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OPERATION MANUAL SERIES MODELS LS-40/40TD/50TD STRUCTURAL CONCRETE PUMPS (DEUTZ F4L2011, BF4L2011 DIESEL ENGINES) Revision #12 (12/05/24) To find the latest revision of this publication or associated parts manual, visit our website www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
SILICOSIS/RESPIRATORY WARNINGS WARNING WARNING SILICOSIS WARNING RESPIRATORY HAZARDS Grinding/cutting/drilling of masonry, concrete, metal and Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition may give other materials can generate dust, mists and fumes off dust or mists containing crystalline silica. Silica is a containing chemicals known to cause serious or fatal basic component of sand, quartz, brick clay, granite and injury or illness, such as respiratory disease, cancer,...
TABLE OF CONTENTS MAYCO LS - 40D/LS - 40TD/ LS - 50TD STRUCTURAL CONCRETE PUMP Proposition 65 Warning ..........2 Silicosis/Respiratory Warnings ........3 Specifications ............5 Dimensions ..............6 Safety Message Alert Symbols .......7-8 Rules for Safe Operation ........9-11 Operation and Safety Decals ......12-13 Important Hand Signals ...........14 General Information ...........15-16 How it Works ............17...
Diesel engine exhaust gases contain complete instructions for the safe and efficient operation poisonous carbon monoxide. This of the Multiquip Mayco LS-40D/LS-40TD/LS-50TD gas is colorless and odorless, and Structural Concrete pump. Refer to the engine can cause death if inhaled. NEVER...
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SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS CAUTION - RESPIRATORY HAZARDS NEVER operate equipment with cov- ALWAYS wear approved respiratory ers, 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 produc-...
■ NEVER use accessories or attachments, which are not or oil. recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result. MAYCO LS-40D/LS-40TD/LS-50TD PUMP — OPERATION MANUAL — REV. #12 (04/05/24) — PAGE 9...
■ Keep the pump in proper running condition. Multiquip for this equipment. Damage to the equipment ■ Fix damage to the pump immediately and always replace and or injury to user may result.
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LS - 40D/LS - 40TD/LS - 50TD PUMP — RULES FOR SAFE OPERATION BATTERY EMERGENCIES The battery contains acids that can cause injury to the eyes ■ ALWAYS know the location of the and skin. To avoid eye irritation, always wear safety glasses. nearest fire extinguisher.
OPERATION AND SAFETY DECALS Machine Safety Decals The LS-40D/LS-40TD/LS-50TD structural concrete pump is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. Figure 2 below illustrates these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
IMPORTANT HAND SIGNALS Figure 3 display's the basic hand signals commonly used in concrete pumping operations. Figure 3 Operation Hand Signals PAGE 14 — MAYCO LS-40D/LS-40TD/LS-50TD PUMP — OPERATION MANUAL — REV. #12 (12/05/24)
GENERAL INFORMATION CONCRETE MIX DESIGN There are four ways in which this seal can be lost: Mix design is most important to achieve maximum pumpability. 1. By pumping excessively wet mixes which do not have Pumpability is affected by, among other factors, the type and enough cohesion to hold together.
GENERAL INFORMATION REGIONAL DIFFERENCES In addition, this Mayco Structural Concrete Pump can be used to pump a large aggregate hard rock as follows: Concrete is made by mixing locally available rock and sand with cement and water. For this reason there are great differ- 1.
HOW IT WORKS The following is a brief explanation of how the concrete cylin- ders, 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.
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PUMP COMPONENTS Figure 6 illustrates the location of the major components for 15. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic the LS-40D/LS-40TD/LS-50TD Structural Concrete Pump. fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if The function of each component is described below: level is low.
CONTROL BOX COMPONENTS Figure 7. Pump Control Box Components Emergency Stop Button – Press emergency stop but- 10. Pumping Control Switch – This 3-position switch ton to stop pump in an emergency. Turn knob counter controls the pumping of the pump. The right most clockwise to disengage the stop button.
ENGINE COMPONENTS Figure 8. Deutz F4L2011F/BF4L2011 Diesel Engine Components INITIAL SERVICING The engine (Figure 8) must be checked for proper lubri- Alternator – Provides power to the electrical system. cation and filled with fuel prior to operation. Refer to the Replace with only manufacturers recommended re- manufacturers Engine manual for instructions &...
INSPECTION FUEL CHECK CAUTION - GENERAL SAFTEY GUIDELINES Check the fuel gauge built into the fuel tank cap (Figure 9) to determine if the pump's engine fuel is low. NEVER operate the pump in a con- Refuel as needed fined area or enclosed area structure that does not provide ample free WARNING - EXPLOSIVE FUEL flow of air.
INSPECTION ENGINE OIL CHECK 12 The oil listed in Table 4 is recommended to ensure better engine performance. Use class CD or higher grade Remove the engine oil dipstick from its holder motor oil. (Figure 11). Figure 11. Engine Oil Dipstick 8.
