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PAGE 6 — MAYCO LS300G CONCRETE PUMP • OPERATION MANUAL — REV. #2 (09/09/19)

SAFETY INFORMATION

Do not operate or service the equipment before reading

the entire manual. 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.

SAFETY MESSAGES

The four safety messages shown below will inform you

about potential hazards that could injure you or others. The

safety messages specifi cally address the level of exposure

to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL

result in

DEATH

SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided,

COULD

result in

DEATH

SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided,

COULD

result in

MINOR

MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

Potential hazards associated with the operation of this

equipment will be referenced with hazard symbols which

may appear throughout this manual in conjunction with

safety messages.

OFF

Lethal Exhaust Gas Hazards

Explosive Fuel Hazards

Burn Hazards

Respiratory Hazards

Accidental Starting Hazards

Eye and Hearing Hazards

Pressure Hazards

Symbol

Safety Hazard

Rotating Parts Hazards

Hydraulic Fluid Hazards

Содержание MAYCO LS300G

Страница 1: ...ACCOMPANY THE EQUIPMENT AT ALL TIMES Revision 2 09 09 19 SERIES MODEL LS300G CONCRETE PUMP ZENITH Z428 GASOLINE ENGINE To find the latest revision of this publication or associated parts manual visit...

Страница 2: ...PAGE 2 MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PROPOSITION 65 WARNING...

Страница 3: ...se cancer birth defects or other reproductive harm If you are unfamiliar with the risks associated with the particular process and or material being cut or the composition of the tool being used revie...

Страница 4: ...2 25 Digital Control Panel Components 26 27 Engine Components 28 Inspection 29 31 Setup 32 Operation 33 38 Maintenance 39 51 Trailer Maintenance 52 54 Trailer Guidelines 55 69 Appendix Concrete Mix In...

Страница 5: ...MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PAGE 5 NOTES...

Страница 6: ...ER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY WARNING Indicates a hazardous situation which if not avoi...

Страница 7: ...numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency PUMP SAFETY DANGER NEVER pump volatile explosive flammable or low flash poin...

Страница 8: ...tness Also check towing tongue bolt lock nut and wheel lug nuts for wear Test the pump s emergency stop switch The purpose of this test is to shut down the engine in the event of an emergency Refer to...

Страница 9: ...l fuel tank Tighten fuel cap until it clicks BATTERY SAFETY DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarett...

Страница 10: ...and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches...

Страница 11: ...be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product Recyclers and man...

Страница 12: ...428 Weight with fluids 3 955 lb 1 794 kg Tire Size ST 225 75 R15 Options Wireless Remote Control Hopper Screen Vibrator Volume output will vary depending on mix design slump line size used and job sit...

Страница 13: ...RETE PUMP OPERATION MANUAL REV 2 09 09 19 PAGE 13 D C A E B Table 3 Pump Dimensions Reference Letter Dimensions in mm A 158 4 013 2 B 44 1 117 6 C 64 1 615 5 D 21 5 546 1 E 63 5 1 612 9 Figure 1 Dimen...

Страница 14: ...ATION MANUAL REV 2 09 09 19 CHUTE UP CHUTE DOWN STOP START PUMP SPEED UP SLOW PUMP DOWN STOP PUMP LITTLE BIT ADD WATER 4 GALLONS ALL DONE CLEAN UP DRIVE IN BACK UP PULL FORWARD BACK IN IMPORTANT HAND...

Страница 15: ...nuously 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 to...

Страница 16: ...on this Mayco Concrete Pump can be used to pump a large aggregate hard rock as follows Pea rock 1 2 minus pump with mixes being as low as 30 rock and 70 sand Reference Maintenance section for recommen...

Страница 17: ...e as compared to hose When pumping vertically using all hose it is recommended not to go higher than 50 feet with hose The hose should be tied off at intervals of 10 feet if possible Special attention...

Страница 18: ...blockage in the manifold when the pump is started 3 If it is necessary to wait 10 minutes or more for another load of concrete it is wise to start the pump and pump 6 or 8 strokes every 5 minutes to...

Страница 19: ...d where it is and clear it before further pumping DO NOT increase the engine speed to clear the blockage Increasing the engine speed will only compound the problem If a blockage occurs in a hose walk...

Страница 20: ...clamp and flip it up 4 Carefully knock the end of the hose away from the reducer GENERAL INFORMATION 5 Chip the concrete out of the reducer with the pry bar 6 Remove the reducer From the discharge end...

Страница 21: ...RS PISTON CUP CONCRETE CYLINDERS SHUTTLE TUBE SLAVE OIL SHUTTLE TUBE MOTION A B Figure 4 Pumping Cycle 2 In the first cycle Figure 3 hydraulic pressure is applied to cylinder B causing the hydraulic p...

