Multiquip LS500, LS400 User Manual

OPERATION AND PARTS MANUAL

SERIES

MODELS LS400/LS500

CONCRETE PUMPS

(DEUTZ F4L2011, BF4L2011 DIESEL ENGINES)

Revision #6 (09/19/11)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

LS400/LS500 PUMP — PROPOSITION 65 WARNING

Proposition 65 W arning

Diesel engine exhaust and some of

PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

NOTES

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 3

LS400/LS500 PUMP —TABLE OF CONTENTS

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 DRA

COMPONENT DRACOMPONENT DRA

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

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

N View Parts Diagrams

N Order Parts N Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Par ts

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)

Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

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.*

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.*

Note: Discounts Are Subject To Change

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

When ordering parts, please supply:

R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R 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.

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Tr uc k  N Ground N Next Day N Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 5

LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

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 instructions for the safe and efficient operation of the Multiquip Mayco 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.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

LS400/LS500 Concrete

pump. Refer

HAZARD SYMBOLS

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:

WARNING - LETHAL EXHAUST GASES

WARNING - EXPLOSIVE FUEL

is running or hot. 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.

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.

Diesel fuel

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 extremely flammable, and

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 6 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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.

LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hands, hair

moving parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

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.

CAUTION - OVER-SPEED CONDITIONS

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.

and clothing away from all

fingers

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your concrete pump, other property, or the surrounding environment.

ALWAYS wear approved protection.

This machine is capable of producing noise levels above 85 dB. Hearing protection is required.

Always wear eye protection.

respiratory

This

pump

, other property, or the surrounding environment could be damaged if you do not follow instructions.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 7

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

■

DANGER - READ OPERATION AND PARTS

Failure to follow instructions in this manual may lead to

death!

serious injury or even operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the LS400/LS500 concrete pump:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

This equipment is to be

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or pump.

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with cause serious burns.

■

The engine section of this pump requires an adequate free flow of cooling air. operate the 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 pump or engine and may cause injury to people. Remember the pump's engine gives off carbon monoxide gas.

■

ALWAYS refuel in a well-ventilated area, away from sparks and open flames.

hot!

components can

NEVER

DEADLY

■

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.

■

ALWAYS check the machine for loosened threads or bolts before starting.

■

ALWAYS wear proper respiratory (mask),

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.

hearing

and

■

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool.

NEVER machine. Fire or explosion could result from

fuel vapors

engine. NEVER operate the pump in an explosive atmosphere or

near combustible materials. An explosion or fire could result causing severe

Topping-off to filler port is dangerous, as it tends to spill fuel.

ALWAYS remove the unattended.

ALWAYS block the slope.

ALWAYS maintain this equipment in a safe operating condition at all times.

ALWAYS stop the engine before servicing, adding fuel or oil.

smoke

around or near the

, or if fuel is spilled on a

bodily harm or even death.

ignition key

wheels

when leaving the pump

on the unit when using on a

hot!

PAGE 8 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

■

NEVER run engine without air filter. Severe engine damage may occur.

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using pump.

■

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■

DO NOT operate this equipment unless the hopper grate, 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 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.

■

Keep hands out of the hopper when the engine is running.

■

DO NOT disconnect hose couplings or nozzle while under pressure. Relieve pressure by activating the reverse function switch located on the control panel.

■

Unauthorized equipment modifications will void all warranties.

inexperienced

and

unauthorized

people away

TRANSPORTING

■

Towing

■

ALWAYS shutdown engine before transporting the pump. Tighten fuel tank cap securely to prevent fuel from

spilling. Drain fuel when transporting pump over long distances

or bad roads.

Before towing, check the hitch and secure the safety chain to the towing vehicle.

When towing, an adequate safety chain must be 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 steel ball rated for minimum of 6,000 lbs. Use 1" hardened steel pull pin, if not equipped with ball hitch.

This equipment shall not be towed or operated by individuals who cannot read understand the signs, decals or operating instructions.

When towing at night,

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.

always

have rear tail lights ON.

■

Check all fasteners periodically for tightness. Also check towing tongue bolt, lock nut and wheel lug nuts for wear.

■

Test the test is to shut down the engine.

■

Refer to the 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.

pump's ON/OFF

DEUTZ Engine Owner's Manual

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 9

switch. The purpose of this

for engine

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

MAINTENANCE SAFETY

DANGER - AMPUTATION RISK

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

engine is running or if pressure is in the hydraulic system.

Prior to performing any maintenance on the pump, follow described lock out-tag out procedures. Stop the 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 pressure reading on the accumulator pressure gauge ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump.