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INSPECTION 14. If the hydraulic oil level is low, remove the cap just above REAR STABILIZER STAND the oil level sight glass (Figure 14) and add the correct To reduce excessive vibration and rocking of the pump, set amount of hydraulic oil to bring the hydraulic oil level to the rear stabilizers as follows: a normal safe operating level.
START - UP PROCEDURE STARTING PROCEDURE 4. Observe that the Battery and Oil Pressure status indicator lights are ON (Figure 21). WARNING - GENERAL SAFETY GUIDELINES DO NOT attempt to operate this concrete pump until the Safety, General Information and Inspection sec- tions have been read and understood.
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START - UP PROCEDURE 7. Turn the Volume Control (Figure 24), lock nut counter- A. Unlock the throttle cable. To unlock the throttle clockwise (CCW) to release the volume control knob. cable, turn the inner most knob counter clockwise (Figure 27.) UNLOCKING KNOB UNLOCK...
START - UP/SHUT - DOWN PROCEDURE 11. The Accumulator Pressure EMERGENCY SHUTDOWN PROCEDURE Gauge (Figure 29) should read In the event of an emergency, to shut down the pump: approximately 1750 pounds per 1. Depress the Emergency Stop Switch (Figure 19) square inch (psi).
OPERATING PROCEDURES OPERATING PROCEDURES HOSE LUBRICATION This procedure lubricates the hose and prevents separation WARNING - SAFETY GLASSES and blockages in the hose. Inspect the lines at all times to prevent problems. Safety glasses MUST be worn at all times when operating the pump. Before concrete is discharged into the hopper, it is suggested Failure follow safety guidelines can that 3 to 4 gallons of water be sprayed into the hopper,...
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OPERATING PROCEDURES 6. With the pump in FORWARD at 25-30 strokes per min- REMIXTURES ute, slowly discharge the concrete from the ready-mix Remixtures that are designed into the concrete mix by the truck into the hopper and completely fill it. Keep the redi-mix company or an architectural engineering company.
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OPERATING PROCEDURES DOWN-HILL PUMPING NOTICE Down-hill pumping can be a difficult procedure on It is strongly recommended that steel pipe some jobs. The slurry procedure would be the same as be used on all vertical pumping for safety and explained in the Priming the Pump With Slurry Mix- convenience.
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OPERATING PROCEDURES THE EFFECTS OF HEAT AND EXCESSIVE 3. If it is necessary to wait 10 minutes or more for another TIME ON CONCRETE: load of concrete, it is wise to start the pump and pump 6 or 8 strokes every 5 minutes to prevent setting of the Hot concrete, commonly referred to as a hot load, is concrete mix in the system.
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OPERATING PROCEDURES CLEARING THE SYSTEM AFTER MIX SET UP CLEARING CONCRETE BLOCKAGE If, for any reason, the mix should set up in the system, the WARNING - BLOCKAGES following procedure is suggested: If you repeatedly pull the throttle all the way out and 1.
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OPERATING PROCEDURES CLEARING SHUTTLE TUBE BLOCKAGE E. Chip the concrete out of the reducer with the pry bar. The shuttle tube is plugged if volume at the discharge end of F. Remove the reducer. From the discharge end, chip the hose stops and the hydraulic oil pressure gauge reads the concrete out of the shuttle tube with the pry-bar.
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OPERATING PROCEDURES HOPPER REMIXER CONTROL RADIO REMOTE CONTROL (OPTIONAL) The Hopper Remixer Control lever is located to the left of The MAYCO LS-40D/LS-40TD/LS-50TD Concrete Pump the Hydraulic Temperature gauge is (Figure 34). has a remote control feature that allows the pump to be remotely controlled.
TOWING SAFETY PRECAUTIONS TOWING SAFETY PRECAUTIONS ■ Check wheel mounting lug nuts with a torque wrench. Torque wheel lug nuts as described in the "Lug Nut CAUTION - LOCAL TOWING REGULATIONS Torque Requirements", Table 6. Check with your county or state safety towing regula- ■...
TOWING INFORMATION TOWING INFORMATION CAUTION - TRAILER RELEASE LEVER WARNING - LIFTING TRAILER TOUNGE The release lever will close freely with finger pressure when the ball is properly inserted into ball socket. If Use jack stand to lift tongue. DO NOT lift by hand as the release lever does not close freely, do not tow back injury could result.
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TOWING INFORMATION 8. Test the brakes by pulling the emergency stop lever 10. Retract the jack fully. Remove and store the caster, if (Figure 39) forward until it locks into its second notch applicable. position. Attempt to rotate the wheels in a forward direc- 11.
MAINTENANCE ( PUMP ) CLEANING THE PUMP AND DELIVERY SYSTEM DANGER - AMPUTATION RISK Cleaning the pump is a very important operation as it deter- You will be required to put your hand in the concrete mines how the machine will pump the next time it is used. cylinders or near the shuttle tube.
