MULTIQUIP MAYCO LS300 Guide

OPERATION AND PARTS MANUAL
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.
SERIES
MODEL LS300
CONCRETE PUMP
(DEUTZ TD2009L04 DIESEL ENGINE)
Revision #4 (06/21/10)
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PAGE 2 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
Diesel engine exhaust and some of
PROPOSITION 65WARNING
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PAGE 4 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
TABLE OF CONTENTS
Specification and part number are subject
to change without notice.
Mayco LS300
Concrete Pump
Proposition 65 Warning .............................................2
Table of Contents......................................................4
Parts Ordering Procedures.......................................5
Safety Message Alert Symbols............................. 6-7
Rules for Safe Operation .................................... 8-10
Specifications ..........................................................12
Dimensions .............................................................13
Important Hand Signals ..........................................14
General Information.......................................... 15-16
How It Works ...........................................................17
Pump Components ........................................... 18-19
Digital Control Panel Components ..........................20
Digital Readout Screen ...........................................21
Engine Components ...............................................22
Inspection.......................................................... 23-25
Set-Up .....................................................................26
Start-Up Procedure.................................................27
Operation .......................................................... 28-31
Pumping Information......................................... 32-35
Maintenance (Pump) ........................................ 36-43
Maintenance (Trailer)........................................ 44-46
Trailer Safety Guidelines ................................... 47-61
Troubleshooting (Pump).................................... 62-63
Troubleshooting (Engine)........................................64
Troubleshooting (Trailer Brake System)..................65
Troubleshooting (Electrical) .............................. 66-68
Wiring Diagram (Control Box) ........................... 69-72
Wiring Diagram (Digital Readout Screen)...............73
Wiring Diagram (Hopper Vibrator) ..........................74
Hydraulic System Diagram .....................................75
Manifold Block Ports................................................76
Appendix–Concrete Mix Information................. 77-78
Appendix–Slump Test Procedure............................79
Appendix–Recommended Shotcrete System ... 80-81
Appendix–Recommended Shotcrete Accessories ..... 82-83
Explanation of Code in Remarks Column...............84
Suggested Spare Parts...........................................85
Component Drawings
Nameplate and Decals...................................... 86-89
Frame Assembly. .............................................. 90-91
Axle Assembly................................................... 92-93
Brake Line Assembly ........................................ 94-95
Brake Light Assembly ....................................... 96-97
Trailer Hitch Assembly....................................... 98-99
Battery Assembly .......................................... 100-101
Hopper Assembly.......................................... 102-103
Hopper Attachment Assembly ...................... 104-105
Hopper Interior Assembly ............................. 106-107
Shuttle Cylinder Assembly ............................ 108-109
Lubrication Pistons Assembly ....................... 110-113
Fuel Tank/Water Separator Assembly........... 114-115
Heat Exchanger Assembly............................ 116-117
Accumulator Assembly.................................. 118-119
Lubrication Panel Assembly.......................... 120-121
Engine Cover Assembly................................ 122-123
Hydraulic Tank Assembly .............................. 124-125
Engine Assembly .......................................... 126-127
Throttle Assembly ......................................... 128-129
Hydraulic Pump Assembly ............................ 130-131
Manifold Assembly........................................ 132-133
Control Box Assembly................................... 134-135
Control Box Harness Assembly .................... 136-137
Terms and Conditions of Sale .............................. 138
Mayco Pump Warranty......................................... 139
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PAGE 6 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand
theSafety MessagesandOperatingInstructionscould result
in injury to yourself and others.
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
This Owner's Manual has been developed
to provide complete instructions for the safe
and efficient operation of the Multiquip
Mayco
LS300 Concrete pump.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.
SAFETY MESSAGE ALERT SYMBOLS
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,orCAUTION.
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
You CAN be injured if you do not follow directions
HAZARD SYMBOLS
Dieselengineexhaustgasescontainpoisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a
confinedarea orenclosed structurethatdoesnotprovide
ample free flow air.
