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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