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Multiquip LS500 User's Manual

1. C n n ALTERNATOR ON 8 7 6 5 8 7 6 5 SS YELLOW a 43 A d gt NS gt J2 42 MM J 2 WHITE 87615 8716 J 4321 4312 2 S MUN Kite 4 INSIDE OUTSIDE Ws FUEL SOLONOID 2221 i i CONTROL J1MALE CONTROL INTERFACE BOX CONNECTOR alo YELLOW 1 P1 10AWG RED 12AwG RED EMERGENCY 1 4 STOP 2 3 SWITCH 3 2 14 AWG PINK BLK STARTER SOLENOID 4 1 sawe GREEN 12 AWG RED 5 8 L1SAWG YELLOW 6 7 _18 AWG ORANGE 7 6 14 awe RED 8 5 14 AWG BLACK GND INSIDE OUTSIDE CONTROL CONTROL OIL PRESSURE SWITCH FUEL SOLENOID SHUT DOWN IGNITION SWITCH CIRCUIT ACTIVE 12VDC CIRCUIT OFF GND 12VDC POWER IN ENGINE CRANK J2 MALE D INTERFACE LowBATTERY CONNECTOR MAIN B WHITE DEUTZ 10 PIN TACH INPUT P2 P2 ENGINE LOW OIL INPUT zu RED CONNECTOR SWING A 2 3 ses SRN 3 2 THROTTLE WHT BLK 4 1 BRN 12vDc POWER OUT GROUND BLK 5 8 RED EVEL SOLENOID 6 7 SHUT DOWN 7 6 8 5 e AWG WHITE VAAN INSIDE OUTSIDE CONTROL CONTROL BOX BOX CONTROLLER GND BLACK POTTED ENGINE SPEED SOLENOID Figure 62 Connections to Digital Control Box J1 and J2 Connectors 1 of 2
2. CYLINDERS PISTON i SHUTTLE TUBE Figure 3 Pumping Cycle 1 HIGH PRESSURE j E OIL FROM PUMP i of PROXIMITY 1 SWITCH THEY HYDRAULIC CYLINDERS CONCRETE CYLINDERS H PISTON HYDRAULIC ind i SHUTTLE CYLINDER n i SHUTTLE TUBE Figure 4 Pumping Cycle 2 In the first cycle hydraulic pressure is applied to cylinder 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
3. RES 2 gt LU ES lt lt N E a a z lt z lt LU a a a LO 77 lt 2 lt a ACCUMULATOR PRESSURE LS400 LS500 PUMP NAMEPLATE AND DECALS NAMEPLATE AND DECALS NO PARTNO PART QTY REMARKS 1 DECAL IMPACT HAZARD 1 2 97070 DECAL ACCUMULATOR PRESSURE INCLUDED W ITEM 4 3 EM985 DECAL HYDRAULIC OIL ONLY 1 4 97070 DECAL PUMPING PRESSURE DECAL INCLUDED W ITEM 2 5 DCL300 DECAL DANGER LUBRICATION BOX 1 6 DCL301 DECAL SHUTTLE TUBE DANGER 1 7 517640 DECAL MQ MAYCO LS400 LOGO 15 24 USED LS400 MODELS 8 517642 DECAL MQ MAYCO LS500 LOGO ener err USED ON LS500 MODELS 9 TBD DECAL FAULT LOCATOR 1 10 EM696 DECAL CAUTION TOWING DECAL 1 11 DCL302 DECAL WARNING BURN HAZARD 1 12 SERIALPLATE seiirt CONTACT MQ PARTS DEPT 13 TBD DECAL TIRE LOADING 1 14 49002 DECAL WARNING COUPLER 1 15 DECAL VIN IDENTIFICATION 1 LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 89 FRAME ASSY 15400 5500 PUMP FRAME ASSY Oh ANC fe V B ora 0 0 0 q NM M 0 SEE NAMEPLATE AND D
4. PRESSURE A GAUGE Figure 66 Hydraulic System Diagram MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 75 LS400 LS500 PUMP MANIFOLD BLOCK PORTS MANIFOLD BLOCK PORTS Connect to Accumulator Gauge Figure 67 Manifold Block Ports PAGE 76 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 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 These weights and proportions illustrate that when the sieve analysis is ideal the sand rock ratio can be adjusted 65 sand 35 rock and pumpability should be excellent EXAMPLE 1 A California Test Lab Report JOB Building Foundations Water Project Sacks per cu yd 6 5 designed for 2 500 105 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 15 T 3 4 38 4 8 16 30 50 100 200 W C Sand 100 99 7 79 1 604 365 143 40 1 1 Pea Gravel 100 9 0 Comb 100 66 51 39 23 9 9 1 0 DESIGN FOR ONE YARD OF CONCRETE SATURATED amp SURFACE DRY Absolute volume of aggregate in one yard 17 78 cu ft Specif
5. FUEL OM EM14407 O RING 20763 FILTER FUEL IN LINE EM16174 O RING dunt P53712 CARTRIDGE WATER SEPARATOR 2222 EM98163 SWITCH PROXIMITY 01174416 FILTER OIL ENGINE 510265 BOLT HEX HEAD 3 8 NC x 3 1 4 IN G8 01174696 FILTER FUEL ENGINE 34507 CAP FUEL 1319257 INSERT AIR FILTER 20763 FILTER FUEL 1880870 AIR CARTRIDGE SAFETY SENE 53712 CARTRIDGE WATER SEPARATOR NUM 98163 PROXIMITY SWITCH o 01174416 FILTER OIL ENGINE 98121 ELEMENT RETURN OIL 9 01174696 FILTER FUEL ENGINE NM S N 281100 AND BELOW 9 1319257 INSERT AIR FILTER 98275 ELEMENT RETURN OIL 9 1180870 AIR CARTRIDGE SAFETY S N 281101 AND ABOVE 2 EM98121 ELEMENT RETURN OIL S N 281100 AND BELOW B enna EM98275 ELEMENT RETURN OIL MOLIRI S N 281101 AND ABOVE Part numbers on this Suggested Spare Parts List may supersede or replace the P N shown in the text pages of this book MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 85 LS400 LS500 PUMP NAMEPLATE AND DECALS NAMEPLATE AND DECALS QA
6. 92 93 Brake Line Assy 94 95 Brake Lights 96 97 Trailer Hitch ASSY 98 99 Battery ASS 100 101 Hopper cc 102 103 Hopper Attachment Assy 104 105 Hopper Interior ASSY 106 107 Shuttle Cylinder 108 109 Lubrication Pistons Assy 110 111 Fuel Tank Assy 112 115 Heat Exchanger 116 117 Accumulator ASSY 118 119 Remixer Control ASSY 120 121 Lubrication Panel Assy 122 123 Engine Cover ASSY 124 125 Hydraulic Tank ASSV 126 127 ENGINE 128 129 Throttle 130 131 Water Separator ASSY 132 133 Hydraulic Pump Assy iustitie 134 135 Manifold Assy 136 137 Control Box ASSY 138 139 Control Box Harness 5 140 141 Remote Control Cable Assy 142 143 Hydraulic Stabilizer Assy Optional 144 145 Terms and Conditions of Sale Parts 146 Mayco Pump Warranty pp 147 Specification and part number are subject to change without notice PAGE 4 MAYCO LS400 LS500 PUMP OPERATI
7. REPLACES 503982 10 EM923348 WASHER LOCK 5 8 IN 4 11 EM25803 DISCHARGE PLATE BEARING 1 12 98065 SEAL RUBBER 1 13 512212 DISCHARGE NIPPLE 1 14 491701 GREASE FITTING 3 15 EM210 BOLT 5 8 X 2 IN 6 17 16811 SHUTTLE CYLINDER 1 18 25843 NUN PLATE 1 19 104 BOLT HEX HEAD 5 8 X 2 4 REPLACES 503982 20 491719 PIN 1 21 EM923348 WASHER LOCK 5 8 IN 4 25 EM514357 HOPPER SCREEN 1 26 EM98021 PLATE WEAR HF 1 27 EM969023 NUT 5 8 IN NC INS REPLACES 492586 28 EM265 BOLT COUNTER SUNK 5 6 11 x 3IN 2 29 EM923350 WASHER LOCK 3 4 IN REPLACES EM492628 30 EM151 BOLT HEX HEAD 3 4 10 X 2 IN 2 31 EM264 BOLT COUNTER SUNK 1 2 13x3IN 2 32 EM517700 O RING 2 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 107 15400 5500 PUMP SHUTTLE CYLINDER ASSY SHUTTLE CYLINDER ASSY MANIFOLD PAGE 108 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP SHUTTLE CYLINDER ASSY SHUTTLE CYLINDER ASSY NO PART NAME QTY REMARKS 1 16145 SWING AXLE BUSHING 2 2 EM510684 GREASE FITTING 1 3 EM16169 THRUST WASHER 1 4 25236 SHUTTLE CRANK SPLINED SHAFT 1 5 EM505490 GREASE FITTING 2 6 EM16814 TENSIONER 1 7 EM424 HEX NUT 1 IN 14NF 1 7A EM924006 COTTER PIN 5 32 X 2 IN 1 8 4
8. REPLACES 492393 2 6109180 WASHER LOCK 1 2 IN ssis REPLACES 492626 3 EM98261 MANIFOLD ASSY COMPLETE REPLACES EM98109 INCLUDES ITEMS W 4 98220 CYCLING VALVE SWING W PILOTS poems INCLUDES ITEMS W 5 EMBK227 SHCS 1 2 x 2 1 4 12 6t EM98223 PILOT VALVE SHUTTLE 1 7 EMBK2097 BOLT SHCS 1 2 X 1 1 4 8 EM98221 CYCLING VALVE MAIN 9 amp EM98222 PILOT VALVE MAIN CYLINDER 10 98227 CHECK VALVE 12 98228 COIL 12VDC ACCUMULATOR 12A 98229 ACCUMULATOR UNLOADER CARTRIDGE ASSY 13 EM25498 ADAPTER 14 509401 ADAPTER 15 EM514488 ADAPTER 16 EM25459 ADAPTER 17 EM98226 UNLOADING RELIEF VALVE SHUTTLE 18 EM514231 ADAPTER 19 EM514489 ADAPTER 20 EM491372 ADAPTER 21 506193 ADAPTER 22 EM25462 ADAPTER 23 EM509353 ADAPTER 24 EM25429 ADAPTER 29 TBD CHECK VALVE m INCLUDES ITEM W amp MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 137 L 400 LS500 PUMP CONTROL ASSY CONTROL BOX ASSY PAGE 138 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 L 400 LS500 PUMP CONTROL BOX ASSY CONTROL BOX ASSY NO PARTNO PART QTY REMARKS 1 CONTROL BOX ASSY tian ppm CONTACT FACTORY 2 0202 BOLT
9. OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP TRAILER SAFETY GUIDELINES Tow Vehicle The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow The hitch capacity must also be matched to the tow vehicle capacity Your vehicle dealer can provide and install the proper hitch on your tow vehicle Suspension System Sway bars shock absorbers heavy duty springs heavy duty tires and other suspension components may be required to sufficiently tow the trailer and pump Brake Controller For trailers equipped with electric brakes the electric brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer Side View Mirrors The size of the trailer that is being towed and your state law regulations determine the size of the mirrors However some states prohibit extended mirrors on a tow vehicle except while a trailer is actually being towed In this situation de tachable extended mirrors are necessary Check with your dealer orthe appropriate state agency for mirror requirements Heavy Duty Flasher A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached to the tow vehicle flasher circuit Electrical Co
10. PAGE 70 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 WIRING DIAGRAM CONTROL BOX L 400 LS500 PUMP SA y 119000000000 110000000000 77777777744 77777772774 000000000 40000000000 40000000000 1000000000 200000000 200000000 27777772722 Figure 62 Connections to Digital Control Box J1 and J2 Connectors 2 of 2 N 9 lt eo E gt lt D lt 70 co lt cS lt lt 9 A e 7p e e 2 O gt lt L 400 LS500 PUMP WIRING DIAGRAM CONTROL BOX CONTROL J3MALE CONTROL BOX INTERFACE BOX A CONNECTOR EI B PROXIMITY NOT USED 16 AWG WHITE SWITCH 3 NOT USED 16 AWG BLUE SIGNAL SIGNAL 2 1 2 3 4 5 NOT USED USED 12 VDC 6 8 PROXIMITY SWITCH A INSIDE CONTROL BOX OUTSIDE CONTROL BOX ENG SOL POWER 35A 1 SEC OVER TEMP PROXA PROX B PROX ma SE PROX D POWER GROUND AUTO LUBE CONTROLLER FLOWA 12VDC BLACK FLowB 12vDc POTTED BOX NOT USED HEAT EXCHANGER COOLING FAN BROKEN FAN BELT UNLOADER P4 4 V B
11. There is appropriate slack in the breakaway switch pullpin cable E Tires are not visibly low on pressure AX WARNING Drive Safely Driving too fast in severe road conditions can result in loss of control and cause death or serious injury Decrease your speed as road weather and lighting conditions deteriorate ALWAYS check for local trailer tow speed limits in your area MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 47 15400 5500 PUMP TRAILER SAFETY GUIDELINES CAUTION Local Towing Regulations Check with your county or state safety towing regulations department before towing your trailer Driving Conditions When towing a trailer you will have decreased acceleration increased stopping distance and increased turning radius which means you must make wider turns to keep from hit ting curbs vehicles and anything else that is on the inside corner In addition you will need a longer distance to pass due to slower acceleration and increased length Be alert for slippery conditions You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer than driving a tow vehicle without a trailer Check rearview mirrors frequently to observe the trailer and traffic NEVER drive faster than what is safe A WARNING Transporting Personnel DO NOT transport people on the trailer The transport of people puts their l
12. sure the maximum tire life and tread wear M 00 NOT bleed air from tires when they are hot Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma M Remove bits of glass and foreign objects wedged in the tread LS400 LS500 PUMP TRAILER SAFETY GUIDELINES Make sure your tire valves have valve caps ALWAYS check tire pressure on tow vehicle and trailer before towing Check tire pressure at least once a month m DO NOT overload tow vehicle Check the tire information and loading placard for safe allowable tire loading conditions Tire Repair The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole Punctures through the tread can be repaired if they are not too large but punctures to the sidewall should not be repaired Tires must be removed from the rim to be properly inspected before being plugged and patched Replacing Worn or Damaged Tires Replace the tire before towing the trailer if the tire treads have less than 1 16 inch depth or the telltale bands are visible Check inflation pressure weekly during use to insure the maximum tire life and tread wear A bubble cut or bulge in a side wall can result in a tire blowout Inspect both side walls of each tire for any bubble cut or bulge and replace a damaged tire before towing the trailer Table 8 below will help pinpoint
13. Hot concrete commonly referred to as a hot load is concrete that has been in the redi mix truck in excess of 2 to 3 hours On a hot day this amount of time is even less A brief explanation of why heat and time affect concrete Concrete starts setting by drying up through a chemical reaction The catalyst to this reaction is heat When pumping a hot load it is important to remember that when you have to stop pumping for any reason add water to the concrete in the hopper and hand mix and move concrete in the hose every 5 minutes If the shut down time becomes too long wash out immediately If itis necessary to wait 1 2 hour or more for another load of concrete to prevent setting of the mix in the system it is advisable to consider the following factors A through D affecting the concrete A How old is the concrete B Is there an accelerator calcium chloride red label etc in the concrete C The temperature of the day 80 90 degrees D How much system you have out and how stiff was the mix you were pumping PREVENTING MIX SET UP AFTER PUMP SHUTDOWN When the pump is stopped for any reason during a pour e g moving hose waiting for redi mix truck the following sugges tions are offered 1 Leavethe hopper full of concrete at the time of shutdown It is important not to let the redi mix driver wash too much water into the hopper as this could cause separa tion of the concrete in the hopper 2 Ifthe shut
14. are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apart from such written statement of warranty there are no warranties express implied or statutory which extend beyond the description of the products on the face hereof Effective February 22 2006 PAGE 146 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 MAYCO PUMP WARRANTY MECHANICAL DRIVE MODELS MAYCO PUMP hereinafter referred to as Manufacturer warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship under normal use and service for a period of one year after the date of delivery to the original retail purchaser Manufacturer will at its option replace or repair at a point designated by the Manufacturer any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point to have been defective in material or workmanship This warranty does not obligate the Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair the of the