Страница 22: ...PAGE 22 MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 Figure 5 Pump Components 1 3 4 4 2 13 16 14 15 19 20 5 9 7 11 10 8 18 6 17 12 2 PUMP COMPONENTS...

Страница 23: ...ponents section for component callouts 10 Inline Fuel Filter Replace or clean fuel filter as specified in the Maintenance section of this manual 11 OilFilter Preventsdirtandotherdebrisfromentering the...

Страница 24: ...PAGE 24 MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PUMP COMPONENTS CONTINUED Figure 6 Pump Components Cont 33 41 41 34 35 36 25 30 31 23 24 40 21 37 38 26 32 39 29 27 28 22...

Страница 25: ...newithoutanairfilter withadamaged air filter or with a filter in need of replacement will allow dirt to enter the engine causing rapid engine wear 31 Fuel Pump Delivers gasoline from the fuel tank to...

Страница 26: ...ch controls the pumping function The leftmost position AUTOMATIC sets the pump to automatic cycling Set the switch to this position for normal pump operation The rightmost position JOG changes the pum...

Страница 27: ...Screen 5 Displays the ON OFF electrical signal status of the various 12 volt solenoids Swing A circuit Main A circuit Main B circuit Screen 6 Displays the ON OFF electrical signal status for the Proxi...

Страница 28: ...or Provides power to the electrical system Replace with only manufacturer s recommended replacement parts 5 Oil Pan Holds a maximum of 4 quarts 3 8 liters of engine oil 6 Starter Solenoid This engine...

Страница 29: ...g any kind of maintenance service on the pump NOTICE ReferenceFigures5 6 and7forthelocationofanycontrol or component referenced in this section DANGER Handle fuel safely Motor fuels are highly flammab...

Страница 30: ...ngine crankcase with lubricating oil through filler hole but DO NOT overfill 5 The oil listed in Table 4 is recommended to ensure better engine performance Use class CD or higher grade motor oil Hydra...

Страница 31: ...ER LUBRICATION BOX SAE 30 WT MOTOR OIL INSPECTION CLEANINGTHE RADIATOR The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with comp...

Страница 32: ...le tee bolt eye and then pull the handle tee to release the stabilizer jack Figure 18 Rear Stabilizer Jack WARNING NEVER place feet under jack while operating ALWAYS retract rear stabilizer jacks prio...

Страница 33: ...tch is in the closed position STOP engine will not start To start the engine make sure the emergency stop switch is in the OPEN position fully extended 4 Place the direction control switch to the FORW...

Страница 34: ...ter 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 position This will star...

Страница 35: ...the OFF position Refer to Clearing Concrete Blockage Section THROTTLE ON STROKES 100 STROKES MIN 10 0 YDS HR 0 0 7 HYDRAULIC OIL TEMPERATURE 7 It is important that once the slurry procedure is complet...

Страница 36: ...MO TE CO NT RO L FL OW DIR EC TIO N VO LU ME LOC AL FOR WA RD AUT OM ATIC JOG RES ET SET DEC REA SE INC REA SE SCR OLL JOG A CYL IND ER STR OKE JOG B REV ERS E CEN TER OFF REM OTE ST AR T REMOVE 2 SCR...

Страница 37: ...p completely in an emergency PUMP ON OFF Starts and stops the forward pumping PUMP REV Momentarily pumps in reverse direction E STOP ON OFF PUMP REV VOLUME VOLUME PUMP ON OFF POWER LED NOTE OLDER MODE...

Страница 38: ...digital panel Figure 37 Remote Control Cable Before the remote control cable can be used the pumping volume rate must be set 1 Start the pump as outlined in the pumping section of this manual 2 Place...

Страница 39: ...y Acid Level X Check Fan Belt Condition X Check for Leaks X Check for Loosening of Parts X Replace Engine Oil and Filter 1 X Clean Air Filter X Check Fuel Filter Water Separator Bowl X Clean Unit Insi...

Страница 40: ...run Ensure that the maintenance area is well ventilated Exhaust contains poisonous carbon monoxide gas that can cause unconsciousness and may result in DEATH CAUTION ALWAYS allow the engine to cool b...

Страница 41: ...CE DO NOT run the engine with the air cleaner removed or without an element Checking Engine Oil Daily 1 When checking or adding oil place the machine so the engine is level 2 Pull the engine oil dipst...

Страница 42: ...bricating oil filter head 2 Using an oil filter wrench Figure 42 remove engine oil filter Figure 42 Engine Oil Filter Removal 3 Coat the rubber seal gasket surface of oil filter Figure 42 with clean 1...

Страница 43: ...iator cap until the unit has completely cooled The possibility of hot coolant exists which can cause severe burns Table 7 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point...