■

NEVER lubricate components or attempt service on a running pump .

MUST

of injury or

read

AMPUTATION

if the

■■

■

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 immediately with plenty of water.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

■■

contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

EMERGENCIES

clothing or skin

, rinse skin or clothing

■

ALWAYS allow the pump a proper amount of time to cool before servicing.

■

Keep the pump in proper running condition.

■

Fix damage to the pump immediately and always 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.

BATTERY

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

always

wear safety glasses.

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

■

In emergencies nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

fire extinguisher

first aid kit

always

know the location of the

keep a phone on the job site

and

fire department

. This

PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

NOTES

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 11

LS400/LS500 PUMP — SPECIFICATIONS

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dohteMgnipmuPnotsiPgnitacorpiceR

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thgieHgnipmuPlacitreV )m67(.tf052fossecxEotpU

erusserPecaFnotsiPisp

ecnatsiDgnipmuPlatnoziroH *)m503(.tf0001

yticapaCxoBnoitacirbuLrednilyC )sretiL6.7(snollaG2

iulFciluardyH )sretiL981(snollaG05

SeriT )mm653xmm781(.ni41x.ni53.7

yticapaCd

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yticapaCreppoH reximerver/dwflanoi

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PAGE 12 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — DIMENSIONS

SNOISNEMID.3ELBAT

.FERSNOISNEMID

A).mc2.901(.ni34

B).mc734(.ni271

C).mc16(.ni42

D).mc8.771(.ni07

E).mc2.271(.ni86

Figure 1. Dimensions

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 13

LS400/LS500 PUMP — IMPORTANT HAND SIGNALS

Figure 2 displays the basic hand signals commonly used in concrete pumping operations.

Figure 2. Operation Hand Signals

PAGE 14 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — GENERAL INFORMATION

CONCRETE MIX DESIGN

Mix design is most important to achieve maximum pumpability. Pumpability is affected by, among other factors, the type and gradation of aggregate used. Natural aggregates make a more workable mix and pump more readily than crushed aggregates. 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 aggregates in the mix.

The term “aggregates” describes all of the solid materials, from the largest rock to the smallest grain of sand, contained in the concrete mix.

Concrete mixes with a consistency as dry as one-inch slump and as wet as ten-inch slump have been pumped; but for maximum efficiency from the pump, a slump ranging from two to six inches will produce a more workable mix than one that contains more or less water.

The principle of concrete pumping is based on self-lubrication. As it moves through the transfer line, the concrete takes the shape of a plastic cylinder. It is forced through the transfer line on a film of mortar that is self-troweled to the service of the transfer line around its full periphery by the slug of concrete itself.

A slump rating should be used with discretion; it is not always a 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 tend to separate. In addition to affecting the strength and quality of the concrete, the delivery system will not tolerate separation. Overly dry mixes are similarly unsatisfactory if they lack plasticity and tend to be crumbly. To be properly pumped, the mix must be able to continuously coat the inside of the line with a lubricating seal of mortar.

There are four ways in which this seal can be lost:

1. By pumping excessively wet mixes which do not have enough cohesion to hold together.

2. By pumping harsh undersanded concrete with poorly graded aggregates which can jam together when the pressure becomes too great for the insufficient amount of sand to hold the aggregates apart.

3. By getting a rock pocket, such as mixer tailings, into the pump valve. This rock pocket will have an insufficient coating of mortar and the mix will not be plastic enough to allow the valve to operate or the mix to move in the line.

4. Through excessive bleeding. If the mix is short or fines, but the sand is otherwise fairly well graded, bleeding will not normally create any problems as long as the pump continues operation. But, if the pump is shut down, bleeding can result in a loss of lubrication and blocked erratic flow.

The above are bad concrete practices, regardless of how the mix is to be placed. But, these points do show that special mixes are not always needed, within limits, for pumping concrete. Good aggregate gradation is most important to pump concrete the maximum distance.

The use of admixtures can have a beneficial effect on pumpability. Most of the dispersing agents will fatten, retard bleeding, and increase workability. Thus, the average concrete can be pumped for appreciably longer distances. Air entraining agents will also improve workability, although they cannot be used as a substitute for good gradation of the aggregate. Pumping will not appreciably affect the final air content of the mix. High-early cement tends to give a more readily pumpable mix with superior water retaining qualities. However, if delays are likely to occur, extra care must be exercised due to the faster setting time over regular cement.

The Mayco LS400/LS500 models will pump a wide variety of concrete pump mixes. But, there are guidelines that must be followed. Use this information in conjunction with the section of this manual.