15. maintenance service on the pump section Read safety instructions atthe beginning of manual Clean the entire pump removing dirt and dust particu larly the engine cooling air inlet and heat exchanger Check the air filter for dirt and dust If air filter is dirty replace air filter with a new one as required Check fastening nuts and bolts for tightness AX WARNING EXPLOSIVE FUEL Handle fuel safely Diesel fuel is highly flammable and can be dangerous if mishandled DO NOT smoke while refueling DO NOT attempt to refuel pump if the engine is hot or running ALWAYS allow engine to cool before refueling See Figures 5 6 and 7 for the location of any control or component referenced in this LS400 LS500 PUMP INSPECTION FUEL CHECK 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 m Diesel fuel is extremely flammable and 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 Figure 8 Fuel Cap Gauge
16. stiff concrete shotcrete long pushes thata 2 1 2 line be used asfar as possible The advantages of using the 2 1 2 line are improved pumpability less pumping pressure and less wear on the pump 7 Following the pump operation proper wash out of all materials or build up within the pump manifold and hoses will prevent problems when starting the next job 8 A thorough inspection of the drive components and greasing of all bearings after each job will ensure ad equate lubrication and service to the pump which is normally operating in wet gritty conditions Over greasing any bearing on your Mayco pump will not damage the bearing CLEARING THE SYSTEM AFTER MIX SET UP If for any reason the mix should set up in the system the following procedure is suggested 1 Disconnect the hose from the pump and wash the pump out immediately A WARNING HOSE LINE PRESSURE When disconnecting hoses use EXTREME CAUTION The hose is under pressure 2 Reconnect the hose and fill the hopper with water 3 Reconnect the hose and fill the hopper with water DO NOT try to push all the concrete out of all ofthe hose lines at one time For example If you had 200 ft of system out you would disconnect each hose Clean it out by pushing water through the first hose off the pump then continue progressing through all the hoses until all the system is clean 4 If waiting time is excessive it would be wise to wash out
17. 1 2 X 4 1 2 IN 3 EM492600 WASHER FLAT 1 2 IN 3 3 2 2 1 EM492584 NUT LOCK 1 2 IN EM507658 BOLT HEX HEAD 5 8 NC X 4 1 2 IN G5 EM492586 NUT LOCK 5 8 IN 16137 TOW RING 3 IN LUNETTE EYE ON CO MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 99 LS400 LS500 PUMP BATTERY ASSY PAGE 100 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP BATTERY ASSY BATTERY ASSY NO PART NO PART NAME QTY REMARKS 1 EM34506 BATTERY BOX W BELT 1 2 16738 BATTERY 12 125A 1 3 514856 BATTERY CABLE POSITIVE 1 4 513577 BATTERY CABLE NEGATIVE 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 101 LS400 LS500 PUMP HOPPER ASSY HOPPER ASSY PAGE 102 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 5400 5500 PUMP HOPPER ASSY HOPPER ASSY NO PART NO PART NAME QTY REMARKS 1 EM515980 HOPPER ASSY 1 2 16184 HOPPER SEAL 1 3 EM516779 REMIXER SHAFT 1 4 EM200303 FOLLOWER RING 2 5 EM200301 GRAPHITE SEAL 6 6 EM516820 COMPRESSION SPRING 2 7 EM514339 HOPPER SPRING SEAT 2 8 510717 BOLT 1 2 X 1 3 4 IN 4 9 EM514338 SUPPORT LEFT 1 10 EM514706 END CAP SHAFT SUPPORT 1 11 902153 BEARING 2 12 EM200018 SET COLLAR 1 13 EM703 SET SCREW V REPLACES 492470 14 500264
18. 6 09 19 11 LS400 LS500 PUMP HOW IT WORKS Thefollowing 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 andthe 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 id 5 4 HIGH PRESSURE TOTANK E I OIL FROM PUMP 8 PROXIMITY HYDRAULIC SWITCH CYLINDERS SLAVE 5 2 Ys i
19. AXLE ASSY RIGHT LEFT AXLE ASSY RIGHT LEFT Q SN d NOTES TORQUE LUG NUTS PER LUG NUT TORQUE TABLE REFERENCED IN THIS MANUAL RIGHT AND LEFT SIDE AXLE ASSEMBLIES ARE IDENTICAL WITH THE EXCEPTION OF THE BRAKE ASSEMBLY PAGE 92 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP AXLE ASSY RIGHT LEFT AXLE ASSY RIGHT LEFT NO PART NO PART NAME QTY REMARKS 1 98116 AXLE TORSION BAR ASSY 2 2 092305 BRAKE ASSY COMPLETE RIGHT oom INCLUDES ITEMS W 2 092306 BRAKE ASSY COMPLETE LEFT INCLUDES ITEMS W Mm SEE NOTE BELOW 3 363198 OIL SEAL 1 4 363196 INNER BEARING CONE 2 IN 1 5 383911 INNER BEARING CUP 2 IN 1 6 363909 WHEEL STUD 1 2 IN 20 UNF PRESSIN 8 7 363239 HUB AND DRUM ASSY 2 8 363916 OUTER BEARING CONE 1 9 363420 OUTER BEARING CUP 1 10 568326 LOAD WASHER 1 IN T5 1 11 363257 SLOTTED NUT 1 IN UNF 2 12 363258 COTTER PIN 3 16 IN X 1 1 2 2 13 EM514813 RIM AND TIRE 2 14 363203 WHEEL LUG NUTS 1 2 UNF 60 CON 8 15 363199 GREASE CAP 2 16 EM104 BOLT HEX HEAD 5 8 IN NC X 2 IN G5 A REPLACES 503982 17 0401450160 WASHER FLAT 5 8 IN B einen REPLACES 492602 18 EM969023 NUT LOCK 5 8 IN REPLACES 492586 RIGHT AND LEFT SIDE AXLE ASSEMBLIES ARE IDENTICAL WITH
20. B LEVER OPERATING INSTRUCTIONS HOPPER REMIXER CAUTION MINIMUM PULL UPTO OPERATE NEUTRAL LEVEL Foe Vases PULL UP TO EXTEND PULL UP TOEXTEND PUSH DOWN TO REVERSE Oil level below minimum PUSH DOWN TO RETRACT PUSH RETRACT can cause hydraulic pump and system damage Oil temperature should not exceed 170 F 77 C 4 DANGER AMPUTATION DANGER KEEP HANDS CLEAR 5 5 SHUTTLE TUBE PIVOTS RAPIDLY AND WILL CRUSH YA TAMAYCO MULTIGUIP a LS SDD ZE Improper accumulator charging can result in explosion causing serious injury or death Why Why Refer to manual for service instructions Charge only with dry nitrogen USE DIESEL EL ONLY Read Operator s book To avoid injury you MUST read and understand operator s manual before using this machine This machine to be operated by qualified personnel only Ask for training as needed CAUTION Grease every two hours of operation NOTES A PLACE DECAL ON LS400 MODELS ONLY A PLACE DECAL ON LS500 MODELS ONLY CAUTION Grease every two hours of operation PAGE 86 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 USE THIS DECAL OPTION WHEN HYDRAULIC STABILIZER JACKS ARE INSTALLED LS400 LS500 PUMP NAMEP
21. FUEL FILTER 5 16 IN A R 11 EM20763 FILTER FUEL 2 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 115 15400 5500 PUMP HEAT EXCHANGER ASSY HEAT EXCHANGER ASSY MANIFOLD REMIX VALVE HYDRAULIC TANK RETURN FILTER N NN 0000090009900 0000000000000 0700000000000 0000000000000 2000000000000 2 PAGE 116 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP HEAT EXCHANGER ASSY HEAT EXCHANGER ASSY NO PART NO PART NAME QTY REMARKS 1 EM98118 HEAT EXCHANGER 1 2 514175 COVER HEAT EXCHANGER 1 3 EM963610 BOLT 3 8 IN X REPLACES 492375 4 3019092 O RING 3 8 1 REPLACES 492598 5 0166 A WASHER LOCK 3 8 1 REPLACES 492624 6 0202 BOLT 5 16 X TIN ossi LI REPLACES 492364 7 EM923023 WASHER FLAT 5 16 IN B asso REPLACES 492597 8 2105164 NUT REPLACES 492582 9 EM25497 ADAPTER 1 10 514607 HOSE 4000 PSI 1 11 EM25566 ADAPTER 1 12 EM509345 ADAPTER 1 13 EM514606 HOSE 2000 PSI 1 14 EM509401 ADAPTER 1 15 514604 HOSE 2000 PSI 1 16 EM98264 MOTOR AND FAN ASSY 1 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 117 LS400 LS500 PUMP ACCUMULATOR ASSY ACCUMULATOR ASSY 19
22. General Information and Inspection sections have been read and understood 1 Locate the Emergency Stop Switch Figure 19 on the 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 CLOSED position stop engine will not start To start the engine make sure the Emergency Stop switch is in the OPEN position fully extended 2 Turn the Cylinder Stroke Control Switch to the AUTOMATIC position Figure 20 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 REMOTE CENTER OFF Figure 21 Pumping Control Switch OFF 4 Place the Direction Control Switch to the FORWARD position Figure 22 FORWARD REVERSE Figure 22 Direction Control Switch FORWARD 5 To start the engine insert the key Figure 23 into the ignition switch and turn the key to the ON position ON OFF START IGNITION Figure 23 Ignition Switch 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 LS 400 OFF 1 0000 ENG RPM BATTERY 12 5 V LOW OIL PSI LS 400 OFF 1 0000 ENG RPM BATTERY 12 5 V LOW RPM FAULT Y LS 4
23. INDICATES NO MESSAGE OR OF FAULTS INSTRUCTION DETECTED 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 A RUNNING COUNT OF NO OF STROKES 4 0000 PRESS RESET MESSAGE OR INFORMATION Screen 5 Displays the ON OFF electrical signal status of the various 12 volt solenoids Swing A circuit Main A circuit Main B circuit INDICATES SWING A SWING AOFF 5 MAIN A OFF INDICATES MAIN B OFF INDICATES MAIN B MAIN A CIRCUIT IS OFF 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 INDICATES PROXIMITY A PROXIMITY B CIRCUIT IS CIRCUIT IS ON INDICATES INDICATES UNLOADER FUEL SOLENOID CIRCUIT IS OFF 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 INDICATES THE THROTTLE NUMBER OF IS ON STROKES STROKES 20 STROKES MIN 8 2 INDICATES YDS HR 10 7 INDICATES THE NO OF YARDS NO OF STROKES PER HOUR PER MINUTE 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 contr
24. REPAIR KIT MANIFOLD PAGE 118 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP ACCUMULATOR ASSY ACCUMULATOR ASSY NO PART NO PART NAME QTY REMARKS 1 97015 ACCUMULATOR 1 GAL 1 2 97016 BRACKET ACCUMULATOR 1 3 EM9603055 BOLT HHCS 3 8 IN DIA 2 4 3019092 WASHER FLAT 3 8 IN 2 5 0166A WASHER LOCK 3 8 IN DIA 2 6 EM509425 FITTING STRAIGHT 1 7 EM509353 FITTING 90 ELBOW 1 8 514603 HOSE ACCUMULATOR 1 9 98009 ACCUMULATOR REPAIR KIT 1 10 98052 ACCUMULATOR TEST CHARGE KIT 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 119 LS400 LS500 PUMP REMIXER CONTROL ASSY REMIXER CONTROL ASSY SECONDARY PUMP REMIX MOTOR PAGE 120 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP REMIXER CONTROL ASSY REMIXER CONTROL ASSY NO PART NO PART NAME QTY REMARKS 1 25495 VALVE REMIXER W LEVER 1 2 515384 ADAPTER FITTING T 1 3 506195 ADAPTER FITTING 90 ELBOW 1 4 25509 ADAPTER FITTING STRAIGHT 2 5 EM218 BOLT 5 16 X 2 1 2 IN 2 6 EM923343 WASHER LOCK 5 16 1 REPLACES 492623 7 2105164 NUT HEX 8 16 ua AL REPLACES 492553 8 98015 COUPLING 1 9 98014 TEST PORT 1 15400 5500 PUMP OPERA
25. TABLE 8 TIRE TORQUE REQUIREMENTS First Pass Second Pass Third Pass Meal Size FT LBS FT LBS FT LBS 20 25 35 40 50 65 65 20 25 35 40 NN 65 20 25 50 60 90 120 20 25 50 60 90 120 20 25 50 60 90 120 4 LUG NUTS 6 LUG NUTS LUG NUTS 8 LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 59 Wheel Lug Nuts Tightening Sequence PAGE 60 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP TRAILER SAFETY GUIDELINES CONNECT TO CHASSIS GROUND WHITE COMMON GROUND GREEN BROWN YELLOW BROWN TAIL LIGHT LICENSE TAIL LIGHT FLAT 4 PIN MOLDED MATING CONNECTOR FLAT 4 PIN MOLDED CONNECTOR TAIL LIGHT Figure 60 Trailer to Tow Vehicle Wiring Diagram Lights and Signals Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation A WARNING Trailer Lights Replace any broken or burned out lamps as necessary Improper operating taillights stoplights and turn signals Check the wire harness for cuts fraying or other damage If can cause collisions it needs replacing contact your dealer Check all lights before each tow MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 61 LS400 LS500 PUMP TROUBLESHOOTING PUMP The hydraulic troubleshooting procedures listed below are intended for use by individuals equip
26. THE EXCEPTION OF THE BRAKE ASSEMBLY MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 93 15400 5500 PUMP BRAKE LINE ASSY BRAKE LINE ASSY 5 TRAILER HITCH FUEL TANK CONTROL PANEL SIDE PAGE 94 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP BRAKE LINE ASSY BRAKE LINE ASSY NO PART NO PART NAME QTY REMARKS 1 34566 KIT MAIN BRAKE LINE 1 2 512877 ADAPTOR STRAIGHT 2 3 EM512876 ADAPTOR ELBOW 2 4 34565 KIT WHEEL BRAKE LINE 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 95 15400 5500 PUMP BRAKE LIGHT ASSY BRAKE LIGHT ASSY PAGE 96 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP BRAKE LIGHT ASSY BRAKE LIGHT ASSY NO PART NO PART NAME QTY REMARKS 1 29242 BRAKE LIGHT ASSY 2 2 29207 HARNESS ASSY W RECEPTACLES 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 97 15400 5500 PUMP TRAILER HITCH ASSY TRAILER HITCH ASSY PAGE 98 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP TRAILER HITCH ASSY TRAILER HITCH ASSY NO PART NO PART NAME QTY REMARKS 1 29228 COUPLING TRAILER 2 IN BALL 6000185 1 EM19067 ACTUATOR BRAKE 1 503111 BOLT HEX HEAD
27. 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 affectthe 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 Operation section of this manual 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 ar
28. Use the help numbers found on the back page of the manual if there are any questions NOTICE The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST PART REMARKS 1 123455 BOLT 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 2345B AND ABOVE NO Column Unique Symbols All items with same unique symbol or gt in the number column belong to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A blank entry generally indicates tha
29. 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 A ee e PAGE 6 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 WARNING ROTATING PARTS 4 NEVER operate equipment with covers AO or guards removed Keep fingers P hands hair and clothing away from all moving parts to prevent injury AX CAUTION ACCIDENTAL STARTING OFF 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 AX CAUTION OVER SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings Personal injury and damage Y to the engine or equipment can result if operating in speed ranges above maximum allowable if you do not follow instructions This pump other property or the surrounding environment could be damaged LS400 LS500 PUMP SAFETY MESSAGE ALERT SYMBOLS AX CAUTION RESPIRATORY HAZARDS ALWAYS wear approved respiratory protection AX CAUTION SIGHT AND HEARING HAZARDS This machine is capable of producing noise levels above 85 dB Hearing protection is required Always wear eye protection AX CAUTION EQUIPMENT DAMAGE MESSAGES Other important messages are provi
