipped with ball hitch coupler, use only a 2” all  
steel ball rated for a minimum of 5000 lbs. Use a 1” hardened  
steel pull pin, if the pump is equipped with a pin hitch.  
ALWAYS check the machine for loosened threads or bolts  
before starting.  
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 11  
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