Potential hazardsassociatedwithoperationofthe pump will
bereferencedwith HazardSymbolswhichappearthroughout
thismanual, andwillbereferencedin conjunctionwithSafety
Message Alert Symbols. Some examples are listed below:
Diesel fuel is extremely flammable, and
itsvaporscancausean explosionifignited.
DO NOT start the engine near spilled fuel
or combustible fluids. DO NOT fill the fuel
tank while the engine is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comesintocontactwithhot engineparts orsparksfrom
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.
Enginecomponents cangenerateextreme
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.
SAFETY MESSAGE ALERT SYMBOLS
WARNING
DANGER
CAUTION
WARNING - LETHAL EXHAUST GASES
WARNING - BURN HAZARDS
WARNING - EXPLOSIVE FUEL
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 7
ALWAYS placethe Engine ON/OFF switch
in the OFF position. NEVER perform
maintenance on the unit with the ignition
key in the ON position.
ALWAYS wear approved respiratory
protection.
This machine is capable of producing noise
levels above 85 dB.
Hearingprotectionis required.
Always wear eye protection.
SAFETY MESSAGE ALERT SYMBOLS
Other important messages are provided throughout
this manual to help prevent damage to your concrete
pump, otherproperty, orthesurroundingenvironment.
This pump , other property, or the
surroundingenvironmentcould bedamaged
if you do not follow instructions.
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.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - ACCIDENTAL STARTING
CAUTION - RESPIRATORY HAZARDS
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER operate equipment with covers, or
guards removed. Keep fingers , hands ,
hair andclothing awayfromallmovingparts
to prevent injury.
WARNING - ROTATING PARTS
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PAGE 8 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
Thefollowingsafetyguidelinesshould alwaysbeusedwhen
operating the LS300 concrete pump:
GENERAL SAFETY
■ DO NOT operate or service this equipment
before reading this entire manual.
■ NEVER touchthe hotexhaustmanifold,muffler
orcylinder.Allowthesepartstocoolbefore
servicing engine or pump.
■ HighTemperatures –Allowthe engine
tocool beforeadding fuelor performing
service and maintenance functions.
Contact with
hot! components can
cause serious burns.
■ Theenginesectionofthis
pump requires an
adequate free flow of
cooling air. NEVER
operate the pump in any
enclosed or narrow area
where free flow of the air
isrestricted.If theair flowisrestricted itwill causeserious
damage to the pump or engine and may cause injury to
people.Remember the pump's engine gives off DEADLY
carbon monoxide 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.
■ NEVER smoke aroundornearthemachine.
Fire or explosion could result from fuel
vapors , or if fuel is spilled on a hot! engine.
■ NEVER operate the 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 removethe ignitionkey whenleavingthepump
unattended.
■ ALWAYS block the wheels on the unit when using on a
slope.
■ ALWAYS maintain this equipment in a safe operating
condition at all times.
■ ALWAYS stopthe enginebeforeservicing,adding fuelor
oil.
RULES FOR SAFE OPERATION
■ ALWAYS checkthemachinefor loosenedthreads orbolts
before starting.
■ ALWAYS wear proper respiratory(mask), hearing and
eye protection equipment when operating the pump.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ 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.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ Thisequipmentshould notbe operatedbypersons under
18 years of age.
■ NEVER operatethisequipment without properprotective
clothing,shatterproofglasses, steel-toedbootsand other
protective devices required by the job.
DANGER - READ OPERATION AND PARTS
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
equipmentis for industrial use only.
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 9
■ NEVER run engine without air filter. Severe engine
damage may occur.
■ ALWAYSbesuretheoperatorisfamiliarwithpropersafety
precautionsandoperationtechniquesbeforeusingpump.
■ ALWAYS store equipment properly when it is not being
used.Equipment shouldbe storedinaclean,drylocation
out of the reach of children.
■ DO NOT operatethisequipmentunlessthehoppergrate,
guards and safety devices are attached and in place.
■ CAUTION must be exercised while servicing this
equipment.Rotating and moving parts can cause injury
if contacted.