30. by activating the reverse function switch located on the control panel Unauthorized equipment modifications will void all warranties Check all fasteners periodically for tightness Also check towing tongue bolt lock nut and wheel lug nuts for wear Test the pump s ON OFF switch The purpose of this test is to shut down the engine Refer to the DEUTZ Engine Owner s Manual for engine 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 TRANSPORTING 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 Towing 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 Ibs load f unit is equipped with ball hitch coupler use only 2 all steel ball rated for minimum of 6 000 105 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 always have rear tail lights O
31. coupler connection comes loose Jackstand A device on the trailer that is used to raise and lower the coupler The jack is sometimes called the landing gear or the tongue jack An improperly coupled trailer can result in death or serious injury DO NOT move the trailer until e The coupler is secured and locked to hitch e The safety chains are secured to the tow vehicle e The trailer jack s are fully retracted DO NOT iow the trailer on the road until e Tires and wheels are checked The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer The trailer lights are connected and checked MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 51 15400 5500 PUMP TRAILER SAFETY GUIDELINES Coupler Types The trailer is shipped from the factory with a 2 inch ball cou pler Ball Hitch Coupler A ball hitch coupler Figure 52 connects to a ball that is located on or under the rear bumper of tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as bumper pull A ball hitch trailer may be fitted with a tongue jack that can raise and lower the coupler The tongue jack is mounted to the A frame front or tongue part of the trailer By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer Figure 52 Ball Hitch Coupler Adjustable Tongue
32. discharge line See Figure A This condition can easily be observed 1 The sudden change of the level of concrete inside the hopper during each pumping stroke 2 Concrete slurry squirting into the air from the hopper Volcano effect 3 When the output volume at the end of the delivery line decreases in pressure 4 Unusual frequent material packs in the Shuttle tube GOOD SEAL It is important that the wear components be inspected weekly for proper sealing Failure to inspect will eventually cause severe damage to the nun plate and material cylinders Visually inspect wear plate and cutting ring to ensure surfaces are sealed against each other If a deep groove or a wide space has developed on the sealing surfaces 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 two times per wear plate 2 to 1 When replacing the wear ring also replace the rubber energizer ring RUBBER GUTTING RING WEAR PLATE ENERGIZER LEAKING Figure A Wear Plate and Cutting Ring PAGE 40 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP MAINTENANCE PUMP CHANGING THE CONCRETE CYLINDER PISTON CUPS The Rubber piston cups will occasionally require replacement depending on the following factors The fluid level and cleanliness of
33. inspected annually for signs of wear or deformations WARNING Cracked or Broken Welds Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death DO NOT repair cracked or broken welds unless you have a certified welder perform the repair If not have the welds repaired by your dealer A Danger Trailer Welds Broken or damaged welds can cause injury or severe damage to your trailer and contents Inspect all of the welds for cracks or failure at least twice a year Torsion Suspension The mounting bracket Figure 49 of the torsion suspension assembly is bolted directly to the trailer frame Except for periodic inspection of the 5 fasteners to the trailer frame no other suspension maintenance is required on the axles 5 8 18 X 2 MOUNTING BOLT MOUNTING TORSION 5 8 18 NYLOC NUT GRADE C Figure 49 Torsion Suspension A Danger Worn or Defective Suspension Worn or broken suspension parts can cause loss of control damage to equipment and severe bodily injury even death Check suspension regularly PAGE 46 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP TRAILER SAFETY GUIDELINES TRAILER SAFETY INFORMATION ALWAYS use lower gears for climbing and descending Safety precautions should be followed at all times when operating this equipment Failure to read un
34. luggage capacity calculated in Step 4 If your vehicle will be towing a trailer load from your trailer will be transferred to your vehicle Consult the tow vehicle s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle Studies of tire safety show that maintaining proper tire pressure observing tire and vehicle load limits not carrying more weight in your vehicle than your tires or vehicle can safely handle avoiding road hazards and inspecting tires for cuts slashes and other irregularities are the most important things you can do to avoid tire failure such as tread separation or blowout and flat tires These actions along with other care and maintenance activities can also improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Increase the tire life Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure Tire Fundamentals Federal law requires tire manufacturers to place standard ized information on the sidewall of all tires Figure 57 This information identifies and describes the fundamental char acteristics of the tire and also provides a tire identification number for safety standard cert
35. of the battery and adds to maintenance cost When handling the battery do the following careful not to let the battery electrolyte come in contact with your body or clothing Always wear eye protection and rubber gloves since 2 Check for any leaks in the brake system Periodic checks A CAUTION BATTERY MAINTENANCE SAFETY Lubricate the hitch ball with conventional automotive grease or a lubricant made for hitch balls the battery contains sulfuric acid which burns skin and should be made on all hoses to guard against cuts and eats through clothing worn hoses which may cause failure leaks rupturing Always check the battery terminals periodically to under pressure and collapsing Replace defective hoses ensure that they are in good condition Use wire brush or sand paper to clean the battery terminals Always check battery for cracks or any other damage If white pattern appears inside the battery or paste has accumulated at the bottom replace the battery lf the pump will not be in operation for a long period of time store in cool dry place and check the battery charge 3 Check the brake fluid level in the master cylinder reservoir level every month to maintain the performance of the Keep it filled to within 72 from the top of the reservoir battery 4 At the beginning of each year inspect the brakes for Check the battery regularly and make sure that each excessive wear replace the l
36. safety The brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain in spect the brakes more frequently Hydraulic Brakes If your trailer has hydraulically operated brakes they function the same way the hydraulic brakes do on your tow vehicle The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle but no less than once per year This inspection includes an assessment of the condition and proper operation of the wheel cylinders brake shoes brake drums and hubs Manually Adjusting the Brakes Most axles are fitted with a brake mechanism that will adjust the brakes during a hard stop However some braking systems are not automatically adjusted by hard stopping These brakes require manual adjustment The following steps apply to adjust most manually adjustable brakes 1 Jack up the trailer and secure it on adequate capacity jack stands 2 Be sure the wheel and brake drum rotate freely 3 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 4 With a screwdriver or standard adjusting 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 No
37. the causes and solutions of tire wear problems TABLE 7 TIRE WEAR TROUBLESHOOTING EAR PATTERN CAUSE SOLUTION Adjust pressure to particular load per tire manufacturer Over Inflation Edge Wear Adjust pressure to particular load per tire manufacturer Under Inflation Make sure load does not exceed axle rating Align wheels Incorrect toe in Align wheels Cupping Flat Spots Loss of chamber or overloading Out of balance Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Wheel lockup amp tire skidding MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 59 15400 5500 PUMP TRAILER SAFETY GUIDELINES WARNING Flying Objects ALWAYS wear safety glasses when removing or installing force fitted parts DO NOT attempt to repair or modify a wheel DO NOT install an inner tube to correct a leak through the rim If the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury P Wheel Rims If the trailer has been struck or impacted on or near the wheels or if the trailer has struck a curb inspect the rims for damage i e being out of round and replace any damaged wheel Inspect the wheels for damage every year even if no obvious impact has occurred Wheels Bearings and Lug Nuts A lo
38. the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s manual If not contact a local tire dealer Note You may not find this information on all tires because it is not required by law M S The 5 or M S indicates that the tire has some mud and snow capability Most radial tires have these markings hence they have some mud and snow ca pability Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time The ratings range from 99 miles per hour mph to 186 mph These ratings are listed in Table 7 Note You may not find this information on all tires because it is not required by law Table 6 Speed Rating Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168 mph 186 mph lt 3 lt U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the plant code where it was manufactured and the last four numbers represent the week and year the tire was built For example the numbers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire Ply Co
39. to insure safe operation of your trailer trailer wheel bearing is immersed in water it must be replaced If the pump trailer has not been used for an extended amount of time have the bearings inspected and packed more frequently at least every six months and prior to use Follow the steps below to disassemble and service the wheel bearings After removing the dust cap cotter pin spindle nut and spindle washer remove the hub and drum to inspect the bearings for wear and damage AX DANGER Wheel Bearings If trailer wheels are under water for a long period of time wheel bearings may fail If this is the case service wheel bearings immediately The possibility exists of the wheels falling off causing equipment damage and severe bodily harm even death Replace bearings that have flat spots on rollers broken roller cages rust or pitting Always replace bearings and cups in sets The inner and outer bearings are to be replaced at the same time Replace seals that have nicks tears or wear Lubricate the bearings with a high quality EP 2 automotive wheel bearing grease BEARING WHEEL 6 HUB eo OIL SEAL COTTER PIN BEARING CUP DUST LUG CAP NUT SPINDLE WASHER CASTLE NUT Figure 48 Wheel Hub Components Wheel Hub Adjustment Every time the wheel hub is removed and the bearings are reassembled follow the steps below to check the wheel bearings for free running and a
40. x 356 mm Wireless Remote Control Hopper Screen Vibrator Options Hydraulic Rear Stabilizer Volume output will vary depending on mix design slump line size used and job site condititons TABLE 2 ENGINE SPECIFICATIONS Deutz F4L2011F Deutz BF4L2011F Diesel Engine Diesel Engine Type 4 stroke Air cooled Diesel No of Cylinders 4 19 in x 5 in Pora x Stroke 106 mm x 127 mm Rated Output 60 HP 3000 rpm 79 HP 3000 rpm Displacement 167 cu in 2 73 L Starting Electric 12VDC PAGE 12 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP DIMENSIONS TABLE 3 DIMENSIONS meses _ meme 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 CHUTE UP CHUTE DOWN STOP START PUMP SLOW PUMP SPEED UP DOWN STOP PUMP LITTLE BIT ADD WATER ALL DONE 4 GALLONS CLEAN UP 4 m cV y DRIVE IN BACK UP PULL FORWARD BACK IN 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 desi
41. 00 OFF 1 0000 ENG RPM BATTERY 12 5V END OF MESSAGE Figure 24 Primary Screen Ignition Key ON 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 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 itis 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 opera tions of the pour PRIMING THE PUMP WITH SLURRY MIXTURE 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 Failure to properly prepare the pump and system will result in a dry pack of concrete blocking the shuttle valve tube or delivery line 1 Connectthe entire delivery system to the pump Pour 5 gal
42. 1 Hopper Remixer Control Lever BLADES REVERSE CCW SHAFT ROTATION Figure 32 Hopper Remixer Blades Rotation 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 AX CAUTION BLOCKAGE If hoses or lines are blocked for any reason or if the lines are kinked 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 or 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 itis 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 i
43. 1 4 turn or to the nearest CYLINDER STROKE locking hole or sufficiently to allow the wheel to rotate freely within limits of 001 to 010 end play Lock the nut at this position JOG JOG 4 nstall the cotter pin and dust cap and tighten all A lt hardware Figure 43 Manual Cylinder Jogging Switch EXTENDED STORAGE INSTRUCTIONS 13 The Pumping Pressure Gauge Figure 44 should read The following preventative maintenance is recommended eee for extended periods of storage 1 Check brake system for proper fluid level in master cylinder and bleed all lines 2 Lubricate all links and pivots to prevent any rusting 3 Remove wheel and drum assemblies and spray a good anti corrosion compound CRC formula 5 56 under rubber PUMPING boot on forward end of brake wheel cylinder Avoid PRESSURE spraying drum and brake lining Figure 44 Pumping Pressure Gauge 4 Grease all bearings and reinstall wheel and drum assemblies 5 Make sure breakaway cable is fully released 6 After extended storage refer to the Maintenance Steps listed above to insure that the trailer is ready for towing MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 43 LS400 LS500 PUMP MAINTENANCE TRAILER The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance Trailer Brakes Properly functioning brake shoes and drums are essential to ensure
