Multiquip manual LS400/LS500 PUMP - MAINTENANCE PUMP, Danger - Amputation Risk

LS400/LS500 PUMP — MAINTENANCE (PUMP)

CHANGINGTHE CONCRETE CYLINDER PISTON CUPS

The Rubber piston cups will occasionally require replacement depending on the following factors.

■The fluid level and cleanliness of the lubrication box.

■The size and type of aggregate.

■The type of concrete being pumped.

It is time to replace the cups when increasingly large particles of sand and cement pass into the lubrication box. Do not allow the cups to become so worn that they begin to pass lubrication into the material cylinders. If the liquid level of the lubrication box becomes to low, the rubber cups will severely deform due to excessive heat. Whenever replacement is due, both cylinder cups should be replaced.

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 of injury or AMPUTATION if the engine is running or if pressure is in the hydraulic system.

Prior to performing any maintenance on the pump, 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 MUST read ZERO. ALWAYS make sure the accumulator circuit pressure reads

zero prior to performing any maintenance on the pump.

CYLINDER CUP REPLACEMENT PROCEDURE

1.Remove the two hydraulic hoses connected to the remix motor. Plug the ports with fittings (not provided) to prevent hydraulic hose leakage.

2.Remove the hopper discharge nipple and loosen sleeve seal. Inspect and replace if wear is excessive.

3.Remove the two tie rod nuts and the four eyebolt nuts securing the hopper to the pump frame.

4.Using an approved lifting device, remove the hopper using extreme care not to damage the hopper seal.

5.Start the engine and turn on the pressure test switch. Cycle pump in reverse until hydraulic system obtains maximum pressure, then turn pump and engine

off.

Remove ignition key and disconnect battery. Think safety! Check the hydraulic gauges on panel and make sure accumulator pressure reads zero. One piston should be in the fully discharged position at the end of the concrete cylinder.

6.Remove the three 3/8 – 16 x 3” bolts from the piston. Remove the front faceplate.

7.Install two the 3/8’ 16x3” bolts back into the piston – do not tighten. Use the two bolts as leverage to remove the rubber piston cup and rear components.

8.Obtain two 3/8 16x7” full thread studs (these studs will be used to assist in assembly alignment) insert the two studs into the piston adapter. Coat the concrete cylinder with grease.

9.Install the “O” Ring around the oiler plate. Install the plate into the concrete cylinder utilizing the studs for alignment.

Felt ring must be saturated with 30 wt. oil prior to installation.

10.Install the felt holder over the oiler plate. Install felt ring into felt holder. Install the bronze ring.

11.Using silicon sealant place a small bead of sealant material on the front of the rubber piston cup and the rear of the face plate. Install over alignment studs and into concrete cylinders.

12.Insert one 3/8”16x3” bolt into the open bolt hole, remove the alignment studs one at a time and install the remaining 3/8” 16x3” bolts.

Before installing 3/8” bolt, coat the back of bolt heads with silicon sealant.Torque all three bolts equal at 55 ft. lbs. each.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 41