■ Keep all inexperienced and unauthorized peopleaway
from the equipment at all times.
■ Before start-up, check the hopper and remove all foreign
matter and debris.
■ DO NOT use worn or damaged hose couplings, inspect
all hoses and couplings for wear. Replace any worn or
defective hose or couplings immediately.
■ Keephands outofthe hopperwhentheengineisrunning.
■ DO NOT disconnecthosecouplingsornozzlewhile under
pressure. Relieve pressure by activating the reverse
function switch located on the control panel.
■ Unauthorized equipment modifications will void all
warranties.
■ Checkallfasteners periodicallyfor tightness. Alsocheck
towing tongue bolt, lock nut and wheel lug nuts for wear.
■ Test the pump's ON/OFF switch. The purpose of this
test is to shut down the engine.
■ Refertothe DEUTZ Engine Owner's Manual for engine
technical questions or information recommended by
Multiquip for this equipment. Damage to the equipment
and or injury to user may result.
■ Always use properly rated hoses and clamps — 1500
PSI and higher.
TRANSPORTING
■ ALWAYSshutdownenginebeforetransportingthe pump.
■ Tighten fuel tank cap securely to prevent fuel from
spilling.
■ Drain fuel when transporting pump over long distances
or bad roads.
Towing
■ Before towing, check the hitch and secure the safety
chain to the towing vehicle.
■ Whentowing,anadequatesafety chainmustbefastened
to the frame, refer to Towing Guidelines.
■ Tow only with a vehicle and hitch rated to pull a 6,000
lbs. load.
■ If unit is equipped with ball hitch coupler, use only 2" all
steelballratedforminimumof6,000lbs.Use1"hardened
steel pull pin, if not equipped with ball hitch.
■ This equipment shall not be towed or operated by
individualswho cannotreadunderstandthesigns, decals
or operating instructions.
■ When towing at night, always have rear tail lights ON.
■ DO NOT tow unit with hopper full of material.
■ DO NOT tow unit with hoses attached.
■ DO NOT tow unit in excess of 55 MPH on highways.
MAINTENANCE SAFETY
■ NEVER lubricate components or attempt service on a
running pump .
■ ALWAYS allow the pump a proper amount of time to
cool before servicing.
■ Keep the pump in proper running condition.
■ Fixdamage tothe pumpimmediately andalways replace
broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel and
fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
RULES FOR SAFE OPERATION
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PAGE 10 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
EMERGENCIES
■ ALWAYS know the location of the
nearest fire extinguisher .
■ ALWAYS know the location of the
nearest and
first aid kit .
■ In emergencies always know the location of the
nearest phone or
keep a phone on the job site .
Also know the phone numbers of the nearest
ambulance , doctor and fire department . This
information will be invaluable in the case of an
emergency.
BATTERY
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wearsafety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
■■
■■
■ DO NOT drop the battery.There
is the possibility of risk that the
battery may explode.
■■
■■
■ DO NOT expose the battery to
open flames, sparks, cigarettes
etc.The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
■■
■■
■ ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
■■
■■
■ ALWAYS keep battery charging and cables in good
working condition. Repair or replace all worn cables.
■■
■■
■ ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■■
■■
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
■■
■■
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plentyofwater,thencontactthenearestdoctororhospital,
and seek medical attention.
RULES FOR SAFE OPERATION
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 11
NOTES
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PAGE 12 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
SPECIFICATIONS
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 13
SNOISNEMID.3ELBAT
.FERSNOISNEMID
A).mc2.901(.ni34
B).mc104(.ni851
C).mc9.64(.ni5.81
D).mc6.761(.ni66
E).mc1.561(.ni56
Figure 1. Dimensions
DIMENSIONS
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PAGE 14 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
IMPORTANT HAND SIGNALS
Figure 2. Operation Hand Signals
Figure2 displaysthe basichand signalscommonly used inconcrete pumpingoperations.
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 15
CONCRETE MIX DESIGN
Mixdesign ismost important to achievemaximumpumpability.