44. 17 NUT 1 IN 14NF 1 9 EM98106 SHUTTLE CYLINDER ASSY pm INCLUDES ITEMS W 9A EM98106SK SEAL KIT SHUTTLE CYLINDER 1 10 254549 1 11 492397 BOLT 1 2 X 2 1 2 IN 4 12 621 WASHER 1 2 IN 4 13 6109180 WASHER LOCK 1 2 IN REPLACES 492626 14 492584 NUT 1 2 IN 4 15 0820270000 CLEVIS PIN 3 4 IN 2 16 0820270000 COTTER PIN 2 18 515249 JAM NUT 1 19 0509440000 FEMALE CLEVIS 2 20 3322 FITTING ELBOW 2 21 EM514590 HOSE 1 22 EM514591 HOSE 1 23 517742 COVER SHUTTLE CYLINDER 1 24 0202 BOLT REPLACES 492364 25 EM923023 WASHER FLAT Sandi REPLACES 492597 26 2105164 REPLACES 492582 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 109 LS400 LS500 PUMP LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSY CYLINDER CYLINDER B E MANIFOLD 9 NOTES 6 HOPPER INTERIOR ASSEMBLY SEE ITEM 26 5 ay PAGE 110 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSY NO PARTNO PART NAME QTY REMARKS 1 EM510265 BOLT HEX HEAD 3 8 NC X 3 1 2 IN BLACK OXIDE 08 6 2 EM16464 FACE PLATE 2 3 EM16465 PISTON CUP SPACER 6 4 EM98050 CUP PISTON ORANGE 2 5 EM14408 RING BRONZE 2 6 EM16493 RING FELT
45. 188 GAUGE LEVEL amp TEMP ee d tune REPLACES EM16478 24 EM97066 GAUGE 3000 51 ACCUMULATOR 1 25 97067 GAUGE 5000 PSI MAIN 1 26 25523 ADAPTER 2 27 EM509517 HOSE 4000 PSI MAIN GAUGE 1 28 EM514602 HOSE 4000 PSI ACCUMULATOR GAUGE 1 29 EM16517 STRAIGHT MALE ADAPTER 0102 24 16 1 30 EM98112A RETURN FILTER ASSY epee S N 281101 AND BELOW 30A 98275 ELEMENT RETURN FILTER m S N 281102 AND ABOVE 31 516814 90 FITTING 1 33 EM16513 DIFFUSER 1 34 492376 BOLT 3 8 X 1 1 4 IN 4 35 492598 WASHER FLAT 3 8 IN 4 36 509343 TEE FITTING 1 41 TBD BOLT 2 45 516813 BUSHING 1 46 409401 ADAPTOR 3903 16 16 1 47 EM16414 VALVE NEEDLE 1 48 16516 PIPE 14122 a a crx Ds jm S N 281101 AND BELOW 49 509344 ADAPTOR 063T 16 16 1 50 514604 1 51 514604 1 LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 127 LS400 LS500 PUMP ENGINE ASSY LS 40TD LS 50TD ENGINE ASSY Q 7 gt lu lt 2 lt lt e lt lt lu gt lt 2 gt lt cN lt LS400 LS500 PUMP ENGINE ASSY ENGINE ASSY NO PART NAME QTY REMARKS 1 EM98189 ENGINE DEUTZ TURBO 76 HP BF4L2011 1 2 492401 BOLT1 2 IN X 4 FT
46. 2 7 2 8 2 2 2 4 8 8 EM16462 FELT HOLDER EM16461 OILER PLATE 9 EM14407 O RING OILER PLATE 10 EM25801 CYLINDER CONCRETE 11 EM25110 RETAINER CYLINDER 12 EM963610 BOLT 3 8 NG X gt neice REPLACES 492375 13 0166 WASHER COCK 3 8 N Die REPLACES 492624 14 3019092 WASHER FLAT3 8 N REPLACES 492598 16 EM514197 LUBRICATION BOX 1 17 EM507895 PLUG 1 18 EM515796 COVER LUBRICATION BOX 1 19 514610 LATCH COVER 1 20 491754 RIVET AM 66 2 2 492378 BOLT 3 8 NC X 1 3 4 IN G5 6 22 0166 WASHER COCK 3 8 Duane REPLACES 492624 23 EM274351 SEAL LUBE BOX 2 24 EM50425 FLANGE RING 2 25 492451 BOLT 3 8 24 X 1 IN HEX HEAD 8 26 EM50443 SEAL OIL BOX 8 27 514208 BAR PROXIMITY SWITCH SUPPORT 1 28 98163 SWITCH PROXIMITY W CABLE 2 29 EM98135 CABLE HOUSING FEMALE 2 30 EM98134 SEAL CONNECTOR HOUSING 6 31 EM98138 TERMINAL PIN FEMALE 6 32 514611 GROMMMET 2 33 504505 WRAP TIE 8 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 111 LS400 LS500 PUMP LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSY CYLINDER CYLINDER B MANIFOLD NOTES 6 NG HOPPER INTERIOR ASSEMBLY SEE ITEM 26 5 ay N PAGE 112 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSY NO PART
47. 3 12 EM516382 HYDRAULIC STABILIZER 2 13 517107 FITTING STRAIGHT 1 14 517105 HOSE 1 15 517100 HOSE 2 16 517106 HOSE 1 17 517153 BOLT 2 18 517154 BOLT 2 19 490957 SNAP RING 8 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 145 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subject to the following provisions 1 A Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain a Return Material Authorization a list must be provided to Multiquip Parts Sales that defines item numbers quantities and descriptions of the items to be returned 8 Theparts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated c The list must state the reason s for th
48. 3 full by volume Rod this second layer 25 times with the rod penetrating into but not through the first layer Distribute rodding evenly over the entire cross section of the layer 8 Lay straight edge Figure 68 F across the top of the slumped cone Measure the amount of slump in inches from the bottom of the straight edge to the top of the slumped concrete at a point over the original center of the base The slump operation must be com plete in a maximum elapsed time of 1 2 minutes Discard the concrete DO NOT use it in another tests Figure 68 E Slump Test Cone Invert Figure 68 B Slump Test 2 3 Full Figure 68 F Slump Test Measurement MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 79 APPENDIX RECOMMENDED SHOTCRETE SYSTEM Al Fil s AIR COMPRESSOR 125 TO 250 CFM AN EE SSH FH 22 7 Figure 69 Recommended Shotcrete System PAGE 80 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 APPENDIX RECOMMENDED SHOTCRETE SYSTEM RECOMMENDED SHOTCRETE SYSTEM NO PART NO PART NAME QTY REMARKS 1 EM28906 COUPLING 5 H D CF 2 EM25837 ELBOW 5 x4 x90 3 EM28905 COUPLING 4 H D w GASKET amp PIN 4 EM402552 REDUCER 4 2 5 53 H D ENDS 5 EM28061 PIPE 2 5 x120w x 10 H D 6 EM289035 COUPLING 2 5 H D w GASKET amp PIN 7 EM28001DD REDUC
49. 4 3 6109170 WASHER FLAT 1 2 tasted REPLACES 492600 4 6109180 WASHER LOCK 1 2 IN nente 4 REPLACES 492626 5 EM511021 AIR DUCTING CLAMP 2 6 EM510725 AIR DUCTING CLAMP 2 7 EM511019 AIR DUCTING DUCTING 1 8 TBD CLAMP 3 9 EM510888 CONNECTOR AIR FILTER 1 10 22001301 HOSE ELBOW 90 1 11 22002183 AIR CLEANER INCLUDES ITEMS W 12 01881280 HOOD AIR CLEANER 1 13 01319257 INSERT AIR FILTER 1 14 01880870 CARTRIDGE SAFETY AIR 1 15 01881413 DUST EJECTOR 1 16 492366 BOLT 5 16 X 1 1 2 IN 2 17 EM492623 WASHER LOCK 5 16 IN 2 18 492597 WASHER FLAT 5 16 4 19 492553 NUT HEX 5 16 IN G5 2 24 EM514633 REDUCTION TUBE EXHAUST 1 25 492371 BOLT 5 16 NC X 3 IN G5 2 26 EM923023 WASHER FLAT 5 16 IN REPLACES 492597 27 EM514714 SPACER EXHAUST 2 28 EM923343 WASHER LOCK 5 16 IN REPLACES 492623 29 2105164 HEX NUT 5 16 5 REPLACES 492553 30 EM510897 CAP EXHAUST 2 1 2 IN 1 31 01174416 FILTER OIL ENGINE 1 32 01174696 FILTER FUEL ENGINE 1 33 EM516434 PIPE EXHAUST ASSY 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 129 15400 5500 PUMP THROTTLE ASSY THROTTLE ASSY PAGE 130 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP THROTTLE ASSY
50. 5 16 X TIN u REPLACES 492364 3 EM923023 WASHER FLAT 5 16 IN a REPLACES 492597 4 2105164 NUT SIBI a r REPLACES 492582 5 TBD OVERLAY CONTROL PANEL 6 EM98206 IGNITION SWITCH ASSY 7 EM98206K IGNITION 8 517177 EMERGENCY STOP SWITCH ASSY 8A EM517186 CONTACT BLOCKS EMERGENCY SWITCH 12 EM98120 FLOW DIRECTION SWITCH ASSY 13 EM98119 MAIN CONTROL SWITCH ASSY 14 EM98121 AUTO JOG SWITCH ASSY 15 EM98122 JOG SWITCH ASSY 18 EM97068 RECEPTACLE REMOTE co 19 TBD VOLUME SWITCH ASSY 20 TBD SCROLL SWITCH ASSY 21 TBD RESET SWITCH ASSY MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 139 15400 5500 PUMP CONTROL BOX HARNESSES ASSY CONTROL BOX HARNESSES ASSY an 3 Se PAGE 140 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP CONTROL BOX HARNESSES ASSY CONTROL BOX HARNESSES ASSY NO PART NO PART NAME QTY REMARKS 1 EM514635 WIRE HARNESS 1 1 2 344102000 FUSE 30 AMP 1 3 EM514636 WIRE HARNESS 2 1 4 514637 WIRE HARNESS 3 1 5 EM514638 WIRE HARNESS 4 1 6 509588 POLY FLEX TUBE 1 2 IN BLACK AR 7 16716 CONDUCTIVE DIVIDER 3 8 IN AR MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 141 LS400 LS500 PUMP REM
51. 500 PUMP TROUBLESHOOTING ENGINE 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 Engine Troubleshooting Table 9 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 TABLE 10 ENGINE TROUBLESHOOTING Speed control lever is in STOP position No fuel reaching injection pump Defective fuel pump Fuel filter clogged Replace fuel filter and clean tank Engine will not start or start is Faulty fuel supply line Replace or repair fuel line delayed although engine can be Check piston cylinder and valves Adjust or turned over repair per engine repair manual r Repair or replace injector accordance with Fuel injector not working correctly engine repair manual Oil pressure too low Check engine oil pressure Low starting temperature limit exceeded comply i ae Starling nations And proper oil viscosity Check whether clear not turbid fuel emerges from the fuel line detach from injection Fuel separates has inadequate resistance to pump If the fuel is turbid or separated warm At low temperatures engine low temperatures up the engine or drain the complete fuel f will not start supply system Refuel with winter grade diese
52. 60CC PARKER P1 60 SERIES USED ON LS400 ONLY 16 EM98256 PUMP MAIN 75CC PARKER P1 75 SERIES USED ON LS500 ONLY 17 EM98273 FLOW CONTROL VALVE 1 18 EM506953 BOLT 7 16 X 3 IN 4 19 EM16190 GASKET 1 20 EM98107 PUMP SECONDARY 1 21 EM963610 nr ren B REPLACES 492375 22 0166 WASHER LOCK 3 8 IN a Eanes REPLACES 492624 23 EM25498 STRAIGHT ADAPTER 1 24 EM25429 ELBOW ADAPTER 1 25 EM514599 HOSE 4000 PSI SENSOR USED ON LS400 ONLY 25 EM516875 HOSE 4000 PSI SENSOR nssr Toons USED ON LS500 ONLY 26 EM25429 ELBOW ADAPTER 1 27 EM491372 STRAIGHT ADAPTER 1 29 EM25498 STRAIGHT ADAPTER 1 30 EM16524 ELBOW ADAPTER 90 MALE 2 31 506200 ELBOW ADAPTER 1 32 514601 HOSE 2000 PSI REMIX VALVE 1 33 EM517649 MOTORIZED FLOW CONTROL MANIFOLD ASSY 1 34 EM517038 HOSE MAIN MANIFOLD 1 35 509353 ELBOW 1 36 VALVE MAIN RELIEF 1 37 EM514608 HOSE 1 99 EM25459 ELBOW 1 40 EM25429 ELBOW ADAPTER 1 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 135 15400 5500 PUMP MANIFOLD ASSY MANIFOLD ASSY FRONT MACHINE EA A PAGE 136 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP MANIFOLD ASSY MANIFOLD ASSY NO PARTNO PART QTY REMARKS 1 EM963102 BOLT iile
53. Before each tow coat the ball with a thin layer of automo tive bearing grease to reduce wear and ensure proper opera tion Check the locking device that secures the coupler to the ball for proper operation If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the ball or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system All bent or broken coupler parts must be replaced before towing the trailer The coupler handle lever must be able to rotate freely and automatically snap into the latched position Oil the pivot points sliding surfaces and spring ends with SAE 30W motor oil Keep the ball socket and latch mechanism clean Dirt or contamination can prevent proper operation of the latching mechanism The load rating of the coupler and the necessary ball size are listed on the trailer tongue You must provide a hitch and ball for your tow vehicle where the load rating of the hitch and ball is equal to or greater than that of your trailer Also the ball size must be the same as the coupler size If the hitch ball is too small too large is underrated is loose or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury THE TOW VEHICLE HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR IT IS E
54. CTION READING PROBABLE CAUSE SOLUTION Screen 1 Burnt 12 V cycling solenoid Measure solenoid coil resistance It should MAIN A OPEN read 6 ohms Replace burnt solenoid Wire connection broken Replace broken wire MAIN A SHORTED The 12 volt cycling solenoid is shorted directly to ground Wire connection is shorted directly to the ground Measure solenoid coil resistance It should read 6 ohms Replace shorted solenoid Correct connection MAIN B OPEN Burnt 12 V cycling solenoid Measure solenoid coil resistance It should read 6 ohms Replace burnt solenoid Wire connection broken Replace broken wire MAIN B SHORTED The 12 volt cycling solenoid is shorted directly to ground Measure solenoid coil resistance It should read 6 ohms Replace shorted solenoid Wire connection is shorted directly to the ground Correct connection SWING OPEN Burnt 12 V cycling solenoid Wire connection broken Measure solenoid coil resistance It should read 6 ohms Replace burnt solenoid Replace broken wire SWING SHORTED The 12 volt cycling solenoid is shorted directly to ground Measure solenoid coil resistance It should read 6 ohms Replace shorted solenoid Wire connection is shorted directly to the ground Correct connection MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 67 LS400 LS500 PUMP TROUBLESHO
55. ECALS SERIAL PLATE ITEM 12 NOTES o Erg gt d lt gt z lt CD lt z lt z lt 5 e e 9 lt a 5400 5500 PUMP FRAME ASSY FRAME ASSY NO PART NO PART NAME QTY REMARKS 1 514355 FRAME MAIN 1 2 516581 CHAIN TRAILER HITCH 3 8 X 40 GRADE40 2 3 EM25610 JACK STAND FRONT 1 5 744 CLEVIS PIN 2 8 EM491686 PIN 2 10 EM491744 RIVET POP AM 44 2 11 509562 BOLT 3 8 NC X 5 8 G5 2 12 0166A LOCK WASHER 3 8 REPLACES 492624 13 503112 BOLT 3 8 X 2 3 4 1 14 3019092 WASHEEUS REPLACES 492598 15 EM969013 NUT iad rai aya REPLACES 492583 16 517985 FENDOR BOLT ON 2 17 504456 BOLT 1 2 NC X 3 4 G5 12 18 6109180 WASHER LOCK 1 2 IN 12 2 REPLACES 492626 19 517113 STABILIZER STAND 2 20 492376 BOLT 3 8 NC X 1 1 4 G5 2 21 0166 WASHER LOCK 3 8 4 REPLACES 492624 23 EM969013 PUT REPLACES 492583 24 517124 BOLT 3 4 NC X 1 G5 10 25 EM923350 WASHER LOCK 3 4 IN nciht REPLACES 492628 26 517092 SUPPORT PLATE RIGHT 1 27 517095 SUPPORT PLATE LEFT 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 91 LS400 LS500 PUMP
56. ELT BREAK GND i 3 B SWITCH 14 AWG BLACK 1 O d 2 8 7 6 16 AWG RED 12VDC bs 5 L16AWG BLACK NOTE 2 BOK eis WHEN MEASURING VOLTAGE J4 MALE AT CONNECTOR P4 PINS 2 AND 3 INTERFACE PLACE NEGATIVE LEAD OF CONNECTOR VOLTMETER TO FLOW CONTROL SWITCH WHITE BODY GROUND ACCUMULATOR DUMP VALVE UNLOADER CONNECTIONS TO J3 AND J4 CONNECTORS ON DIGITAL CONTROL BOX LS400 AND LS500 Figure 63 Connections to Digital Control Box J3 and J4 Connectors 1 of 2 PAGE 72 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 WIRING DIAGRAM CONTROL BOX L 400 LS500 PUMP Sor 7 lt LL AU Y smmm 77 277777777 27700000004 27777772774 27777777727 V6666666666 27777777777 277277777 800000000 9000000000 Figure 63 Connections to Digital Control Box J3 and J4 Connectors 2 of 2 N lt a gt LU ER lt Z lt CD lt a lt lt LU a gt a a ce LO 70 40 l e gt lt LS400 LS500 PUMP WIRING DIAGRAM HOPPER VIBRATOR CONTROL BOX EMERGENCY i STOP SWITCH DIGITAL READOUT SC