Operation

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 15

LS400/LS500 PUMP — GENERAL INFORMATION

REGIONAL DIFFERENCES

Concrete is made by mixing locally available rock and sand with cement and water. For this reason there are great differences in 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 concrete pump be will working in. Therefore, the mixes listed in Appendix - Concrete Mix Information will provide a basic guideline for establishing the proper mix design for your area.

Use this information to specify your requirements to your local ready-mix batch plant, contractor and civil engineer. It may take minor adjustments to make a mix pumpable, so you should explain your needs.

The elements that have to be controlled and consistently maintained by the batch plant are:

1. The sizing and mix percentage of rocks, gap graded from the largest down through the smallest sizes.

2. Sand with a sieve analysis that has the proper percentage of fines, ASTM C33 spec.

3. Sufficient cement to produce the required design strength of the concrete and provide the lubricating binder to pump the concrete through the delivery system.

5. The proper amount of water to make a workable slump and plasticize the mix.

In addition, this Mayco Concrete Pump can be used to pump a large aggregate hard rock as follows:

1. Pea rock (1/2" minus) pump with mixes being as low as 30% rock and 70% sand. (See page 44, for comments on cleaning the pump.)

2. Shortening pea rock when used with an air compressor and nozzle. (See back pages for recommended setup.)

3. “Mud Jacking”, high pressure grouting.

Use a minimum of:

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. Admixture pump-aid if necessary.

PAGE 16 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — HOW IT WORKS

The following is a brief explanation of how the concrete cylinders, hydraulic cylinders, shuttle tube, valves and hopper work in sequence to pump 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 hydraulically connected together creating a “slave circuit,” which allows hydraulic oil to transfer from one piston to the other.

The two part cycling sequence is initiated by an electrical signal generated by two proximity switches activated by the drive cylinder. The proximity switches are normally open, 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 and the shuttle cylinder.

A one-gallon accumulator assists the movement of the shuttle tube. This circuit assures that the shuttle tube will throw with the same intensity of each stroke regardless of how fast the main drive cylinders are cycling.

TO TANK

HYDRAULIC CYLINDERS

SLAVE

OIL

SHUTTLE TUBE MOTION

HIGH PRESSURE

OIL FROM PUMP

PROXIMITY

SWITCH

CONCRETE CYLINDERS

PISTON

CUP

SHUTTLE TUBE

Figure 4. Pumping Cycle 2

In the first cycle, hydraulic pressure is applied to cylinder (B), causing the hydraulic piston, which is connected to the concrete piston and piston cup, to discharge concrete into the delivery line (Figure 3).

As one cylinder is discharging concrete, the hydraulic oil from the rod side (B) of the drive cylinders is being transferred through the slave circuit causing the opposite cylinder (A) to move back on the suction stroke, filling the cylinder with concrete.

The shuttle tube is sequenced to pivot to each concrete cylinder as the drive cylinders stroke to push concrete. As the second cycling sequence begins (Figure 4), the shuttle tube pivots to the opposite cylinder (A). The hydraulic piston passes under the proximity switch and sends pressure to the piston, causing it to stroke and discharge concrete into the delivery line. Hydraulic oil is transferred through the slave circuit to cylinder B, causing it to start a suction stroke, refilling it with concrete. The pumping sequence then repeats for the duration of the operation.

Figure 3. Pumping Cycle 1

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 17

LS400/LS500 PUMP — PUMP COMPONENTS

Figure 5. Major Pump Components

PAGE 18 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — PUMP COMPONENTS

Figure 5 illustrates the location of the major components for the LS400/LS500 Concrete Pump. The function of each component 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 – Use this jack stand to level and support the rear end of the pump. NEVER deploy on un-level ground and always check for firmness of ground.

7. Shuttle Cylinder – Under pressure, the shuttle cylinder 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. Tire inflation pressure is the most important factor in tire life. Pressure should be checked to 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.

50 psi cold

15. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if level is low.

16. Accumulator Pressure Gauge– Used to monitor accumulator pressure. Pressure should read at least 1750 psi for correct pump operation.

17. Pumping Pressure Gauge – Used to monitor pressure in the concrete cylinders and shuttle tube.

18. Control Box – Contains the electrical components required to run the pump. See Control Box Components section for component callouts.

19. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell) holds approximately 40 gallons (176 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, replace 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 sure both the right and left running lights are functioning correctly before towing the pump.

9. Battery – This unit uses a +12 VDC type battery. ALWAYS use gloves and eye protection when handling the battery.

10. Hydraulic Pump – This unit incorporates an axial variable displacement hydraulic piston pump.

11. Heat Exchanger – Reduces temperature of the hydraulic oil. The exchanger draws oil from the hydraulic tank through a filter and into the heat exchanger before allowing it to flow into the hydraulic system.