Pumpability is affected by, among other factors, the type and
gradationof aggregateused.Natural aggregatesmakea more
workablemixand pumpmorereadilythan crushedaggregates.
A blend of natural and crushed aggregates will produce a
workable mix.The type and gradation of aggregates is equally
important for workability as the size and percentage of coarse
aggregatesin themix.
Theterm “aggregates”describesall ofthesolid materials,from
the largest rock to the smallest grain of sand, contained in the
concretemix.
Concrete mixes with a consistency as dry as one-inch slump
and as wet as ten-inch slump have been pumped; but for
maximumefficiencyfromthepump,aslumprangingfromtwoto
six inches will produce a more workable mix than one that
containsmore orlesswater.
Theprinciple of concrete pumping isbased onself-lubrication.
As it moves through the transfer line, the concrete takes the
shapeofaplasticcylinder.Itisforcedthroughthetransfer lineon
afilmof mortar that isself-troweledto theserviceof thetransfer
linearound itsfull peripheryby the slugof concreteitself.
Aslump ratingshouldbe usedwith discretion;itis notalwaysa
real indication of the pumpability of the mix.The concrete may
be workable in the sense that it will readily flow into place, but
the same mix may not respond to pressure. Overly wet mixes
tendtoseparate. Inadditiontoaffectingthe strengthandquality
ofthe concrete,thedelivery system willnottolerate separation.
Overlydrymixesaresimilarlyunsatisfactoryiftheylackplasticity
andtendto becrumbly.Tobeproperlypumped, themixmustbe
ableto continuouslycoatthe insideof the linewith alubricating
sealofmortar.
GENERAL INFORMATION
There are four ways in which this seal can be lost:
1. By pumping excessively wet mixes which do not have
enoughcohesion tohold together.
2. Bypumpingharshundersandedconcretewithpoorlygraded
aggregates which can jam together when the pressure
becomes too great for the insufficient amount of sand to
holdthe aggregatesapart.
3. By getting a rock pocket, such as mixer tailings, into the
pumpvalve.Thisrockpocketwillhaveaninsufficientcoating
ofmortarand themixwillnot beplasticenoughto allowthe
valveto operateor themix tomovein theline.
4. Throughexcessivebleeding.Ifthe mixisshort orfines,but
the sand is otherwise fairly well graded, bleeding will not
normallycreateanyproblemsaslongasthepumpcontinues
operation.But,ifthepumpis shutdown,bleedingcanresult
in a loss of lubrication and blocked erratic flow.
The above are bad concrete practices, regardless of how the
mixistobe placed. But,thesepointsdoshowthat special mixes
arenotalwaysneeded,withinlimits,forpumpingconcrete.Good
aggregate gradation is most important to pump concrete the
maximumdistance.
Theuseofadmixturescanhaveabeneficialeffectonpumpability.
Most of the dispersing agents will fatten, retard bleeding, and
increaseworkability.Thus,theaverageconcretecan bepumped
forappreciably longerdistances. Air entrainingagents willalso
improveworkability,althoughtheycannotbeusedasasubstitute
forgoodgradationoftheaggregate.Pumpingwillnotappreciably
affectthefinal aircontentofthemix. High-earlycementtendsto
givea morereadilypumpable mixwith superiorwaterretaining
qualities.However, if delays are likely to occur, extra care must
beexercised duetothefaster settingtimeover regularcement.
TheMayco LS300models willpump a widevariety ofconcrete
pump mixes. But, there are guidelines that must be followed.
Use this information in conjunction with the
Operation section
ofthis manual.
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PAGE 16 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
GENERAL INFORMATION
REGIONAL DIFFERENCES
Concreteismade bymixinglocallyavailablerockand sandwith
cementand water.Forthisreason therearegreatdifferencesin
the pumpability of concrete from one region of the country to
another.
It is impossible to define a specific mix for each region that the
concretepump bewill workingin.Therefore,the mixeslistedin
Appendix - Concrete Mix Information will provide a basic
guidelinefor establishingthe propermix designfor your area.