57. ER 2 5 x2 x36 H D 8 EM23815D REDUCER 2 5 x2 w AIR VIBRATOR 9 EM28902 COUPLING 2 H D w GASKET 10 EM23101 AIR VIBRATOR ASSY 11 EM28131D 2 x2 ELBOW 90 12 EM24841 HOSE 2 x25 H D w ENDS 13 EM23808D NOZZLE ASSEMBLY 2 H D 14 EM23806 NOZZLE TIP RUBBER 1 3 8 15 EM23807 NOZZLE TIP RUBBER 1 25 GENERAL RECOMMENDATIONS if the site will permit use steel pipe from the pump to the pool perimeter It will reduce line pressures which is highly recommended The vibrator on the reducer by the pool improves pumpability Turn both air vibrators off whenever the pump is stopped to prevent separation of mix The air vibrators are low consumption 4 2 scfm Leave the air on at the nozzle when the pump is stopped to prevent clogging of air the hoses in the air insert Use item 11 steel elbow at the edge of the pool to prevent collapse of the rubber hose which can cause blockage MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 81 APPENDIX RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES NOZZLE FOR SHOTCRETE Figure 70 Shotcrete System Accessories 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 Disassemble and clean the no
58. ER TOP 1 2 492356 BOLT 1 4 NC X 3 4 G5 16 3 EM923057 LOCK WASHER 1 4 IN REPLACES 492596 4 2101402 WASHER atout 10 6 REPLACES 492622 6 517730 COVER FRONT ENGINE 1 7 492541 NUT 5 16 NC G2 2 8 TK6737260 DOCUMENT CYLINDER 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 125 LS400 LS500 PUMP HYDRAULIC TANK ASSY HYDRAULIC TANK ASSY MANIFOLD MAIN HYDRAULIC PUMP HEAT EXCHANGER SECONDARY A PUMP NOTES MANIFOLD A SEE HYDRAULIC PUMP ASSY PAGE 126 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP HYDRAULIC TANK ASSY HYDRAULIC TANK ASSY NO PARTNO PART NAME QTY REMARKS 1 514040 HYDRAULIC TANK LS S 1 3 0166 LOCK WASHER 3 8 IN 4 aaa REPLACES 492624 4 EM517295 HANDLE 1 5 EM251191 TANK COVER PLATE 1 6 EM25184 RESERVOIR GASKET 1 7 492362 BOLT 5 16 X 5 8 IN 20 8 EM923343 WASHER LOCK 5 16 IN eU oss REPLACES 492623 9 EM98263 CAP ASSEMBLY 1 10 492267 BOLT 3 16 X 5 8 IN 6 11 16433 TUBE 1 12 491189 FITTING 1 13 18436 90 MALE ADAPTER 2103 16 16 1 14 514605 1 15 514622 FITTING 1 IN 1 16 514597 1 17 491164 ELBOW 3 4 IN 1 18 509784 ADAPTER 1 19 517002 1 20 509369 STRAIGHT MALE ADAPTOR 0101 08 08 1 2 491237 VALVE 1 2 IN 1 22 506094 CAP 1 2 IN 1 23 98
59. ER SAFETY GUIDELINES Lug nuts are also prone to loosen after first being assembled When driving a new trailer or after wheels have been remounted check to make sure they are tight after the first 10 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel parting from the trailer and a crash leading to death or serious injury AX WARNING Lug Nut Loosening Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving A WARNING Improper Lug Nut Torque Improper lug nut torque can cause a wheel parting from the trailer leading to death or serious injury Be sure lug nuts are tight before each tow Determining Load Limit of Trailer Determining the load limits of a trailer includes more than understanding the load limits of the tires alone On all trail ers there is a Federal certification VIN label that is located on the forward half of the left road side of the unit This certification VIN label will indicate the trailer s Gross Vehicle Weight Rating GVWR This is the most weight the fully loaded trailer can weigh It will also provide the Gross Axle Weight Rating GAWR This is the most a the axle can weigh There is a vehicle placard Figure 56 located in the same location as the certifica
60. From high est to lowest a tire s resistance to heat is graded as A or C PAGE 58 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 Reference Figure 58 for additional tire information for light trucks Maximum load amp inflation when used as a dual Load Range Severe snow conditions Maximum load amp inflation when used as a single Load inflation limits Figure 58 UTQGS Tire Information Tires for light trucks have other markings besides those found on the sidewalls of passenger tires LT The LT indicates the tire is for light trucks or trailers ST An ST is an indication the tire is for trailer use only Max Load Dual kg 05 at kPa psi Cold This informa tion indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg 05 at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabili ties and its inflation limits Tire Safety Tips Slow down if you have to go over a pothole or other object in the road m DO NOT run over curbs or other foreign objects in the roadway and try not to strike the curb when parking m Check tire inflation pressure weekly during use to in
61. 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 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 17 LS400 LS500 PUMP PUMP COMPONENTS S 4 SYN XS Ses Figure 5 Major Pump Components RES 2 gt Llu ES lt lt N E a lt z lt LU 9 a 77 lt cJ lt 2 LU a 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 T Tow Hitch Coupler Requires a 2 inch ball hitch or a 3 inch pintle Capable of towing 6 000 lbs Documentation Box Contains engine and pump operation parts and maintenance information Manifold Access Door Release latch and lift door to access the Hydraulic Manifold Block Hydraulic Manifold Block Manifold block that controls the flow of hydraulic pressure to the components required to control the pump Hopper Discharge Sleeve Connect hoses or steel pipes to the discharge sleeve for pouring concrete Pump End Jack Stand Use this jack stand to
62. If fuel is low remove fuel filler cap and fill with 2 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 6 Theoillisted in Table 4 is recommended to ensure better 1 Remove the engine oil dipstick from its holder engine performance Use class CD or higher grade motor Figure 10 lt oil Table 4 Oil Selection Chart OIL SAE OIL Figure 10 Engine Oil Dipstick 2 Make sure pump engine is placed on level ground HYDRAULIC OIL CHECK 3 Pull the engine oil dipstick Figure 11 from its holder 1 Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass Figure 12 NORMAL OIL LEVEL ENGINE OIL DIPSTICK HYDRAULIC OIL TEMPERATURE MINIMUM OIL LEVEL SAFE OPERATING OIL LEVEL 1 ADD ENGINE OIL Figure 11 Engine Oil Level Figure 12 Hydraulic Oil Sight Glass 4 Verify that oil level Figure 11 is maintained between the two notches on the dipstick 5 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 LS400 LS500 PUMP INSPECTION 2 Ifthe hydraulic oil level
63. KEY 3 8 IN 1 16 EM511428 BOLT 1 2 X 3 1 2 IN 4 17 EM516780 HOUSING 1 18 EM98108 MOTOR REMIX 1 19 505989 BOLT 1 2 X 1 1 4 IN 2 20 6109180 WASHER LOCK 1 2 IN REPLACES 492626 21 EM25508 ADAPTER FITTING 2 22 EM70860 1 PISTON CUP HOLDER 1 23 50417 PISTON CUP 1 24 508830 1 25 492378 BOLT 3 8 X 1 3 4 IN 4 26 0166 WASHER LOCK 3 8 1 LM REPLACES 492624 29 EM514081 PADDLE ARM END 2 30 EM514032 PADDLE ARM MOTOR END 2 31 EM514033 PADDLE ARM CENTER 2 32 513454 BOLT 1 2 X 3 1 4 IN 6 33 6109180 WASHER LOOK 1 2 1 REPLACES 492626 34 492589 HEX NUT 1 2 REPLACES 507661 35 EM25483 HOSE 2 36 EM70860 HANDLE ASSY 1 37 EM515460 RETAINING RING 1 39 516799 SPACER 6MM 1 40 702 DOG POINT SET SCREW 3 8 1 41 EM703 SET SCREW 3 8 3 42 516787 REMIX SHAFT COUPLER 1 43 500264 SQUARE KEY 3 8 1 4490 516776 DRIVE MEMBER COUPLER 1 4590 516775 MOTOR SHAFT COUPLER 1 46 516786 COUPLER ASSY annuus de INCLUDES ITEMS W MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 103 LS400 LS500 PUMP HOPPER ATTACHMENT ASSY HOPPER ATTACHMENT ASSY PAGE 104 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 HOPPER ATTACHMENT ASSY NO PART NO PART NAME 1 514204 SPLASH PLATE 2 EM514620 HINGE PI
64. LATE AND DECALS NAMEPLATE AND DECALS NO PARTNO PART QTY REMARKS 1 970 DECAL HOPPER REX MIXER 1 1 DECAL LEVER OPERATING INSTRUCTIONS 1 OPTION HYD JACKS 2 EM511091 DECAL MINIMUM OIL LEVEL 1 3 EM97072 DECAL CAUTION OP INSTRUCTIONS 2 4 517639 DECAL MQ MAYCO 15400 LOGO USED ON LS400 MODELS 5 517641 DECAL MQ MAYCO LS500 LOGO lass USED ON LS500 MODELS 6 513580 DECAL ENGINE RPM SETTING T EM97084 DECAL MAINTENANCE 8 EM995 DECAL CAUTION DIESEL FUEL 9 EM98000 DECAL CAUTION GREASE 2 HOURS 10 511709 DECAL 800 30 MAYCO 11 35137 DECAL CAUTION READ MANUAL 12 517907 DIGITAL CONTROL PANEL LOGO 13 EM955 DECAL DANGER CHARGING ACCUM 14 DCL304 DECAL DANGER IMPROPER CHARGING 15 DCL301 DECAL SHUTTLE TUBE DANGER MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 87 o S 508 4 6 6 22 gt 2 oZ S paas d 89 zE Ww iy SEE WIN lt lt ANNS E 39 3 gt gt NAMEPLATE AND DECALS DANGER AMPUTATION DANGER KEEP HANDS CLEAR LS 5002 PUMPING PRESSURE Los LL MULTIQUIP 15400 5500 PUMP 2 F CH
65. LS400 LS500 PUMP WATER SEPARATOR ASSY WATER SEPARATOR ASSY NO PARTNO PART NAME QTY REMARKS 1 514340 BRACKET WATER SEPARATOR 1 2 TBD BOLT 2 3 EM16747 WATER SEPARATOR ASSEMBLY 1 53712 CARTRIDGE WATER SEPARATOR 1 4 492364 BOLT 5 16 X 1 IN 3 5 2105164 HEX NUT 5 16 N dades vei REPLACES 492582 6 EM514559 ELBOW ADAPTER 90 MALE 2 7 EM506208 CLAMP HOSE 2 8 EM514536 HOSE 5 16 IN TBD MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 133 LS400 LS500 PUMP HYD PUMP ASSY HYDRAULIC PUMP ASSY HYDRAULIC lt TANK MANIFOLD PAGE 134 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP HYD PUMP ASSY HYDRAULIC PUMP ASSY NO PART NO PART NAME QTY REMARKS 1 O RING 1 2 EM514719 FLANGE SUCTION PIPE th suede P INCLUDES ITEMS W 3 EM492444 BOLT 1 2 X 1 1 4 IN 4 4 6109180 WASHER LOCK 1 2 IN REPLACES 492626 5 514718 SUCTION PIPE ADAPTER 40 SPECIAL 1 6 EM515207 CLAMP 2 7 EM514623 HOSE SUCTION 2 IN 1 8 EM514627 ADAPTER SUCTION PIPE 32 1 9 EM514628 FLANGE SUCTION PIPE 2 ppm INCLUDES ITEMS W 10 EM510902 BOLT 1 2 X 1 1 2 IN 4 11 6109180 WASHER OCK REPLACES 492626 12 O RING 1 13 EM98128 COUPLER ENGINE ASSY 1 14 EM510902 BOLT 1 2 X 1 1 2 IN 2 16 EM517674 PUMP MAIN
66. Machine does not deliver volume and Volume control set to low Adjust control to full open setting pressure Main ycraulipressuretoolow 078 for proper pressure or for Main Main hydraulic pressure toa low contaminated relief cartridge Check fan electrical connection or for Cooling fan maaa fan motor Fan Fan rotating in wrong direction in wrong direction Contaminated cooler fins Clean cooler fins Hydraulic fluid gets hot Return filter element closed Replace filter Main relief cartridge contaminated or Replace or set to proper pressure Hydraulic oil level too low Fill to proper level Accumulator bottle low on notrogen Check precharge pressure 1100 PSI Contaminated safety relief cartridge Replace cartridge Accumulator gauge reads below 1750 Defective unloader cartridge electrical PSI coil Heplace Unloader cartridge coil not energizing Check for 12 Volt signal voltage Defective gear pump Replace pump ae Worn or defective urethane cups or ncrete slurry in lubrication box worn material cylinder geet Material cylinder piston cups Check oil level Excessive amount of hydraulic on Inspect cylinder Check values for Cylinders not completely extended cylinder rod side contamination or faulty spring short stroke ic cli i 2 cylinder piston head seal Replace seals PAGE 64 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS
67. N 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 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 9 15400 5500 PUMP RULES FOR SAFE OPERATION MAINTENANCE SAFETY AX 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 NEVER lubricate components or attempt service on a running pump 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 containe
68. N 3 EM491686 COTTER PIN 1 8 X 1 1 2 IN 4 EM70134 2 PIN SPLASH PLATE 5 EM505723 COTTER PIN 5 32 X 1 1 2 IN 6 EM16166 TIE ROD 7 505728 NUT HEX 1 IN NC 8 EM14165 EYE BOLT 3 4 IN 9 EM619 O RING 3 4 IN 10 EM968446 NUT HEX 3 4 IN 11 505121 BOLT 3 4 IN X 3 IN 12 EM968446 HEX NUT 3 4 IN 13 505123 HEX BOLT 1 2 X 2 1 2 IN 14 492491 HEX BOLT 1 2 X 1 1 2 IN 15 6109160 HEX W2 IN 16 492379 SCREW CAP 3 8 17 3019092 WASHER FLAT 3 8 18 515395 BOLT 7 16 NC X 4 G5 19 492584 NUT LOCK 1 2 20 EM969013 NUT NYLOC LS400 LS500 PUMP HOPPER ATTACHMENT ASSY QTY 1 1 1 1 1 4 2 4 4 4 4 4 2 1 T 3 REMARKS REPLACES 492556 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 105 15400 5500 PUMP HOPPER INTERIOR ASSY HOPPER INTERIOR ASSY PAGE 106 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP HOPPER INTERIOR ASSY HOPPER INTERIOR ASSY NO PART NAME QTY REMARKS 1 EM16145A SWING AXLE BUSHING 2 2 EM284 STUD 1 IN 14 UNF 1 3 EM16175 O RING 1 4 16170 RING SEAL SHUTTLE AXLE 1 5 EM16176 O RING 1 6 EM98022 WEAR RING HF 1 6A EM16816 1A RING ENERGIZER RUBBER 1 7 EM16816 2 RING INSERT STEEL 1 8 EM16804 SLEEVE IN JUNE 2008 AND BELOW 8 EM16804A SLEEVE 2 JULY 2008 AND ABOVE 9 EM104 BOLT 58
69. NG Improper Electrical Connections Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow Check that the taillights brake lights and turn signals work Check that the electric brakes work by operating the brake controller inside the tow vehicle Uncoupling the Ball Hitch Follow these steps to uncouple ball hitch from tow vehicle Block trailer tires to prevent the trailer from rolling be fore jacking the trailer up Disconnect the electrical connector Disconnect the breakaway brake switch cable Promptly replace the pullpin in the switchbox Before extending jackstand make certain the ground surface below the jackstand foot will support the tongue load Rotate the jackstand handle or crank clockwise This will slowly extend the jack and transfer the weight of the trailer tongue to the jack TIRE SAFETY Unsafe Tires Lug Nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load Therefore it is essential to inspect the trailer tires before each tow If a tire has a bald spot bulge cuts is showing any cords or is cracked replace the tire before towing If a tire has uneven tread wear take the trailer to a dealer service center for diagnosis Uneven tread wear can be caused by tire imbalance axle misalignment