12. Accumulator – Stores hydraulic oil under pressure and releases it to the shuttle cylinder and provides the pressure needed to ensure enough force is provided during cycle.

13. Remixer Control Lever – Controls the forward/reverse motion of the hopper remixer paddles.

14. Hydraulic Oil Sight Glass – Use to determine the amount of hydraulic oil remaining in tank. The sight glass also contains a temperature gauge for monitoring the temperature of the hydraulic oil.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 19

23. Remixer Motor – Drives the remixer paddles inside

24. Hopper/Hood – Lift hood to fill. Concrete from a Redi-

25. Tow End Jack Stand – Use this jack stand to level

the hopper. The motor direction is controlled by the remixer control lever.

Mix truck is poured into this hopper. The hopper can hold 10 cu. ft of concrete with optional forward/reverse mixer. NEVER put hands or any other parts of you body into the hopper.

and support the tow end of the pump.

LS400/LS500 PUMP — DIGITAL CONTROL PANEL COMPONENTS

ACCUMULATOR

PRESSURE

PUMPING

PRESSURE

DECREASE

FORWARD

AUTOMATIC

RESET

SET

VOLUME

FLOW

DIRECTION

INCREASE

REVERSE

JOG

SCROLL

Figure 6. Pump Digital Control Panel Components

1. Emergency Stop Button – Press emergency stop

9. Cylinder Stroke Control Switch – This 2-position

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.

10. Manual Cylinder Jogging Switch – This 2-position

4. Scroll Switch – Allows the operator to scroll the various 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

11. Stroke Volume Control Switch – Increases or

controls the direction of flow for any mix in the pump. The

leftmost

forward and the

position sets the pumping direction to

rightmost

position sets the pumping

12. Accumulator Pressure Gauge – This gauge monitors

direction to reverse.

8. Pumping Control Switch – This 3-position switch controls the pumping of the pump. The position (REMOTE) is for use with the remote control unit, the pumping operation, and the

leftmost

position (LOCAL) is for normal

centermost

rightmost

13. Main Pressure Gauge – This gauge monitors the

position

(CENTER OFF) prevents pumping.

OFF

START

CONTROL

REMOTE

LOCAL

CENTER

OFF

CYLINDER STROKE

JOG “B”

JOG “A”

switch controls the pumping function. The position (AUTOMATIC) sets the pump to

cycling

. Set the switch to this position for normal pump

IGNITION

REMOTE

leftmost

automatic

operation. The

rightmost

automatic to to be manually cycled using the

Jogging Switch

position (JOG) changes the pump from

manual cycling

. This allows the cylinders

Manual Cylinder

switch allows the operator to manually jog the cylinders to assist in clearing material line packs and is used to test pumping pressure (See

Initial Start-up Procedure

section of this manual for testing procedure). The

leftmost

rightmost

position jogs Cylinder “A” and the

position jogs Cylinder “B”.

decreases the number of strokes per minute of the pump.

the internal pressure of the Accumulator tank. Normal internal pressure should read approximately 1750 PSI during pumping.

system pressure while pumping material. The maximum pressure rating is 4400 PSI ± 50.

PAGE 20 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — DIGITAL READOUT SCREEN

PRIMARY SCREEN

Screen 5

Displays the ON/OFF electrical signal status of the various

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.

12 volt solenoids (Swing A circuit, Main A circuit, Main B circuit).

INDICATES

SWING A CIRCUIT IS OFF

Indicates electrical malfunction - Refer to Troubleshooting section.

INDICATES STATUS OF PUMP ( ON OR OFF)

INDICATES BATTERY CHARGE

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW OIL PSI

SECONDARY SCREENS

INDICATES ENGINE RPM

INDICATES ELECTRIC MALFUNCTION

INDICATES

MAIN B CIRCUIT IS OFF

Screen 6

Displays the ON/OFF electrical signal status for the Proximity Switch A, Proximity Switch B, Engine Fuel Solenoid, and Unloader Solenoid.

INDICATES

PROXIMITY A CIRCUIT IS OFF

Screen 2

Displays the position of the VOLUME CONTROL switch by indicating whether the increase or decrease position is on or off.

INDICATES VOLUME SWITCH IS NOT IN

THE - POSITION

FLOW DEC OFF FLOW INC ON

INDICATES VOLUME SWITCH IS IN THE + POSITION

INDICATES UNLOADER CIRCUIT IS OFF

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.