Use this information to specify your requirements to your local
ready-mixbatch plant,contractorandcivil engineer.It maytake
minor adjustments to make a mix pumpable, so you should
explainyour needs.
The elements that have to be controlled and consistently
maintainedby thebatch plant are:
1. The sizing and mix percentage of rocks, gap graded from
thelargest downthroughthe smallestsizes.
2. Sand witha sieveanalysis thathas the properpercentage
offines,ASTM C33spec.
3. Sufficient cement to produce the required design strength
of the concrete and provide the lubricating binder to pump
theconcrete through thedeliverysystem.
Usea minimumof:
500 lbs. of cement/cu yd for 2500 p.s.i. concrete after 28
days.
530 lbs. of cement/cu yd for 3000 p.s.i. concrete after 28
days.
600 lbs. of cement/cu yd for 4000 p.s.i. concrete after 28
days.
4. Admixturepump-aidif necessary.
5. Theproperamount ofwatertomake aworkableslumpand
plasticizethe mix.
In addition, this Mayco Concrete Pump can be used to pump a
largeaggregate hardrock asfollows:
1. Pearock(1/2"minus)pumpwithmixesbeingaslowas30%
rockand 70%sand.
2. Shorteningpearockwhen usedwithanaircompressorand
nozzle.(Seeback pagesforrecommended setup.)
3. “MudJacking”, highpressuregrouting.
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 17
HOW ITWORKS
Thefollowingisabriefexplanationofhowtheconcretecylinders,
hydraulic cylinders, shuttle tube, valves and hopper work in
sequencetopump concrete.
The hydraulic pressure is generated by a variable volume,
pressure compensated, axial piston pump that is driven by a
diesel engine. The rod sides of the drive cylinders are
hydraulicallyconnectedtogether creatinga“slave circuit,”which
allowshydraulic oilto transferfrom onepiston totheother.
Thetwopart cyclingsequenceis initiated by anelectrical signal
generated by two proximity switches activated by the drive
cylinder.Theproximityswitches are normallyopen,magnetically
sensing the movement of the main drive cylinder.As the drive
cylinder piston head passes the proximity switch, an electrical
signal is sent to the solenoid operated pilot valve which in turn
directs pilot oil to the four valves controlling the drive cylinder
andthe shuttlecylinder.
Figure 3. Pumping Cycle 1
TO TANK HIGH PRESSURE
OIL FROM PUMP
PROXIMITY
SWITCH
HYDRAULIC
CYLINDERS
PISTON
CUP
CONCRETE
CYLINDERS
SHUTTLE TUBE
SLAVE
OIL
SHUTTLE TUBE MOTION
A
B
In the first cycle, hydraulic pressure is applied to cylinder (B),
causingthehydraulicpiston, whichisconnectedtotheconcrete
piston and piston cup, to discharge concrete into the delivery
line(Figure 3).
As one cylinder is discharging concrete, the hydraulic oil from
therodside(B)ofthedrivecylindersisbeingtransferredthrough
theslave circuitcausingthe opposite cylinder(A)to moveback
onthe suctionstroke,filling thecylinderwith concrete.
Theshuttletube issequencedtopivotto each concretecylinder
as the drive cylinders stroke to push concrete. As the second
cycling sequence begins (Figure 4), the shuttle tube pivots to
theoppositecylinder(A). Thehydraulicpistonpassesunder the
proximityswitch andsends pressuretothe piston,causing itto
stroke and discharge concrete into the delivery line. Hydraulic
oilistransferredthrough the slavecircuittocylinderB,causingit
to start a suction stroke, refilling it with concrete.The pumping
sequencethen repeatsforthe durationofthe operation.
Figure 4. Pumping Cycle 2
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PAGE 18 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
PUMP COMPONENTS
Figure 5. Major Pump Components
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 19
PUMP COMPONENTS
Figure 5 illustrates the location of the major components for
theLS300Concrete Pump.Thefunction ofeachcomponent
is described below:
1. Tow Hitch Coupler – Requires a 2-inch ball hitch or a
3-inch pintle. Capable of towing 6,000 lbs.