70. NO PART NAME QTY REMARKS 34 492366 BOLT HEX HEAD 5 16 NC X 1 IN G5 6 35 EM492623 WASHER LOCK 5 16 IN 4 36 EM514216 ADJUSTMENT ROD PROXIMITY SWITCH 2 37 EM492556 NUT HEX 1 2 IN 4 38 EM514207 BRACKET ADJUSTMENT ROD 2 39 EM492597 WASHER FLAT 5 16 IN 6 40 EM492582 NUT HEX HEAD 5 16 IN 2 41 98211 CYLINDER MAIN 2 42 EM514920 HOSE MAIN HYD CYLINDER 2 43 EM514202 EXTENSION SPACER 2 44 EM185 BOLT SOCKET HEAD 3 8 NC X 3 IN BLACK OXIDE 68 6 45 EM25497 FITTING 90 4 46 EM25474 HOSE HYDRAULIC SLAVE 1 47 16459 PIN WRIST 2 48 EM505723 PIN COTTER 4 49 EM491701 FITTING GREASE 2 50 EM517126 LOCK WASHER 6 51 EM513352 SEAL SQUARE 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 113 15400 5500 PUMP FUEL TANK ASSY FUEL TANK ASSY NOTES CONNECT TO FILTER INLET HOSE WATER SEPARATOR ASSY NOTE 1 CONNECT TO FILTER OUTLET HOSE WATER SEPARATOR ASSY NOTE 2 PAGE 114 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP FUEL TANK ASSY FUEL TANK ASSY PART NO PART NAME QTY REMARKS 1 EM514084 COVER DIESEL TANK 4 2 514080 GASKET 4 3 492362 BOLT 5 16 X 5 8 IN 56 4 EM923343 WASHER LOCK 5 16 1 96 REPLACES 492623 5 34507 CAP FUEL W GAUGE 1 6 EM514559 ADAPTOR 7 506208 CLAMP 5 8 EM514536 HOSE FUEL RETURN 5 16 IN A R 9 EM20426 ADAPTER 1 10 EM514536 HOSE
71. ON AND PARTS MANUAL REV 6 09 19 11 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options CT January 1s 2006 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 View Parts Diagrams com Order Parts To obtain an MQ Account contact your District Sales Manager for more information E Print Specification Information ose c un MCI T E q Goto www multiquip com and click on Use the internet and qualify for a 5 Discount Parts log in and save on Standard orders for all orders which include complete part numbers L Order via Fax Dealers Only Fax your order in and qualify for a 2 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial complete part numbers 1 800 6 PARTS 7 800 672 7877 4 Note Discounts Are Subject To Change tiguip com Order via Phone Domestic US Dealers Call 1 800 427 1244 EU puce Non Dealer Customers Contact your local Multiquip Dealer for Hes parts call 800 427 1244 for help in locating a dealer near you Parts Or
72. ON RISK Prior to performing any maintenance on the pump follow described lock out tag out procedures Stop the Carefully disconnect the first hose joint at the shuttle tube discharge elbow PAGE 36 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP MAINTENANCE PUMP 5 Add water to the hopper Pump and flush clean the entire hopper shuttle tube and discharge elbow with water 6 Scoop out 12 inches of concrete from the inboard end of the delivery hose Cork screw a 6 x 6 x 8 sponge into the end of the first hose section Reconnect the hose to the discharge elbow 7 Fillhopper with water Pump until sponge and clean water come out the discharge end of the hose and line system 8 When the pump has been used to pump small aggregate concrete pea rock 2 minus or mixes with high fines content 6096 or more sand there will be a tendency for hardened concrete to build up on the inside surface of the shuttle tube Therefore at the end of every such pour after the pump and system have been cleaned and the engine shut off remove all remaining concrete 9 Whenthe pump has been used to pump large aggregate concrete to 1 follow the instructions in step 8 once per week AX WARNING ACID CLEANING NEVER use muriatic acid to clean the pump Acid will dissolve the chrome finish on material cylinder bore and main hydraulic cylinder rods Use only a 2 dia
73. OPERATION AND PARTS MANUAL VS MULTIQUIP 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 ALLTIMES LS400 LS500 PUMP PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 ps 2 un assays 4 Parts Ordering Procedures 5 Safety Message Alert Symbols 6 7 Rules for Safe Operation 8 10 Specifications 12 19 Important Hand Signals a 14 General Information 15 16 a arch 17 Pump Components ps 18 19 Digital Control Panel Components 20 Digital Readout S
74. OTE CONTROL CABLE ASSY REMOTE CONTROL CABLE ASSY NOTES N INCLUDED WITH ITEM 1 COMPLETE CORD ASSY INCLUDES ITEMS WITHIN DASHED LINE PAGE 142 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP REMOTE CONTROL CABLE ASSY REMOTE CONTROL CABLE ASSY NO PART NO PART NAME QTY REMARKS 1 16753 JUNCTION BOX 1 2 EM16754 SWITCH 1 2A EM97075 SWITCH 1 3 EM491897 CONNECTOR RING 3 16 IN 4 4 EM16756 GUARD SWITCH ALUMINUM 2 5 EM26791 SEAL GRIP CORD 1 26790 CORD MX 25 FT 1 7 26793 ADAPTER CORD GRIP 1 2 IN 1 8 97065 100 1 9 97099 COMPLETE CORD ASSY 25 INCLUDES ITEMS W MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 143 15400 5500 PUMP HYDRAULIC STABILIZER ASSY OPTIONAL SECONDARY PUMP HEAT EXCHANGER PAGE 144 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP HYDRAULIC STABILIZER ASSY OPTIONAL OPTIONAL HYDRAULIC STABILIZER ASSY NO PART NO PART NAME QTY REMARKS 1 BOLT 2 2 WASHER 2 3 TBD NUT 2 4 EM98046 VALVE REMIXER W 3 LEVERS 1 4A EM98047 HANDLE DIRECTIONAL VALVE 3 5 506200 FITTING 45 5 6 517101 HOSE 1 7 517102 HOSE 1 8 517103 HOSE 1 9 517104 HOSE 1 10 512655 FITTING 90 7 11 25909 FITTING STRAIGHT
75. OTING ELECTRICAL TABLE 12 ELECTRICAL TROUBLESHOOTING continued MALFUNCTION READING PROBABLE CAUSE SOLUTION Screen 1 Burnt 12 V cycling solenoid Measure solenoid coil resistance It should ycing read 6 ohms Replace burnt solenoid THROTTLE SOLENOID OPEN Wire connection broken Replace broken wire The 12 volt cycling solenoid is shorted Measure solenoid coil resistance It should directly to ground read 6 ohms Replace shorted solenoid THROTTLE SOLENOID SHORTED Wire connection is shorted directly to the Correct connection ground Burnt 12 V cycling solenoid Measure solenoid coil resistance It should yeng read 6 ohms Replace burnt solenoid FUEL SOLENOID OPEN Wire connection broken Replace broken wire The 12 volt cycling solenoid is shorted Measure solenoid coil resistance It should directly to ground read 6 ohms Replace shorted solenoid FUEL SOLENOID SHORTED Wire connection is shorted directly to the Correct connection ground B rnt 12V cycling solenoid Measure solenoid coil resistance It should vans read 6 ohms Replace burnt solenoid UNLOADER SOLENOID OPEN Wire connection broken Replace broken wire The 12 volt cycling solenoid is shorted Measure solenoid coil resistance It should directly to ground read 6 ohms Replace shorted solenoid UNLOADER SOLENOID SHORTED Wire connection is shorted directly to the ground Correct connection ALTERNATOR FAILURE D
76. REEN T BATTERY 12VDC 0 i 2vDC PUT CHASSIS 5 GND O FUSE RELAY HOLDER K1 1 E s NE TDS S S c ORANGE 71 30 51 87 VIBRATOR 25 AMP NO ON OFF HARNESS ASSY SW1 GND RELAY K1 Z P N EM98002 DIODE 1 AMP 12VDC BLK WHEN USED WITH OPTIONAL WIRELESS RADIO NOT SHOWN MODEL EMDC400 CONNECT RECEIVER VIBRATOR UNLOADER PIN 11 TO RELAY K1 PIN 85 DO NOT GROUND COMPLETE OPTIONAL POWER VIBRATOR KIT INPUT P N EMDC400K T T CONNECTTO CHASSIS GND RELAY KI FUSE HOLDER REAR VIEW P N EM98066 85 30 51 87 FUSE NOT 2 INCLUDED 86 WIKIT Ee 1 P N 52016 NOTE ALL WIRES ARE 10 AWG Figure 65 Optional Hopper Vibrator Wiring Diagram UNLESS OTHERWISE SPECIFIED PAGE 74 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP HYDRAULIC SYSTEM DIAGRAM 9 O 1 1750 PSI gt DE 1 B2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 o 1 I 1 1 1 O ACCUMULATOR Tz Ei 1 1 I 1 T P1 ran T RELIEF OUT 1000 PSI 4400 PSI d B OPTIONAL AGITATORAND IN HYDRAULIC OUTRIGGERS AX ROR 14
77. RTS MANUAL REV 6 09 19 11 15400 5500 PUMP TRAILER SAFETY GUIDELINES Step 1 Locate the statement The weight of cargo should never exceed XXX kg 165 on your vehicle s Tire and Loading Information placard Figure 56 This figure equals the available amount of equipment load capacity Step 2 Determine the weight of the equipment being loaded on the tow vehicle That weight may not safely exceed the avail able equipment load capacity The trailer s Tire Information Placard is attached adjacent to or near the trailer s VIN Cer tification label at the left front of the trailer Determining Load Limit of Tow Vehicle Step 1 Locate the statement The combined weight of occupants and cargo should never exceed XXX 1065 on your vehicle s placard Step 2 Determine the combined weight of the driver and passen gers who will be riding in your vehicle Step 3 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds Step 4 The resulting figure equals the available amount of cargo and luggage capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 5 x 150 650 9 Step 5 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and
78. SE VOLUME DECREASE VOLUME Figure 27 Volume Control A thumping sound cylinder stroke should be heard The thumping sound represents the number of strokes per minute volume of the pump Scroll through the Digital Readout Screen with the scroll switch to go to Screen 7 Figure 28 This screen will show the volume in strokes per minute THROTTLE ON 7 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 Letthe pump cycle until the hydraulic oil temperature Figure 29 is approximately 50 to 60 F HYDRAULIC OIL TEMPERATURE Figure 29 Hydraulic Oil Temperature Gauge The Accumulator Pressure Gauge Figure 30 should read approximately 1750 pounds per square inch psi ACCUMULATOR PRESSURE Figure 30 Accumulator Pressure Gauge 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 aclockwise direction FORWARD To turn the blades in a counterclockwise direction REVERSE push the Hopper Remixer Control lever UPWARD Figure 31 PUSH UP TO REVERSE BLADE ROTATION CCW PUSH DOWN 5 TO OPERATE CW BLADE ROTATION Figure 3
79. SSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER The ball size and load rating capacity are marked on the ball hitch capacity is marked on the hitch When replacing a ball the load rating must match or exceed the GVWR of the trailer Before coupling the tow vehicle to the trailer be sure the size and rating of hitch ball match the size and rating of the coupler Hitch balls and couplers are marked with their size and rating AX WARNING Hitch Ball Load Rating Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler Be sure the SIZE of the hitch ball matches the size of the ball coupler PAGE 52 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP TRAILER SAFETY GUIDELINES AX WARNING Defective Hitch Ball worn cracked or corroded hitch ball can fail while towing and may result in death or serious injury Before coupling trailer inspect the hitch ball for wear corrosion and cracks Replace worn or damaged hitch ball AX WARNING Uncoupled Hitch Ball 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 Rock the ball to make sure it is tightened to the hitch and visually check that the hitch ball
80. THROTTLE ASSY NO PARTNO PART NAME QTY REMARKS 1 510792 SUPPORT 1 2 492356 BOLT 1 4 X 3 4 IN 3 3 EM167 BOLT 1 4 X 1 3 4 IN 4 4 EM923057 LOCK WASHER 1 4 1 B assists REPLACES 492596 5 2101402 WASHER 1 4 IN seisis REPLACES 492622 6 EM16465 PISTON SPACER 2 7 98233 BLOCK 1 8 EM98228 COIL 12V 1 9x EM98232 VALVE 1 10 25429 ELBOW ADAPTER 90 MALE 3 11 EM2551 1 STRAIGHT ADAPTER 1 T2 EM25576 HOSE 20 IN 2 13 EM50449 ELBOW ADAPTER 90 MALE 1 14 EM25504 ELBOW ADAPTER 90 MALE 1 15 50463 HOSE 17 1 2 IN 1 16 50449 ELBOW ADAPTER 90 MALE 1 17 50462 HOSE 10 IN 1 18 50449 ELBOW ADAPTER 90 MALE 1 19 EMCC700 HYDRAULIC CYLINDER 1 20 492581 NUT HEX 1 4 IN 2 21 515812 THROTLE CONTROL PLATE 1 22 513213 THROTTLE CABLE GUIDE 1 23 501102 SLEEVE THROTTLE 1 24 491089 BOLT 8 X 1 4 IN 1 25 510229 CABLE THROTTLE 1 26 492366 BOLT 5 16 X 1 1 2 IN 1 27 2105164 HEX NUT 5 16 REPLACES 492553 28 EM98168 THROTTLE BLOCK ASSY E INCLUDES ITEMS W MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 131 LS400 LS500 PUMP WATER SEPARATOR ASSY WATER SEPARATOR ASSY NOTES CONNECT TO FUEL FILTER FUEL TANK ASSY ITEM 11 CONNECT TO FUEL RETURN HOSE FUEL TANK ASSY ITEM 8 PAGE 132 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11
81. TION AND PARTS MANUAL REV 6 09 19 11 PAGE 121 5400 5500 PUMP LUBRICATION PANEL GREASE POINTS Grease daily two or three hots of 2 multipurpose automotive grease Over greasing any bearing will not damage the machine ALWAYS grease before and after pump operation POSITION LOCATION LENGTH OF LINES es CLEVIS GREASE POINT 34 in 1 1 m ns SWING AXLE BUSHING GREASE POINT 26 in 85 m PIVOT BRACKET GREASE POINT 41 in 1 5 m PAGE 122 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP LUBRICATION PANEL LUBRICATION PANEL ASSY NO PARTNO PART NAME QTY REMARKS 1 491701 GREASE FITTING 3 2 EM508812 CONNECTOR 2 3 EM510684 CONNECTOR 3 4 505516 HOSE PLASTIC A R 5 EM510487 HOSE STEEL 1 15400 5500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 123 ENGINE COVER ASS 15400 5500 PUMP ENGINE COVER ASSY RES gt LU ES lt lt e lt lt z lt LU a 9 a 2 a 77 lt 2 lt lt CN a 15400 5500 PUMP ENGINE COVER ASSY ENGINE COVER ASSY NO PARTNO PART NAME QTY REMARKS 1 EM517737 COV
82. agedhoses with internal restrictions can cause blockages PAGE 34 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP PUMPING INFORMATION CLEARING SHUTTLE TUBE BLOCKAGE The shuttle tube is plugged if volume at the discharge end of the hose stops and the hydraulic oil pressure gauge reads 4400 PSI or more To clear a plug in the shuttle tube great care must be taken as a dangerous condition will exist from pressure build up inside the shuttle tube With the shuttle valve the concrete can be pumped in reverse Use the following procedures to clear the shuttle tubes AX WARNING SHUTTLE TUBES DO NOT open any of the delivery system joint clamps REVERSE PUMPING PROCEDURE A Switch the pump into REVERSE With pump speed at a medium slow approx 12 strokes per min try to pull the pack back into the hopper with 5 or 6 reverse strokes B Remixthe concrete in the hopper C Switch the pump into FORWARD If it is still plugged repeat Reversing procedure three times If concrete still does not move proceed to the Shuttle Tube Inspection Procedure A WARNING ACCUMULATOR PRESSURE Make sure the accumulator pressure gauge reads ZERO psi prior to performing any maintenance or inspection You must follow lock out tag out procedures SHUTTLE TUBE INSPECTION PROCEDURE A Stop the pump Switch off the engine The senior or most experienced operator m
83. ailer to the tow vehicle Be sure the hitch components are tight before coupling the trailer to the tow vehicle AX WARNING Coupler Connection An improperly coupled trailer can result in death or serious injury DO NOT move the trailer until e The coupler is secured and locked to hitch e The safety chains are secured to the tow vehicle e The trailer jack s are fully retracted DO NOT tow the trailer on the road until e Tires and wheels are checked e The trailer brakes are checked e The breakaway switch is connected to the tow vehicle e The load is secured to the trailer The trailer lights are connected and checked AX DANGER Hitch Tow Vehicle Load Rating Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer PAGE 48 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP TRAILER SAFETY GUIDELINES Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in ad