INDICATES THROTTLE IS ON

Screen 3

Displays the number of hours the engine and pump have been used and the number of faults the pump has registered. All three indicators can be reset to zero by the RESET switch on the control panel.

INDICATES NO. OF HOURS PUMP HAS BEEN USED

INDICATES NO. OF FAULTS DETECTED

INDICATES NO. OF HOURS ENGINE HAS BEEN USED

MESSAGE OR INSTRUCTION

E HRS: 00000.0 PMP HRS: 00000.0 FAULTS: 00000000 RESET TO CLEAR

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.

INDICATES THE NO. OF YARDS PER HOUR

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.

INDICATES THE FUEL SOLENOID IS OFF

Screen 9

Displays the communication status of the (optional) radio remote control. To activate a new remote control connection,

INDICATES A RUNNING COUNT OF NO. OF STROKES

STROKE CTR: 0000

PRESS RESET TO ZERO STROKE CTR

MESSAGE OR INFORMATION

use the reset switch on the control panel.

IINSTRUCTION OR MESSAGE

SWING A OFF

MAIN A OFF MAIN B OFF

PROX A OFF PROX B ON FUEL SOL OFF UNLOADER OFF

THROTTLE ON STROKES: 20 STROKES/MIN 8.2 YDS/HR 10.7

TO TEST FUEL SOL PRESS RESET FUEL SOL OFF

RADIO ADDRESS COMMUNICATING PRESS RESET TO LEARN A NEW ONE

INDICATES

MAIN A CIRCUIT IS OFF

INDICATES PROXIMITY B CIRCUIT IS ON

INDICATES

FUEL SOLENOID CIRCUIT IS OFF

INDICATES THE NUMBER OF STROKES

INDICATES THE NO. OF STROKES PER MINUTE

INSTRUCTION

OR MESSAGE

INDICATES THAT RADIO REMOTE IS ON

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 21

LS400/LS500 PUMP — ENGINE COMPONENTS

Figure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components

INITIAL SERVICING

The engine (Figure 7) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1. Fuel Filter – Service the fuel filter as recommended in the maintenance section of this manual.

2. Oil Filter – Prevents dirt and other debris from entering the engine. Service the oil filter as recommended in the maintenance section of this manual.

3. Crankcase Drain Plug – Remove this plug to drain engine oil from the engine crankcase. For best results drain engine oil when oil is warm.

4. Dip Stick – Remove dipstick to determine if the engine oil level is low. If low add oil as specified in Table 4.

5. V-Belt Cover – Remove this cover to gain access to the V-belt. When replacing V-belt, use only recommended type V-belt.

6. Alternator – Provides power to the electrical system. Replace with only manufacturers recommended replacement parts.

7. Air Filter/Cover – Prevents dirt and other debris from entering the fuel system. Release the latches on the side of the air filter cover to gain access to filter element.

8. Oil Filler Port/Cap – Remove this cap to add engine oil to the crankcase. Fill with recommended type of oil as specified in the maintenance section of this manual.

9. Starter/Solenoid – This engine uses a 12 VDC , 2.7kW (3.7 HP) starter motor with solenoid.

Operating the engine without an air filter, with a damaged air filter, or a filter in need of replacement will allow dirt to enter the engine, causing rapid engine wear.

PAGE 22 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — INSPECTION

CAUTION - GENERAL SAFETY GUIDELINES

NEVER operate the pump in a

confined area or enclosed area structure that does not provide ample

free flow of air

NEVER operate the pumps's engine

with the engine hood removed. The possibility exists of and

clothing

the V-belt, causing injury and bodily harm.

NEVER place hands or feet inside the ALWAYS make while the engine is running. ALWAYS

shut down the engine before performing any kind of maintenance service on the pump.

ALWAYS wear approved

hearing

operating the pump .

hands, long hair

becoming entangled with

protection before

eye

and

hopper

FUEL CHECK

1. Check the fuel gauge built into the fuel tank cap (Figure 8) to determine if the pump's engine fuel is low. Refuel as needed.

WARNING - EXPLOSIVE FUEL

Diesel fuel

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 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.

is extremely flammable, and

See Figures 5, 6, and 7 for the location of any control or component referenced in this section.