2. Documentation Box – Contains engine and pump
operation, parts and maintenance information.
3. Manifold Access Door– Release latch and lift door to
access the Hydraulic Manifold Block.
4. Hydraulic Manifold Block – Manifold block that
controls the flow of hydraulic pressure to the
components required to control the pump.
5. Hopper Discharge Sleeve – Connect hoses or steel
pipes to the discharge sleeve for pouring concrete.
6. Pump End Jack Stand – Usethis jackstand tosupport
the rear end of the pump. NEVER deploy on un-level
ground and always check for firmness of ground.
7. ShuttleCylinder – Underpressure,theshuttlecylinder
shears concrete passing from the concrete cylinder to
the delivery line during the cycle phase.
8. Tires — This trailer uses two ST205-750 x15E type
tires. Tireinflationpressureisthemostimportant factor
in tire life. Pressure should be checked to 50 psi cold
before operation. DO NOT bleed air from tires when
they are hot. Check inflation pressure weekly during
use to insure the maximum tire life and tread wear.
9. Battery – This unit uses a +12 VDC type battery.
ALWAYS useglovesandeye protectionwhen handling
the battery.
10. Hydraulic Pump – This unit incorporates an axial
variable displacement hydraulic piston pump.
11. Heat Exchanger – Reduces temperature of the
hydraulicoil.Theexchangerdrawsoilfromthe hydraulic
system into the heat exchanger before allowing it to
flow back into the reservoir.
12. Accumulator – Storesoilunderpressureandreleases
it to the pilot valves to ensure enough pressure is
provided to operate valve.
13. Stroke Volume Control Dial – Turns CW/CCW to
increaseordecrease thenumber ofstrokesper minute
of the pump.
14. Hydraulic Oil Sight Glass – Use to determine the
amount of hydraulic oil remaining in tank. The sight
glassalso containsa temperaturegauge formonitoring
the temperature of the hydraulic oil.
15. Hydraulic OilTank/Cap– Removecaptoadd hydraulic
fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if
level is low.
16. Engine Throttle Lever – Controls the speed of the
engine.For load conditions (pumping water) ALWAYS
run the engine at full speed.
17. Pumping PressureGauge – Usedtomonitor pressure
in the concrete cylinders and shuttle tube.
18. Control Box – Contains the electrical components
requiredto runthepump.See ControlBoxComponents
section for component callouts.
19. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell)
holds approximately 16 gallons (61 liters).DO NOT top
off fuel.Wipe up any spilled fuel immediately.
20. Hydraulic Oil Filter – This in-tank return hydraulic
filter with a 10 micron cleanable filter is designed to
remove all particles large enough to cause wear and
job break down. Under normal conditions, clean every
6 months.
21 Lubrication Box – This box is empty when shipped
from the factory.Please fill with 3 gallons (11.35 liters)
of SAE 30 motor oil for first time use. Also check the
dual clean-out point on bottom of lubrication box for a
secure tight fit.
22. Rear Running Lights – ALWAYS check and make
sureboth theright andleftrunninglightsarefunctioning
correctly before towing the pump.
24. Hopper/Hood – Lift hood to fill. Concrete from a Redi-
Mix truck is poured into this hopper. The hopper can
hold 10 cu. ft of concrete. NEVER put hands or any
other parts of you body into the hopper.
25. Tow End Jack Stand – Use this jack stand to level
and support the tow end of the pump.
26. Fuel Reservoir – Holds 16 gallons (61 liters) of diesel
fuel.
27. Fuel Gauge – Indicates the amount of fuel in the fuel
reservoir.
28. Hydraulic Oil Reservoir – Holds 33 gallons (125 liters)
of hydraulic oil.
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PAGE 20 — MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10)
DIGITAL CONTROL PANEL COMPONENTS
Figure 6. Pump Digital Control Panel Components
1. Emergency Stop Button – Press emergency stop
button to stop pump in an emergency. Turn knob
counterclockwise to disengage the stop button.