84. as it is and consult our company s business office or service plant TABLE 11 BRAKE SYSTEM TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Overheated wheel bearing Replace wheel bearing and pack with grease Low brake fluid Fill and bleed brake system Brakes squeak chatter or chuck Siezed acutator master cylinder Replace Rebuild master cylinder Brake shoe noise Inspect drums Adjust shoes or replace if necessary Leaking wheel cylinder Check and replace wheel cylinder and bleed brake system Low brake fluid level Fill with dot approved brake fluid and bleed brake system Brake actuator frame damage Replace complete actuator unit Brake line being pinched Replace brake line Brakes overheah fail to operate pull to the side or function poorly Seized actuator Replace or rebuild actuator Broken return spring Replace spring Brakes improperly adjusted Check adjustment Break away cable might be pulled Determine cause and correct Pry up on cable until indicator bead touches or rests against cable spring stop This will fully release the frame brakes and prevent drag Break away cable system partially activated PAGE 66 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP TROUBLESHOOTING ELECTRICAL Refer to Figure 61 for the location of components for troubleshooting TABLE 12 ELECTRICAL TROUBLESHOOTING MALFUN
85. ashers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 84 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 15400 5500 PUMP SUGGESTED SPARE PARTS LS400 LS500 LS400 LS500 CONCRETE PUMP CONCRETE PUMP 1 Unit 3 Units Qty Description Qty Description ON EM16462 FELT HOLDER EM16459 PIN EM98050 PISTON CUP ORANGE CMM 25801 CONCRETE CYLINDER EM16493 FELT RING d seo 16462 FELT HOLDER durer EM98033 OIL PLATE Dus EM98050 PISTON CUP ORANGE B om EM14408 BRONZE RING 8 EM16493 FELT RING EM16145 BUSHING SWING AXLE BRONZE 2 Hie 47777 16145 BUSHING SWING AXLE BRONZE EM16816 2 INSERT RING 3 eee EM980214 WEAR PLATE gm EM98065 SLEEVE SEAL 16816 1 ENERGIZER RING EM16816 2 INSERT RING 98022 WEAR RING 98065 SLEEVE SEAL ee EM98065 RUBBER RING 6 98022 WEAR RING 14407 O RING 3 EM98065 RUBBER RING aan 34507
86. box CLEANINGTHE LUBRICATION BOX 1 Remove the top cover and the drain plug Figure 40 located at the bottom of the box and fully drain the inside of the box 2 Once the box is drained start the engine and stroke the cylinder keep hands out of box ten to fifteen times 3 While stroking spray water inside of the box to thoroughly clean out all contamination Figure 40 4 When the box is clean replace drain plug add new lubrication and install the top cover Figure 40 Cleaning the Lubrication Box ACCUMULATOR CIRCUIT AX DANGER ACCUMULATOR CHARGING Improper accumulator charging can result in an explosion causing serious injury or death NEVER use oxygen or compressed air to charge the accumulator Only qualified personal should perform this procedure Use only dry nitrogen to charge the accumulator Contact your Mayco service department or your local Hydac representative for proper charging procedure The accumulator circuit has two functions in the hydraulic system The accumulator circuit furnishes the hydraulic pressure to cycle the shuttle tube The accumulator circuit also furnishes the pilot pressure necessary to activate the hydraulic system The accumulator circuit is equipped with a bladder type accumulator Figure 41 charged with 1100 PSI of dry nitrogen The accumulator stores one gallon of hydraulic oil which is under 1750 PSI of pressure Figure 41 Accumulator Wh
87. creen 21 Engine Components 22 HVS DSC 29 25 Se 26 Start Up Procedure ps 27 COD LSU NR NERO T 28 31 Pumping Information sss 32 35 Maintenance 36 43 Maintenance 44 46 Trailer Safety Guidelines 47 61 Troubleshooting 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 ee 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 85 COMPONENT DRAWINGS Name Plate and Decals 86 89 arf 90 91 Axle ASSY
88. ded throughout this manual to help prevent damage to your concrete pump other property or the surrounding environment 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 serious injury or even death This equipment is to be 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 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 NEVER operate this equipment when not feeling p gt eg well due to fatigue illness or taking medicine E 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 hearing and eye protection equipment when operating the pump E Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacture does not assume respons
89. defective parts This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated to any pump which has been repaired with other than Genuine Mayco Parts nor to any pump which has been altered repaired or used in such manner as to adversely affect its performance nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer Due to the abrasive nature of concrete Mayco does not cover natural component wear THIS WARRANTY AND MANUFACTURER S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE HYDRAULIC DRIVE MODELS MAYCO PUMP hereinafter referred to as Manufacturer warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship under normal use and service for a period of one year or 2000 hours after the date of delivery to the original retail purchaser The Manufacturer will at its option replace or repair at a point designated by Manufacturer any part or parts which shall appear to the satisfaction of Manufacture
90. dering information MEE GEM MEM EE 4 MEC CM When ordering parts please supply Dealer Account Number Specify Preferred Method of Shipment Dealer Name and Address w UPS Fed Ex DHL Shipping Address if different than billing address Priority One Truck Return Fax Number Applicable Model Number Second Third Day 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 WWW WE ACCEPT ALL MAJOR CREDIT CARDS MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 5 15400 5500 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 LS400 LS500 Concrete pump Refer 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 hazar
91. derstand and follow the Operating Instructions could result in injury to yourself and others Loss of control of the trailer or tow ve hicle can result in death or serious injury Common Causes for Loss of Trailer Driving too fast for the conditions maximum speed when towing a trailer is 55 m p h Overloading the trailer or loading the trailer unevenly Trailer improperly coupled to the hitch No braking on trailer Not maintaining proper tire pressure Not keeping lug nuts tight Not properly maintaining the trailer structure Ensure machine is towed level to tow vehicle Trailer Towing Guidelines Recheck the load tiedowns to make sure the load will not shift during towing Before towing check coupling safety chain safety brake tires wheels and lights Check the lug nuts or bolts for tightness Check coupler tightness after towing 50 miles Use your mirrors to verify that you have room to change lanes or pull into traffic Use your turn signals well in advance Allow plenty of stopping space for your trailer and tow vehicle Allow plenty of stopping space for your trailer and tow vehicle DO NOT drive so fast that the trailer begins to sway due to speed Allow plenty of room for passing A rule of thumb 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 cit
92. dition to notifying us If NHTSA receives similar complaints it may open investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or us To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in the Washington D C area or write to NHTSA U S Department of Transportation Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline Inoperable Brakes Lights or Mirrors Be sure that the brakes and all of the lights on your trailer are functioning properly before towing your trailer Check the trailer taillights by turning on your tow vehicle headlights Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights Do the same thing to check the turn signal lights See Trailer Wiring Diagram section in this manual Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear a towed trailer You must provide mirrors that allow you to safely observe approaching traffic AX WARNING CheckingTaillights Brakelights Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow e Check t
93. djust Turn the hub slowly by hand while tightening the spindle nut until you can no longer turn the hub by hand Loosen the spindle nut just until you are able to turn it the spindle nut by hand Do not turn the hub while the spindle nut is loose installa new cotter pin through the spindle nut and axle Check the adjustments Both the hub and the spindle nut should be able to move freely the spindle nut motion will be limited by the cotter pin MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 45 LS400 LS500 PUMP MAINTENANCE TRAILER A Danger Raising the Trailer NEVER crawl under the trailer unless it is on firm and level ground and resting on properly placed and secured jack stands The possibility exists of the trailer falling thus causing equipment damage and severe bodily harm even death A DANGER Trailer Inspection When performing trailer inspection and maintenance ac tivities you must jack up the trailer using jacks and jack stands When jacking and using jack stands place them so as to clear wiring brake lines and suspension parts i e springs torsion bars Place jacks and jack stands in side of the perimeter strip on the supporting structure to which the axles are attached AX WARNING Trailer Impact If the trailer is involved in an accident have it inspected immediately by qualified personnel In addition the trailer should be
94. down period exceeds 2 to 3 minutes turn off the engine so the vibration does not separate the mix in the hopper which can cause a blockage in the manifold when the pump is started lfitis 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 prevent setting of the mix in the system If waiting time is excessive it would be wise to wash out the pump and hoses and start over when the new truck arrives 4 When pumping stiff mixes and there is waiting time between redi mix trucks it is advisable to add some water to the last hopper of material and hand mix to ensure an easier start with the following load 5 Whenthe pumping job requires a stiffer mix the following method is suggested for starting Take a water hose with a nozzle on it and apply water with a fine spray to the concrete as it comes down the redi mix chute into the pump hopper after the slurry procedure is completed and you are ready to start pumping MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 33 LS400 LS500 PUMP PUMPING INFORMATION Using this procedure will make it easier to pump through the clean hose Note Once the concrete has reached the end of the hose do not apply any more water in this manner as this procedure is used for starting only 6 Hose sizing is very important We strongly recommend onharsh mixes vertical pushes
95. ds 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 You WILL be KILLED or SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions 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 AX WARNING LETHAL EXHAUST GASES 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 WARNING EXPLOSIVE FUEL Diesel fuelis extremely flammable and 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 AX
96. e Office 18910 Wilmington Ave Carson CA 90746 Contact mq multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Tel 800 421 1244 Fax 800 537 3927 Fax 310 537 4259 Fax 310 943 2238 Tel 52 222 225 9900 Fax 52 222 285 0420 Contact pmastretta cipsa com mx MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 943 2249 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Tel 0161 339 2223 Fax 0161 339 3226 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2011 MULTIQUIP INC Multiquip Inc the MQ logo and the Mayco logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this p
97. e fan should be running any time the engine is turned on A CAUTION HYDRAULIC OILTEMPERATURE If the hydraulic oil temperature exceeds 170 degrees Fahrenheit shut down the pump DO NOT continue to operate the pump Failure to shut down the pump will result in severe damage to the pump PAGE 42 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP MAINTENANCE PUMP WHEEL BEARINGS PRESSURE TEST After every 6 months of operation inspect the wheel bearings 1 determine the pressure of the Hydraulic System set Once a year or when required disassemble the wheel hubs the Cylinder Stroke Control Switch Figure 42 to the remove the old grease and repack the bearings forcing grease JOG position between rollers cone and cage with a good grade of high 165 speed wheel bearing greases never use grease heavier than 265 A S T M penetration 2 1 Fill the wheel hub with grease to the inside diameter of the outer races and also fill the hub grease cap OFF 2 Reassemble the hub and mountthe wheel Then tighten Figure 42 Cylinder Stroke Control Switch JOG the adjusting nut at the same time turn the wheel in 2 Turn and hold the Manual Cylinder Jogging Switch 2 there isa m bind to be sure all Figure 43 to either JOG A or JOG B position to the bearing surfaces are in contact test the pressure of that cylinder 3 Back offthe adjusting nut 1 6 to
98. e original purchase less a 15 restocking charge 10 In cases where an item is accepted for which the original purchase document can not be determined the price will be based on the list price that was effective twelve months prior to the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change Multiquip reserves the right to quote and sell direct to Government agencies and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge will be added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES No warranties express or implied