Страница 44: ...pressure water or compressed air at greater than 28 psi 193 kPa or a wire brush to clean the radiator fins Radiator fins damage easily MAINTENANCE Fuel Filter Replace the engine in line fuel filter F...

Страница 45: ...hock or Fire due to electric short circuit Disconnect battery cables before inspecting electrical system and never spark battery terminals to test for charge CAUTION Battery Safety Wear safety glasses...

Страница 46: ...to some solid part of the mixer truck to prevent hook from jumping off of the drum Run the pump at 6 strokes per minute maximum speed NOTICE NEVER use muriatic acid to clean the pump Acid will dissolv...

Страница 47: ...from the bottom of the box drain and clean the lubrication box Cleaning the Lubrication Box 1 Remove the top cover and the drain plug Figure 51 located at the bottom of the box and fully drain the in...

Страница 48: ...urfaces it is time for replacement Due to the motion of the shuttle tube the cutting ring experiences a quicker rate of wear as opposed to the wear plate The wear ring typically requires replacement t...

Страница 49: ...ear of the face plate Install over alignment studs and into concrete cylinders NOTICE Felt ring must be saturated with 30 wt oil prior to installation 13 Insert one 3 8 16 3 bolt into the open bolt ho...

Страница 50: ...gine is turned on PressureTest 1 To determine the pressure of the hydraulic system set the cylinder stroke control switch Figure 53 to the JOG position Figure 53 Cylinder Stroke Control Switch JOG NOT...

Страница 51: ...ting 3 Remove wheel and drum assemblies and spray a good anti corrosion compound CRC formula 5 56 under rubber boot on forward end of brake wheel cylinder Avoid spraying drum and brake lining 4 Grease...

Страница 52: ...tool rotate the starwheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Y...

Страница 53: ...te Brake components correct Replace and correct Dragging Brakes Brake lining thickness incorrect or not adjusted correctly Install new shoes and linings Enough brake fluid or correct fluid Replace rub...

Страница 54: ...The possibility exists of the trailer falling thus causing equipment damage and severe bodily harm even death DANGER When performing trailer inspection and maintenance activities you must jack up the...

Страница 55: ...is that the passing distance with a trailer is 4 times the passing distance without the trailer Shift your automatic transmission into a lower gear for city driving ALWAYS use lower gears for climbin...

Страница 56: ...your speed as road weather and lighting conditions deteriorate Always check for local trailer tow speed limits in your area WARNING Do not transport people on the trailer The transport of people puts...

Страница 57: ...s well as the area to the rear of it WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision Before each tow check tha...

Страница 58: ...weights of your tow vehicle without the trailer coupled Some of the trailer weight will be transferred from the trailer to the tow vehicle axles and an axle scale weighs all axles including the tow ve...

Страница 59: ...r are discussed below Ball Hitch Coupler Pintel Eye Coupler BALL HITCH COUPLER A ball hitch coupler Figure C connects to a ball that is located on or under the rear bumper of tow vehicle This system o...

Страница 60: ...ll WARNING A loose hitchball nut can result in uncoupling leading to death or serious injury Be sure the hitch ball is tight to the hitch before coupling the trailer the trailer tongue Wood or concret...

Страница 61: ...h unless the hitch has holes or loops specifically for that purpose Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose Break...

Страница 62: ...intle eye coupler Figure G connects to a pintle hook hitch that is located on or under the rear bumper of the tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as...

Страница 63: ...fail while towing and may result in death or serious injury Before coupling trailer inspect the pintle hitch hook for wear corrosion and cracks Replace worn or damaged pintle hitch hook CouplingTrail...

Страница 64: ...Then have a service garage or trailer dealer tighten the lug nuts to the proper torque WARNING Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel comi...

Страница 65: ...at the left front of the trailer See Figure I The weight of cargo should never exceed XXX kg Or XXX lbs TIRE FRONT REAR SPARE SIZE COLD TIRE PRESSURE TIRE AND LOADING INFORMATION SEE OWNER S MANUAL FO...

Страница 66: ...ontact a local tire dealer Note You may not find this information on all tires because it is not required by law M S The M S or M S indicates that the tire has some mud and snow capability Most radial...

Страница 67: ...the maximum load and tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits Tire SafetyTips Slow down if...

Страница 68: ...s Cupping Out of balance Check bearing adjustment and balance tires Flat Spots Wheel lockup and tire skidding Avoid sudden stops when possible and adjust brakes WARNING ALWAYS wear safety glasses when...

Страница 69: ...ss FT LBS Third Pass FT LBS 12 20 25 35 40 50 65 13 20 25 35 40 50 65 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 Replace any broken or burned out lamps as necessary Check the wi...