2. Ignition Switch – Insert the ignition key here to start
the engine.Turn the key clockwise to the ON position,
then continue turning clockwise to the START position
and release. To stop the engine turn the key fully
counterclockwise to the STOP position.
3. Digital Readout Screen – Displays and monitors the
various functions of the machine.
4. ScrollSwitch –Allowsthe operatortoscrollthevarious
readout screens.
5. Reset Switch – Allows the operator to reset the stroke
counter.
6. Remote Cable Connector – Insert the remote control
input cable into this connector.
7. Direction Control Switch – This 2-position switch
controls the direction of flow for any mix in the pump.
The leftmost position sets the pumping direction to
forward and the rightmost position sets the pumping
direction to reverse.
8. Pumping Control Switch – This 3-position switch
controls the pumping of the pump. The rightmost
position (REMOTE) is for use with the remote control
unit, the leftmost position (LOCAL) is for normal
pumping operation, and the centermost position
(CENTER OFF) prevents pumping.
9. Cylinder Stroke Control Switch –This 2-position
switch controls the pumping function. The leftmost
position (AUTOMATIC) sets the pump to automatic
cycling .Set theswitchtothisposition fornormal pump
operation.
The rightmost position(JOG) changesthe pump from
automaticto manual cycling .Thisallowsthe cylinders
to be manually cycled using the Manual Cylinder
Jogging Switch .
10. Manual Cylinder Jogging Switch – This 2-position
switchallows theoperatortomanuallyjog thecylinders
to assist in clearing material line packs and is used to
testpumping pressure(See InitialStart-up Procedure
section of this manual for testing procedure).
The leftmost position jogs Cylinder “A” and the
rightmost position jogs Cylinder “B”.
13. Main Pressure Gauge –This gauge monitors the
systempressurewhilepumpingmaterial.Themaximum
pressure rating is 3100 PSI ± 50.
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MAYCO LS300 CONCRETE PUMP • OPERATION AND PARTS MANUAL — REV. #4 (06/21/10) — PAGE 21
DIGITAL READOUT SCREEN
PRIMARY SCREEN
Screen 1
Indicates the various modes of the switch settings.
Monitors engine RPM - Idle speed 900, High speed 2550.
Battery charge indicator - Normal charge 13+ volts.
Indicates electrical malfunction - Refer to Troubleshooting
section.
SECONDARY SCREENS
Screen 2
Displays the status of the shuttle cylinder proximity switches.
Screen 3
Displays the number of hours the engine and pump have
been used and the fault codes the pump has registered. All
three indicators can be reset to zero by the RESET switch
on the control panel.
Screen 4
Displays the number of strokes the main hydraulic cylinders
have gone through. This indicator can be reset to zero by
the RESET switch on the control panel.
Screen 5
Displays the ON/OFF electrical signal status of the various
12 volt solenoids (Swing A circuit, Main A circuit, Main B
circuit).
Screen 6
Displays the ON/OFF electrical signal status for the
Proximity Switch A, Proximity Switch B, Engine Fuel
Solenoid,andUnloader Solenoid.
Screen 7
Displays the number of times the main hydraulic cylinders
stroke and the yards per hour output.This indicator can be
reset to zero by the RESET switch on the control panel.
Screen 8
Displays the electrical status of the engine fuel solenoid.To
test the 12-Volt solenoid status, activate with the RESET
switch on the control panel.
INSTRUCTION
OR MESSAGE
INDICATES THE
FUEL SOLENOID
IS OFF
TO TEST FUEL
SOL PRESS RESET
FUEL SOL OFF
8
Screen 9
Displays the communication status of the (optional) radio
remotecontrol.Toactivate anewremote controlconnection,
use the reset switch on the control panel.
INDICATES
THAT RADIO
REMOTE IS ON
IINSTRUCTION
OR MESSAGE
RADIO ADDRESS
COMMUNICATING
PRESS RESET TO
LEARN A NEW ONE
9
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