BEFORE STARTING

1. Read safety instructions at the beginning of manual.

2. Clean the larly the engine cooling air inlet, and heat exchanger.

3. Check the replace air filter with a new one as required.

4. Check fastening nuts and bolts for tightness.

WARNING - EXPLOSIVE FUEL

Handle fuel safely. Diesel fuel is highly can be dangerous if refueling. DO NOT attempt to refuel pump if the engine is hot or running. ALWAYS allow engine to refueling.

entire pump

air filter

, removing dirt and dust, particu-

for dirt and dust. If air filter is dirty,

mishandled. DO NOT

flammable

smoke

cool

before

and

while

Figure 8. Fuel Cap Gauge

2. If fuel is low, remove fuel filler cap and fill with

diesel fuel

(Figure 9).

Figure 9. Adding Diesel Fuel

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 23

LS400/LS500 PUMP — INSPECTION

ENGINE OIL CHECK

1. Remove the engine oil dipstick from its holder (Figure 10).

6. The oil listed in Table 4 is recommended to ensure better engine performance. Use class CD or higher grade motor oil.

Figure 10. Engine Oil Dipstick

2. Make sure pump/engine is placed on level ground.

3. Pull the engine oil dipstick (Figure 11) from its holder.

HYDRAULIC OIL CHECK

1. Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass (Figure 12).

Figure 11. Engine Oil Level

4. Verify that oil level (Figure 11) is maintained between the two notches on the dipstick.

5. If the pump's engine oil is low, fill engine crankcase with lubricating oil through filler hole, but DO NOT overfill.

PAGE 24 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

NORMAL OIL LEVEL

HYDRAULIC OIL TEMPERATURE

MINIMUM OIL LEVEL

Figure 12. Hydraulic Oil Sight Glass

2. If the hydraulic oil level is low, remove the cap just above

the oil level sight glass (Figure 13) and add the correct amount of hydraulic oil to bring the hydraulic oil level to a normal safe operating level. (Use Shell oil Tellus 68 or Mobil oil DFE26).

Figure 13. Hydraulic Oil Filler Hole

LS400/LS500 PUMP — INSPECTION

3. Check the oil level in the

with up to 3 gallons of SAE #30 motor oil (Figure 14). The oil level must be checked daily. The lubrication box should be serviced as described in the maintenance section.

Figure 14. Filling the Lubrication Box

lubrication box

. If low, fill

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 25

LOCATION OF PUMP

1. Place the pump in the best location on the site to pump concrete efficiently.

2. Lay down the hose in the shortest distance possible.

REAR STABILIZER JACKS

To reduce excessive vibration and rocking of the pump, set the rear stabilizers as follows:

LS400/LS500 PUMP — SET-UP

1. Locate both the left and right rear stabilizer jacks (Figure 15).

REAR STABILIZER JACKS

Figure 17. Rear Stabilizer Stand Deployment

HYDRAULIC REAR STABILIZER JACKS (OPTIONAL)

If your pump comes equipped with hydraulic rear stablizers, they can be controlled as follows:

1. Push down the middle control lever (see Figure 18) to extend the right hydraulic rear stabilizer.

2. Push up the middle control lever (see Figure 18) to retract the right hydraulic rear stabilizer.

3. Push down the rightmost control lever (see Figure 18) to extend the left hydraulic rear stabilizer.

4. Push up the rightmost control lever (see Figure 18) to

Figure 15. Locating Rear Stabilizer Jacks

2. Remove the and then

cotter pin

pull

the handle tee to release the stabilizer

from the handle tee bolt eye,

retract the left hydraulic rear stabilizer.

jack (Figure 16).

3. Position both rear stabilizers jacks on firm (not loose)

level

ground (Figure 17).

MIDDLE CONTROL LEVER (CONTROLS RIGHT

HYDRAULIC STABILIZER)

LEFT HYDRAULIC STABILIZER JACK

4. Align the hole on the stabilizer jack with the hole on the frame body and

5. Insert the cotter pin into handle tee bolt eye to lock the

insert

handle tee bolt.

RIGHT HYDRAULIC STABILIZER JACK

stabilizer jack.

COTTER PIN

REAR STABILIZER STAND

Figure 18. Control Levers for Hydraulic Rear Stabilizers

HANDLE T-BOLT

BOLT EYE

NEVER place feet under jack while operating. ALWAYS retract rear stabilizer jacks prior to towing. ALWAYS retract rear stabilizer jacks prior to servicing to

Figure 16. Rear Stabilizer Jack

PAGE 26 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

relieve load (working pressure).

RIGHTMOST CONTROL LEVER (CONTROLS LEFT HYDRAULIC STABILIZER)

WARNING - REAR STABILIZER SAFETY

LS400/LS500 PUMP — START-UP PROCEDURE

STARTING PROCEDURE

4. Place the position (Figure 22).

WARNING - GENERAL SAFETY GUIDELINES

DO NOT attempt to operate this concrete pump until

FORWARD REVERSE

the Safety, General Information and Inspection sections have been read and understood.

