MULTIQUIP MAYCO LS400 Guide

OPERATION AND PARTS MANUAL
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.
SERIES
MODELS LS400/LS500
CONCRETE PUMPS
(DEUTZ F4L2011, BF4L2011 DIESEL ENGINES)
Revision #6 (09/19/11)
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PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
Proposition65Warning
Diesel engine exhaust and some of
LS400/LS500 PUMP — PROPOSITION 65WARNING
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PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
LS400/LS500 PUMP —TABLE OF CONTENTS
Specification and part number are subject
to change without notice.
MAYCO LS400/LS500
CONCRETE PUMPS
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).....................................62-64
Troubleshooting (Engine)........................................65
Troubleshooting (Brake System)............................. 66
Troubleshooting (Electrical) ...............................67-69
Wiring Diagram (Control Box) ............................70-73
Wiring Diagram (Optional 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 Codes In Remarks Column ............ 84
Suggested Spare Parts........................................... 85
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS
Name Plate and Decals .....................................86-89
Frame Assy. .......................................................90-91
Axle Assy............................................................92-93
Brake Line Assy. ................................................94-95
Brake Lights Assy...............................................96-97
Trailer Hitch Assy................................................98-99
Battery Assy. ..................................................100-101
Hopper Assy...................................................102-103
Hopper Attachment Assy. ..............................104-105
Hopper Interior Assy. .....................................106-107
Shuttle Cylinder Assy. ....................................108-109
Lubrication Pistons Assy. ...............................110-111
Fuel Tank Assy. ..............................................112-115
Heat Exchanger Assy.....................................116-117
Accumulator Assy...........................................118-119
Remixer Control Assy.....................................120-121
Lubrication Panel Assy. ..................................122-123
Engine Cover Assy.........................................124-125
Hydraulic Tank Assy. ......................................126-127
Engine Assy....................................................128-129
Throttle Assy. .................................................130-131
Water Separator Assy. ...................................132-133
Hydraulic Pump Assy. ....................................134-135
Manifold Assy. ................................................136-137
Control Box Assy. ...........................................138-139
Control Box Harness Assy. ............................140-141
Remote Control Cable Assy. ..........................142-143
Hydraulic Stabilizer Assy. (Optional) ..............144-145
Terms and Conditions of Sale - Parts ................... 146
Mayco Pump Warranty.......................................... 147
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PAGE 6 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand
theSafetyMessagesandOperating Instructions couldresult
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
LS400/LS500Concrete 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,or CAUTION.
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
Diesel 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.
Potentialhazards associated withoperationof thepump will
bereferencedwithHazardSymbolswhich appear throughout
thismanual,andwillbereferenced in conjunctionwith Safety
Message Alert Symbols. Some examples are listed below:
Diesel fuel isextremelyflammable,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.
DO NOT overfill tank, since spilled fuel could ignite if it
comesinto contact withhotengine parts 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.
Engine components can generate
extremeheat. 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.
LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS
WARNING
DANGER
CAUTION
WARNING - LETHAL EXHAUST GASES
WARNING - BURN HAZARDS
WARNING - EXPLOSIVE FUEL
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MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 7
ALWAYS place the 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.
Hearingprotection isrequired.
Always wear eye protection.
LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS
Other important messages are provided throughout
this manual to help prevent damage to your concrete
pump, other property,or thesurroundingenvironment.
This pump , other property, or the
surroundingenvironment couldbedamaged
if you do not follow instructions.
NEVER tamper with the factory
settings of the engine governor or
settings. Personal injury anddamage
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 operateequipmentwithcovers,
or guards removed. Keep fingers ,
hands , hair and clothing away from all
moving parts to prevent injury.
WARNING - ROTATING PARTS
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PAGE 8 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
Thefollowingsafetyguidelinesshouldalwaysbeused when
operating the LS400/LS500 concrete pump:
GENERAL SAFETY
■ DO NOT operate or service this
equipmentbefore readingthisentire
manual.
■ NEVERtouch the hotexhaust manifold, muffler
orcylinder.Allowthesepartstocoolbefore
servicing engine or pump.
■ HighTemperatures –Allow theengine
tocoolbefore addingfuel orperforming
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. Iftheairflow isrestrictedit willcauseserious
damage to the pump or engine and may cause injury to
people.Remember the pump's engine gives off DEADLY
carbon monoxide gas.
■ ALWAYS refuelinawell-ventilatedarea,awayfromsparks
and open flames.
■ ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool.
■ NEVER smoke around or near the
machine.Fireorexplosioncouldresultfrom
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.
■ ALWAYSremovethe 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 stoptheengine beforeservicing, adding fuelor
oil.
LS400/LS500 PUMP — RULES FOR SAFE OPERATION
■ ALWAYScheckthe machineforloosened threadsor bolts
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.
■ NEVERoperatethisequipmentwhennotfeeling
welldue tofatigue, illnessor taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ This equipment should not be
operated by persons under 18 years
of age.
■ NEVER operatethis equipmentwithout properprotective
clothing,shatterproof glasses,steel-toedboots andother
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
equipmentisfor industrialuseonly.
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MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — 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.Equipmentshouldbe stored inaclean,drylocation
out of the reach of children.
■ DO NOT operatethisequipment unlessthe hoppergrate,
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.
■ Keepall inexperienced and unauthorized people away
from the equipment at all times.
■ Before start-up, check the hopperand 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.
■ Keephandsoutof the hopperwhen the engine isrunning.
■ DO NOT disconnecthosecouplingsornozzle while under
pressure. Relieve pressure by activating the reverse
function switch located on the control panel.
■ Unauthorized equipment modifications will void all
warranties.
■ Checkall fastenersperiodicallyfor 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.
■ Referto the DEUTZ Engine Owner's Manual forengine
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
■ ALWAYSshutdownenginebeforetransporting thepump.
■ 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,anadequatesafetychainmustbe fastened
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
individualswhocannotreadunderstand the signs,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.
LS400/LS500 PUMP — RULES FOR SAFE OPERATION
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PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
LS400/LS500 PUMP — RULES FOR SAFE OPERATION
EMERGENCIES
■ ALWAYS knowthelocation ofthe
nearest fire extinguisher .
■ ALWAYS know the location of the
nearest and first aid kit .
■ In emergencies always know the location of the
nearestphoneor 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
andskin.To avoideye irritation, always wear safetyglasses.
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.
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.
■ Fixdamageto the pumpimmediatelyandalwaysreplace
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.
During routine maintenance or removing material
blockage, you will be required to put your hand in the
concrete cylinders or near the shuttle tube.You are at
EXTREME RISK of injury or AMPUTATION if the
engine is running or if pressure is in the hydraulic
system.
Prior to performing any maintenance on the pump,
followdescribed lock out-tagoutprocedures. Stopthe
engine by turning off the ignition switch and remove
the starter key. Place a “DO NOT OPERATE” tag
over the switch and disconnect the battery. The
pressurereadingonthe
accumulator pressure
gauge
MUST read
ZERO. ALWAYS make
sure the accumulator
circuit pressure reads
zeropriortoperforminganymaintenanceonthepump.
DANGER - AMPUTATION RISK
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MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 11
NOTES
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