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MAINTENANCE ( PUMP ) 5. Add water to the hopper. Pump and flush clean the entire HYDRAULIC OIL SYSTEM MAINTENANCE hopper, shuttle tube and discharge elbow with water. The Mayco pump is equipped with an in-tank return hydraulic 6. Scoop out 12 inches of concrete from the inboard end filter with a 10 micron cleanable filter.
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MAINTENANCE ( PUMP ) BATTERY MAINTENANCE BRAKE SYSTEM The brake system should be periodically checked. Look CAUTION - BATTERY MAINTENANCE SAFETY for fluid leaks worn or cracked hoses. Check the reservoir for proper fluid levels. The Atwood surge brake should be Wear safety glasses or face mask, pro- checked for damage.
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MAINTENANCE ( PUMP ) CYLINDER LUBRICATION BOX ACCUMULATOR CIRCUIT WARNING - FREEZING CONDITIONS DANGER - ACCUMULATOR CHARGING When using the pump during freezing conditions, Improper accumulator charging can result in an ex- completely drain the water box and cover the hopper plosion causing serious injury or death! NEVER use after pumping.
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MAINTENANCE ( PUMP ) CHANGING THE CONCRETE CYLINDER PISTON CUPS Remove the three 3/8 – 16 x 3” bolts from the piston. Remove the front faceplate. The Rubber piston cups will occasionally require replace- ment depending on the following factors. Install two the 3/8’...
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MAINTENANCE ( PUMP ) CHANGING THE WEAR PLATE AND RING Wear Plate Installation Due to the swinging motion of the Nun-plate and the abrasive Install the two cylinder “O” rings. nature of concrete, it is normal for the cutting ring to wear on Using silicon sealant, coat the circumference of the con- the side that shears through the concrete inside the hopper.
MAINTENANCE ( PUMP ) WHEEL BEARINGS EXTENDED STORAGE INSTRUCTIONS After every 6 months of operation inspect the wheel bear- The following preventative maintenance is recommended ings. Once a year, or when required, disassemble the wheel for extended periods of storage. hubs remove the old grease and repack the bearings forcing 1.
MAINTENANCE ( TRAILER ) TRAILER SAFETY PRECAUTIONS 8. Wheel Hub – The wheel hub is connected to the trailer's axle. CAUTION - TRAILER INSPECTION 9. Tire Rim – Tires are mounted on a tire rim. The tire rim must match the size of the tire. ALWAYS make sure that the trailer is in good oper- 10.
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MAINTENANCE ( TRAILER ) TRAILER ACTUATOR TIRES/WHEELS/LUG NUTS The following maintenance steps should be performed Tires and wheels are a very important and critical com- before towing the pump: ponents of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are 1.
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MAINTENANCE ( TRAILER ) LUG NUT TORQUE REQUIREMENTS It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1.
APPENDIX — CONCRETE MIX INFORMATION The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to help create a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete mixes.
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APPENDIX — CONCRETE MIX INFORMATION A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE PAGE 60 — MAYCO LS-40D/LS-40TD/LS-50TD PUMP — OPERATION MANUAL — REV. #12 (12/05/24)
APPENDIX — SLUMP TEST PROCEDURE 5. Fill cone to overflowing 1. To obtain a representative sample (concrete), take (Figure 55-C). Rod this layer several samples at three or more regular intervals throughout the discharge of the mixer or truck. DO 25 times with rod penetrating NOT take samples at the beginning or end of the into but not through, the second...
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES Figure 56. Shotcrete System Accessories NOTICE Use a 1-3/8" rubber nozzle tip for a wide spray pattern. Use a 1-1/4" rubber nozzle tip for a narrow spray pattern. DO NOT INSTALL THE NOZZLE AT THE END OF THE HOSE UNTIL THE FIRST MATERIAL HAS PASSED THROUGH THE ENTIRE HOSE LENGTH.
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APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES PART NO. PART NAME QTY. REMARKS EM26107 HOPPER SCREEN ......1 ... W/AIR VIBRATOR MOUNTING EM23101 AIR VIBRATOR EM132 BOLT, 1/2-13X2 EM23407 AIR HOSE EM23408 BUSHING EM23411 VALVE EM912073 NIPPLE EM23409 COUPLING EM923346 WASHER, 1/2 LOCK EM406...
Hydraulic fluid under pres- Table (Table 8) to identify possible causes for the pump’s sure can penetrate the skin, blind, cause burns or create malfunction. Contact the Multiquip Service department for other potentially dangerous hazards. the proper repair procedure.
TROUBLESHOOTING ( ENGINE ) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a break- down, please take a remedial action following the diagnosis based on the Engine Troubleshooting (Table 9) information shown below and on the proceeding page.
TROUBLESHOOTING ( BRAKE SYSTEM ) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the diagnosis based on the Brake System Troubleshooting (Table 10) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.
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