Figure 22. Direction Control Switch (FORWARD)

5. To start the engine, insert the key (Figure 23) into the

1. Locate the Emergency Stop Switch (Figure 19) on the

ignition switch and turn the key to the ON position.

Hydraulic Pump Control Box. Turn the Emergency Stop switch clockwise and release (open). This will allow the engine to start.

Figure 19. Emergency Stop Switch

If the Emergency Stop switch is in the

6. When the ignition key is in the ON position, the Digital Readout Screen (primary) will cycle through 3 displays as shown in Figure 24.

CLOSED position (stop), engine will not start. To start the engine, make sure the Emergency Stop switch is in the OPEN position (fully extended).

Direction Control Switch

to the FORWARD

Figure 23. Ignition Switch

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW OIL PSI

2. Turn the

Cylinder Stroke Control Switch

to the

AUTOMATIC position (Figure 20).

AUTOMATIC JOG

Figure 20. Cylinder Stroke

Control Switch (Automatic)

3. Place the

Pumping Control Switch

to the CENTER

OFF position (Figure 21) for normal pumping operation.

LOCAL

CENTER

OFF

REMOTE

Figure 21. Pumping Control Switch (OFF)

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW RPM FAULT

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V END OF MESSAGE

Figure 24. Primary Screen (Ignition Key ON)

7. Turn the key to the START position and listen for the engine to start. In warm weather let engine warm up for 5 minutes. In cold weather let engine warm up for 10 minutes.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 27

LS400/LS500 PUMP — OPERATION

HOSE LUBRICATION

Before pumping, it is necessary to lubricate the hose.

PUMPING

WARNING - SAFETY GLASSES

This procedure prevents separation and blockages in the hose. Inspect the lines at all times to prevent problems.

Before concrete is discharged into the hopper, it is suggested that 3 to 4 gallons of water be sprayed into the hopper, followed by approximately 5 gallons of a creamy cement and water slurry (1/2 bag of cement to 5 gallons of water).

Getting the concrete to flow through the hose at the start of the pumping cycle can be one of the most critical operations of the pour.

1. Place the

PRIMING THE PUMP WITH SLURRY MIXTURE

position (Figure 26) for normal pumping operation.

It is CRITICAL to the successful operation of a concrete pump that the manifold and all delivery hoses, pipes and elbows are coated with a film of lubrication BEFORE you attempt to pump concrete.

Safety glasses MUST be worn at all times when operating the pump. Failure to follow safety guidelines can result in

A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job.

Pumping Control Switch

LOCAL

serious

injury.

to the LOCAL

REMOTE

Failure to properly prepare the pump and system will result in a “dry pack” of concrete, blocking the shuttle valve tube or delivery line.

Figure 26. Pumping Control Switch (LOCAL)

1. Connect the entire delivery system to the pump. Pour 5 gallons of water and a bag of raw cement into the hopper.

2. Place the

Direction Control Switch

to the REVERSE

position (Figure 25). This will mix the water and cement

2. Slide the right to increase the volume to approximately 10 strokes

per minute. Sliding the volume control to the left will

decrease

into slurry.

FORWARD

Figure 25. Direction Control Switch (REVERSE)

REVERSE

thumping

The thumping sound represents the number of strokes

3. Mix the slurry to the consistency of a smooth batter.

4. Position the first ready-mix truck at the hopper. Check the concrete. DO NOT discharge concrete into hopper at this time.

5. Place the

Direction Control Switch

in the FORWARD

per minute (volume) of the pump.

3. Scroll through the switch to go to Screen 7 (Figure 28). This screen will show the volume in strokes per minute.

position. This will start the flow of the slurry to the hoses.

6. Keep the slurry flowing until most of it is pumped out. However, make sure that some slurry is left on the hopper when concrete is first discharged from the ready-mix truck.

CENTER

OFF

Volume Control Switch

(Figure 27) to the

pump volume.

DECREASE

VOLUME

INCREASE

VOLUME

Figure 27. Volume Control

sound (cylinder stroke) should be heard.

Digital Readout Screen

THROTTLE ON

with the scroll

STROKES: 100 STROKES/MIN 10.0 YDS/HR 0.0

Figure 28. Strokes Per Minute Display

PAGE 28 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — OPERATION

4. Let the pump cycle until the hydraulic oil temperature

(Figure 29) is approximately 50° to 60° F.

