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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.
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Proposition 65 Warning LS400/LS500 PUMP — PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
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NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 3
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LS400/LS500 PUMP —TABLE OF CONTENTS COMPONENT DRA COMPONENT DRA COMPONENT DRAWINGS WINGS WINGS MAYCO LS400/LS500 COMPONENT DRA COMPONENT DRAWINGS WINGS CONCRETE PUMPS Name Plate and Decals ..................................... 86-89 Frame Assy. .......................................................90-91 Proposition 65 Warning ............................................. 2 Axle Assy. ........................................................... 92-93 Table of Contents ...........................
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PARTS ORDERING PROCEDURES Ordering parts has never been easier! Choose from three easy options: Effective: st January 1 , 2006 Best Deal! Order via Internet (Dealers Only): If you have an MQ Account, to obtain a Username Order parts on-line using Multiquip’s SmartEquip website! and Password, E-mail us at: parts@multiquip. com. View Parts Diagrams To obtain an MQ Account, contact your Order Parts District Sales Manager for more information. Print Specification Information Use the interne
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LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS! Potential hazards associated with operation of the pump will Safety precautions should be followed at all times when be referenced with Hazard Symbols which appear throughout operating this equipment. Failure to read and understand this manual, and will be referenced in conjunction with Safety the Safety Messages and Operating Instructions could result Message Alert Symbols. Some examples a
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LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS CAUTION - RESPIRATORY HAZARDS NEVER operate equipment with covers, ALWAYS wear approved respiratory or guards removed. Keep fingers, protection. hands, hair and clothing away from all moving parts to prevent injury. CAUTION - SIGHT AND HEARING HAZARDS CAUTION - ACCIDENTAL STARTING This machine is capable of ALWAYS place the Engine ON/OFF switch in the OFF position. NEVER producing noise levels above 85 dB. perform maintena
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LS400/LS500 PUMP — RULES FOR SAFE OPERATION ■ NEVER touch the hot exhaust manifold, muffler DANGER - READ OPERATION AND PARTS or cylinder. Allow these parts to cool before servicing engine or pump. Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be ■ High Temperatures – Allow the engine operated by trained and qualified personnel only! This to cool before adding fuel or performing equipment is for industrial use only. service and main
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LS400/LS500 PUMP — RULES FOR SAFE OPERATION ■ NEVER run engine without air filter. Severe engine TRANSPORTING damage may occur. ■ ALWAYS shutdown engine before transporting the pump. ■ ALWAYS be sure the operator is familiar with proper safety ■ Tighten fuel tank cap securely to prevent fuel from precautions and operation techniques before using pump. spilling. ■ ALWAYS store equipment properly when it is not being ■ Drain fuel when transporting pump over long distances used. Equipment should
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LS400/LS500 PUMP — RULES FOR SAFE OPERATION ■■ MAINTENANCE SAFETY ■■■ DO NOT drop the battery. There is the possibility of risk that the battery may explode. DANGER - AMPUTATION RISK ■■■ DO NOT expose the battery to ■■ During routine maintenance or removing material open flames, sparks, cigarettes blockage, you will be required to put your hand in the etc. The battery contains combustible gases and liquids. concrete cylinders or near the shuttle tube. You are at If these gases and liquids come i
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NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 11
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LS400/LS500 PUMP — SPECIFICATIONS TABLE 1. PUMP SPECIFICATIONS M0 odel L0 S-40 LS-50 Up to 40 cu. Up to 50 cu. Pumping Rate yds. per hour* yds. per hour* Pn umping Method Reciprocating Pisto Maximum Aggregate Size 1-1/2 in. minus (38mm) Vertical Pumping Height Up to Excess of 250 ft. (76m) Pi iston Face Pressure 1150 ps Horizontal Pumping Distance 1000 ft. (305m)* Cylinder Lubrication Box Capacity 2 Gallons (7.6 Liters) Hydraulic Fluid Capacity 50 Gallons (189 Liters) Fuel Tank Capacity 40 Gal
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LS400/LS500 PUMP — DIMENSIONS TABLE 3. DIMENSIONS RS EF. DIMENSION A) 43 in. (109.2 cm. B) 172 in. (437 cm. C) 24 in. (61 cm. D) 70 in. (177.8 cm. E) 68 in. (172.2 cm. Figure 1. Dimensions MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 13
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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)
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LS400/LS500 PUMP — GENERAL INFORMATION There are four ways in which this seal can be lost: CONCRETE MIX DESIGN 1. By pumping excessively wet mixes which do not have Mix design is most important to achieve maximum pumpability. enough cohesion to hold together. Pumpability is affected by, among other factors, the type and gradation of aggregate used. Natural aggregates make a more 2. By pumping harsh undersanded concrete with poorly graded workable mix and pump more readily than crushed aggregate
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LS400/LS500 PUMP — GENERAL INFORMATION 5. The proper amount of water to make a workable slump and REGIONAL DIFFERENCES plasticize the mix. Concrete is made by mixing locally available rock and sand with In addition, this Mayco Concrete Pump can be used to pump a cement and water. For this reason there are great differences in large aggregate hard rock as follows: the pumpability of concrete from one region of the country to another. 1. Pea rock (1/2" minus) pump with mixes being as low as 30% r
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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
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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)
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LS400/LS500 PUMP — PUMP COMPONENTS Figure 5 illustrates the location of the major components for 15. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic the LS400/LS500 Concrete Pump. The function of each fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if component is described below: level is low. 1. Tow Hitch Coupler – Requires a 2-inch ball hitch or a 16. Accumulator Pressure Gauge– Used to monitor 3-inch pintle. Capable of towing 6,000 lbs. accumulator pressure. Pressure should rea
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0 0 0 0 0 0 2 2 0 0 0 0 5 5 1 1 P 0 0 5 5 O 2 2 1 1 T S Y C 0 0 0 0 LS400/LS500 PUMP — DIGITAL CONTROL PANEL COMPONENTS 5 3 1 12 4 RESET SCROLL SET 11 VOLUME ON OFF START INCREASE DECREASE ACCUMULATOR 2 PRESSURE IGNITION 13 FLOW CONTROL DIRECTION 7 LOCAL REMOTE FORWARD REVERSE 8 CENTER OFF CYLINDER STROKE AUTOMATIC JOG JOG “A” JOG “B” PUMPING REMOTE PRESSURE 6 9 10 Figure 6. Pump Digital Control Panel Components 1. Emergency Stop Button – Press emergency stop 9. Cylinder Stroke Control Switch –