Страница 70: ...er cu yd 6 5 designed for 2 500 lbs in 28 days Gallons per sack 7 1 Washed Sand 200 wash 1 3 Organic matter OK Specific gravity SSD Sand 2 58 Pea Gravel 2 60 SIEVE ANALYSIS PERCENT PASSING Material 1...

Страница 71: ...MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PAGE 71 APPENDIX CONCRETE MIX INFORMATION A S T M STANDARD SPECIFICATION FOR GRADING AGGREGATE...

Страница 72: ...the entire cross section of the layer Figure O Slump Test 2 3 Full 5 Fill cone to overflowing Figure P Rod this layer 25 times with rod penetrating into but not through the second layer Distribute rod...

Страница 73: ...MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PAGE 73 NOTES...

Страница 74: ...ect Engine RPM setting Verify the engine s high RPM speed is set to 2500 2550 RPM Incorrect Main Hydraulic System Operating Pressure Check the pump pressure gage Verify it is approx 3200 PSI Hopper Di...

Страница 75: ...hine does not deliver volume and pressure Low engine speed Check engine RPM Volume control set to low Adjust control to full open setting Main hydraulic pressure too low Check for proper pressure or f...

Страница 76: ...Charge or replace battery Air or water mixed in fuel system Check carefully for loosened fuel line coupling loose cap nut etc At low temperatures engine will not start Engine oil too thick Refill engi...

Страница 77: ...ce defective part Thermostat defective Check thermostat and replace if necessary Head gasket defective or water leakage Replace parts Engine oil pressure display stays on Faulty engine oil pressure sw...

Страница 78: ...Is there enough brake fluid or correct fluid Fill with DOT 4 fluid Brakes squeak chatter or chuck Overheated wheel bearing Replace wheel bearing and pack with grease Low brake fluid Fill and bleed bra...

Страница 79: ...coil resistance It should read 6 ohms Replace burnt solenoid Wire connection broken Replace broken wire Swing SHORTED The 12 volt cycling solenoid is shorted directly to ground Measure solenoid coil r...

Страница 80: ...ver heating Refer to Engine Troubleshooting Proximity switch A Switch not energizing Check for contact clearance Should be between 0 050 in 1 27mm and 0 065 in 1 651 mm Defective proximity switch Repl...

Страница 81: ...engine completes 2 consecutive start run stop cycles without the fault recurring Table 9 Fault Code Reporting Device Code Format 1 J1939 CAN Digital Control Panel Display SPN FMI Codes 2 PC Service To...

Страница 82: ...ntrol fault 135 P0137 Rear oxygen sensor low voltage 3235 4 137 P0138 Rear oxygen sensor high voltage 3235 3 138 P0141 Rear oxygen sensor heater control fault 141 P0171 Pre cat A F is lean 520200 0 17...

Страница 83: ...ion information lost 520196 1 625 P01609 Calibration mismatch with firmware 630 13 629 P01619 Unauthorized calibration upload or update 520197 1 619 P01681 Customer Auxiliary Shutdown 1 970 31 681 P01...

Страница 84: ...PAGE 84 MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 HYDRAULIC SYSTEM LOCATOR DIAGRAM C A B E H K I J G F...

Страница 85: ...MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 PAGE 85 HYDRAULIC SYSTEM DIAGRAM...

Страница 86: ...PAGE 86 MAYCO LS300G CONCRETE PUMP OPERATION MANUAL REV 2 09 09 19 ELECTRICAL SYSTEM LOCATOR DIAGRAM G A C F E D T S R Q L M J I H B N K O P...

Страница 87: ...RSE FLOW BLUE GREEN PURPLE ON ON OFF SCROLL BLUE GREEN PURPLE ON ON 1 NOTE REFERENCE DISPLAY CARRIER BOARD PURPLE WIRE COMMON CONNECTED TO 12 VDC POWER BUS 2 OFF RESET A J BLUE GREEN PURPLE AUTOMATIC...

Страница 88: ...EVEL DRIVER LAMP P6 4 3 CAN BUS CAN BUS 72 N P BLUE PINK BLUE WHITE TO CONTROLLER CAN BUS CAN BUS TWISTED PAIR 70 57 12 VDC ZENITH ECU CONNECTOR 80 PIN ENGINE CONNECTOR 1 16 PIN 12 VDC INPUT START REQ...

Страница 89: ...2 1 J3 8 7 6 5 4 3 2 1 J4 12VDC 30 17 58 19 15 54 50A IGNITION SWITCH PROXIMITY SWITCH B INDICATOR RED ACTIVE BETWEEN GND 800 mV PROXIMITY SWITCH A PROXIMITY SWITCH D PROXIMITY SWITCH C 16 AWG BLUE 1...

Страница 90: ...ct at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reser...

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