HYDRAULIC OIL TEMPERATURE

Figure 32. Hopper Remixer Blades (Rotation)

Figure 29. Hydraulic Oil Temperature Gauge

5. The Accumulator Pressure Gauge (Figure 30) should

read approximately 1750 pounds per square inch (psi).

Figure 30. Accumulator

Pressure Gauge

6. Push the Hopper Remixer Control Lever DOWNWARD

(Figure 31). The Hopper Remixer Control lever is located to the left of the Hydraulic Temperature gauge. Observe that the blades (Figure 32) inside the hopper are turning in a clockwise direction (FORWARD). To turn the blades in a counterclockwise direction (REVERSE), push the Hopper Remixer Control lever UPWARD (Figure 31).

7. Slide the

Volume Control Switch

(Figure 27) to the right to increase the volume to 25-30 strokes per minute. Slowly discharge the concrete from the ready-mix truck into the hopper and completely fill it. Keep the pump running continuously until concrete is discharging at the end of the delivery system. If the pump is stopped during this procedure, a blockage may occur.

CAUTION - HOSE/LINE BLOCKAGE

If hoses or lines are lines are

kinked

blocked

for any reason, or if the

when starting up or during the 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

whip

move

in a manner

that could cause injury to personnel.

8. It is important that once the slurry procedure is completed, and concrete is flowing through the hose, DO NOT stop the pour until all the slurry is pumped out and the concrete has reached the end of the hose. The only time to stop the pump during the priming procedure is if a blockage occurs.

9. If it is necessary to replace or add a section of delivery system, after the initial lubrication procedure, wet the inside area of the hose, pipe or elbow with 5 gallons of water per 25 foot length, before adding it to the system.

When pumping long distance or pumping stiff mixes, you can expect a drop in volume compared to shorter lines and wetter mixes due to the change in valve efficiency or cavitation.

Figure 31. Hopper Remixer Control Lever

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 29

LS400/LS500 PUMP — OPERATION

REMOTE CONTROL (OPTIONAL)

The LS400/LS500 Concrete Pump has a remote control feature that allows the pump to be remotely controlled. If desired, the pump can be operated via a receiver/transmitter

4. Reinstall the control panel and tighten the 2 screws.

5. On the top of the unit, to the right of the control box (Figure 36), hammer out the knock-out hole and install the remote antenna.

(radio) or a hardwire method, which utilizes a 25-ft. extension cable. Contact MQ Sales Department to order remote control.

Radio Remote Control

KNOCK-OUT

Installation of the Radio Remote Control Assembly

HOLE

1. Remove the two screws on the digital control panel of the pump. See Figure 33.

REMOVE 2 SCREWS

SCR

OLL

RESET

SET

ECREA

CREASE

F L

WARD

C T

I O

REVE

RSE

TOM

LOCAL

TIC

JOG

MOT

CENT

T A

YLINDE

I G N

JOG“A”

RST

I T

I O

ROKE

JOG“B”

R E

O T E

CONTROL BOX

ANTENNA CONNECTOR CABLE

Figure 33. Removing Screws from Control Panel

2. Tilt and slowly pull out the control panel and place on top of box to gain access inside the box. See Figure 34.

6. Connect the antenna cable to the connector on the rear of the control box (Figure 36).

Radio Remote Control Buttons Operation

ANTENNA

REAR OF CONTROL BOX

CONTROL BOX CONNECTOR

Figure 36. Antenna Installation

The pumping operation can be performed by radio remote control (Figure 37). Before using remote control, move the Pumping Control Switch on the control box to the REMOTE position. The buttons on the remote control have the following functions.

ON/OFF - Turns the power on or off. When power is on the power LED lights red. If the battery LED turns red, 9V battery needs to be replaced.

Figure 34. Pulling Out Control Panel

3. Install the wireless remote module with the 2 screws and nuts provided inside the control panel. Connect the 3-wire connector from the wireless remote module to the electronic control unit. See Figure 35.

E-STOP - Turns off the pump completely in an emergency. PUMP ON/OFF - Starts and stops the forward pumping. PUMP REV - momentarily pumps in reverse direction. VOLUME (+) - used to increase the pumping volume. VOLUME (-) - used to decrease the pumping volume.

SCREWS AND NUTS

ELECTRONIC CONTROL UNIT

WIRELESS REMOTE MODULE

CONNECTOR

Figure 35. Installing Remote Control Module

E-STOP

OFF

POWER LED

NOTE: OLDER MODELS MAYINDICATE

FLOW

INSTEAD OF

VOLUME

BATTERY LED

PUMP

ON/OFF

REV

VOLUME VOLUME

Figure 37. Radio Remote Control

PAGE 30 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

+ 118 hidden pages