99. e return d The list must reference the sales order s or invoice s under which the items were originally purchased The list must include the name and phone number of the person requesting the RMA 3 Acopyofthe Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 The following items are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior to the return date c Any line item with an extended dealer net price of less than 5 00 Special order items Electrical components Paint chemicals and lubricants Decals and paper products Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of th
100. ea 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 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 Use a minimum of 500 105 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 Ibs of cement cu yd for 4000 p s i concrete after 28 days 4 Admixture pump aid if necessary 5 Theproper 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 Pearock 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 Mud Jacking high pressure grouting PAGE 16 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV
101. efective alternator Replace alternator V BELT BREAKAGE Engine blower cooling fan V belt is broken requiring replacement Replace v belt PAGE 68 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 gt ALTERNATOR 4 W FUEL SOLENOID PROXIMITY SWITCH B INTERNAL UNLOADER SOLENOID THROTTLE SOLENOID TROUBLESHOOTING ELECTRICAL PROXIMITY SWITCH A 4 nut 900000000000 500000000400 777777727 77772777770 777777777 27777077777 77777777777 77777777777 777777774 1000000081 1000000008 MAIN B MAIN A SOLENOID Figure 61 Location of Components for Electrical Troubleshooting 15400 5500 PUMP o e lt a eo gt lt lt CD lt a lt lt a a a e 2 e e e gt lt L 400 LS500 PUMP WIRING DIAGRAM CONTROL BOX 12 AWG RED 12VDC DIGITAL READOUT MODULE peeeeeee z 2345878 1200 IN 7 sravoc our 1234 5678 GND 1 2 3 4 5 6 ooooooooooocg9 FUSE HOLDER 30AMP FUSE STARTER
102. el ALWAYS remove the ignition key when leaving the pump unattended ALWAYS block the wheels on the unit when using on a slope ALWAYS maintain this equipment in a safe operating condition at all times ALWAYS stop the engine before servicing adding fuel or oil 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 inexperienced and unauthorized people away 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
103. en the pump cycles a part of the stored oil is released to the shuttle cylinder This pressure release assures the shuttle tube has enough force to shear the cylinder of concrete passing from the concrete cylinder to the concrete delivery line during the cycle phase CHECKING ACCUMULATOR BLADDER PRESSURE The normal accumulator charge pressure should be approximately 1100 PSI To check the accumulator pressure 1 Startthe engine and stroke the pump The accumulator pressure gauge Figure 30 should read 1750 PSI 2 To determine the actual accumulator PSI stop the engine and observe the pressure gauge As the PSI reading slowly decreases it will reach a point where there will be a sudden drop in the PSI The PSI reading should be taken just prior to this sudden drop If you do not read 1100 PSI the accumulator may require charging or bladder replacement MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 39 LS400 LS500 PUMP MAINTENANCE PUMP WEAR PLATE AND CUTTING RING Due to the abrasive nature of concrete it is normal for the cutting ring to wear on its sides as it shears through the concrete inside the hopper The metal to metal friction and the abrasiveness of the concrete will cause extreme wear and reduce sealing capability between the cutting ring and wear plate If the two components do not properly seat against each other slurry will pump into the hopper rather than out the
104. eps should be installed at the top and bottom of the steel line Use a 25 ft hose or short section off the pump and for the balance of the horizontal distance to the vertical line use steel pipe This type of installation has been satisfactory on many jobs being pumped in excess of 100 feet high Line pressures are always less using steel pipe 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 should be given when tieing the hose off atthe top as the hose will have a tendency to stretch when filled with concrete This will increase the possibility of a blockage at the point where the hose is tied off To avoid this a long radius of 90 elbow is recommended The suggested place to tie off is on the hose under the clamp It is strongly recommended that steel pipe be used on all vertical pumping for safety and convenience HOSE PULSATION A slight pulsation of the hose will always be noticeable near the pump Excessive pulsation of the hose near the pump is normally due to higher than average line pressures caused by stiff harsh mixes or extremely long pumping distances PAGE 32 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP PUMPING INFORMATION The use of 2 1 2 hose in these extreme cases reduces line press
105. er control lever Hopper Hood Lift hood to fill Concrete from a Redi 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 Tow End Jack Stand Use this jack stand to level and support the tow end of the pump MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 19 LS400 LS500 PUMP DIGITAL CONTROL PANEL COMPONENTS FLOW DIRECTION FORWARD gt PUMPING PRESSURE V S GR GENCY 7 ON OFF START IGNITION CONTROL CENTER OFF 9 Figure 6 Pump Digital Control Panel Components Emergency Stop Button Press emergency stop button to stop pump in an emergency Turn knob counterclockwise to disengage the stop button 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 Digital Readout Screen Displays and monitors the various functions of the machine Scroll Switch Allows the operator to scroll the various readout screens Reset Switch Allows the operator to reset the stroke counter Remote Cable Connector Insert the remote control input cable into this connector Direc
106. f 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 Insertone 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 LS400 LS500 PUMP MAINTENANCE PUMP CHANGINGTHE WEAR PLATE AND RING Due to the swinging motion of the Nun plate and the abrasive nature of concrete it is normal for the cutting ring to wear on the side that shears through the concrete inside the hopper If the wear ring and wear plate do not fully seat against each other the concrete slurry will pump into the hopper This condition can be easily observed by the sudden change of the level of concrete inside the hopper during each stroke Wear Plate and Ring 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
107. gn 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
108. hat the taillights brake lights and turn signals work e Check that the electric brakes work by operating the brake controller inside the tow vehicle Trailer Towing Tips Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow Accelera tion maneuverability and braking are all diminished with a trailer in tow It takes longer to get up to speed you need more room to turn and pass and more distance to stop when towing a trailer You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer Because of the significant differences in all aspects of ma neuverability when towing a trailer the hazards and risks of injury are also much greater than when driving without a trailer You are responsible for keeping your vehicle and trailer in control and for all the damage that is caused if you lose control of your vehicle and trailer As you did when learning to drive an automobile find an open area with little or no traffic for your first practice trailering Of course before you start towing the trailer you must follow all of the instructions for inspection testing loading and coupling Also before you start towing adjust the mirrors So you can see the trailer as well as the area to the rear of it Drive slowly at first 5 mph or so and turn the wheel to get the feel of how the tow vehicle and trailer combina
109. hopper using extreme care not to damage the hopper seal 5 Remove the four 1 2 1 14 bolts that hold the shuttle tube to the nun plate and remove shuttle tube Using two small pry bars remove the rubber energizer ring steel insert ring and wear ring The energizer ring and wear ring will normally have concrete contamination holding them in position It will be required to chip some of the concrete loose to better expose the energizer ring 6 Clean out all concrete build up in and around the nun plate area with a wire brush 7 Inspect the wear components for indications of wear The wear plate has two wear surfaces Wear Plate Installation 1 Install the two cylinder rings 2 Using silicon sealant coat the circumference of the concrete cylinders the back of the wear plate and around the five bolt holes Next install the wear plate and the five bolts The bolts must all be equally snugged and tightened to 100 foot pounds each Wear Ring installation 1 Install the wear ring into the nun plate 2 _ Install the steel insert ring inside of the rubber energizer ring 3 Install the energizer ring assembly into the nun plate After installing the above mentioned components the machine can be reassembled by reversing steps 1 through 5 of the Wear Plate and Ring Replacement Procedure HEAT EXCHANGER COOLING FAN This section is intended to make sure the fan is working properly Under normal conditions th
110. ibility for any accident due to equipment modifications NEVER use accessories or attachments which not recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or pump ill High Temperatures Allow the engine to cool before adding fuel or performing service and maintenance functions Contact with hot components can cause serious burns The engine section of this pump requires an adequate free flow of cooling air NEVER 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 DEADLY carbon monoxide gas ALWAYS refuel in a well ventilated area away from sparks and open flames e ALWAYS use extreme caution when working with flammable liquids When refueling stop the engine and allow it to cool smoke around or near the machine Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine NEVER operate the pump in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death Topping off to filler port is dangerous as it tends to spill fu
111. ic gravity of aggregates in one cu yard 2 58 Weight of aggregates in one cu yard batch 2850 Ibs SPEC GRAVITY ABS VOL W C Sand 65 1800 2 58 11 56 PEA GRAVEL 35 1000 2 60 6 22 WATER 46 gal 1 CEMENT 6 5 sk 611 TOTAL 27 00 ADMIXTURE None SLUMP 4 REMARKS This mix designed for pumping NOTE Due to the availability of well graded sand as shown in the above sieve analysis this mix pumped very successfully MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 77 APPENDIX CONCRETE MIX INFORMATION 5 STANDARD SPECIFICATION FOR GRADING AGGREGATE PERCENTAGE PASSING BY WEIGHT SCREEN TYPE METRIC FINE AGGREGATE Referred to as washed concrete sand 3 8 100 4 760 microns 95 to 100 amp 48 6 2 380 microns 80 to 100 16 1 190 microns 50 to 85 30 590 microns 50 to 85 50 297 microns 10 to 30 149 microns 2 to 10 3 8 9 51 mm PEA GRAVEL AGGREGATE Referenced to as 4 Rock or Gravel or 1 2 minus 12 7 mm size 1 2 100 3 8 85 to 100 4 ED 4 760 microns 10 to 30 8 2 380 micron 0 to 10 1 190 microns 0 to 5 PAGE 78 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 APPENDIX SLUMPTEST PROCEDURE 1 To obtain a representative sample concrete take several samples at three or more regular interva
112. ification and in case of a recall Rim diameter code Load index amp speed symbol U S DOT tire identification number Ratio of height to width aspect ratio Nominal width of tire in millimeters Passenger car tire 153 001 Severe snow conditions Max Tire ply permissable composition inflation V k i and materials pressure used Treadwear traction and temperature grades Max load rating Figure 57 Standard Tire Sidewall Information MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 57 15400 5500 PUMP TRAILER SAFETY GUIDELINES P The indicates the tire is for passenger vehicles Nextnumber This three digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge In general the larger the number the wider the tire Next number This two digit number known as the aspect ratio gives the tire s ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement P stands for radial Radial ply construction of tires has been the industry standard for the past 20 years Next number This two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is
113. igh RPM speed is Main Hydraulic Cylinder will Set to 2550 not cycle Contaminated Main Relief Valve Check the manifold for a contaminated Relief Valve check for obstructions dried material inside the cylinders Incorrect Directional Control Verify the Directional Control operating Operating Pressure pressure is approx 1000 PSI Contaminated Wale a s manifold for a contaminated Hopper Remix Paddles will elie Valve not rotate Check the Hopper Remixer shaft Broken Shaft Coupler Key coupler for a broken key Check the Shaft Retaining Set Collar Loose Shaft Retaining Set Collar for tightness PAGE 62 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 Obstructed Material Cylinders LS400 LS500 PUMP TROUBLESHOOTING PUMP TABLE 9 PUMP TROUBLESHOOTING CONTINUED Possible Problem To Troubleshoot Incorrect Accumulator System Check the system pressure reading Pressure Verify it is approx 1750 PSI Check the manifold for a contaminated Relief Valve Check for burned out solenoid and Swing Solenoid not energizing 12V signal voltage 54 Manually cycle the pump using the Swing Valve not functioning properly manual cylinder jogging switch Improper Flow Control setting Fully open Flow Control Valve Verify the engine s high RPM speed is Incorrect Engine RPM setting set to 2550 Incorrect Main Hydraulic System Check the pump pressure gauge Operating Pressure Verify it is a
114. ilers brake system This actuator changes fluid power into mechanical power Therefore the fluid level must be checked frequently to assure that the brakes function properly HYDRAULIC BRAKE FLUID RESERVOIR Figure 46 Trailer Actuator AX WARNING Actuator Fluid Level Failure to maintain proper fluid level in the actuator may result in loss of braking action which could cause severe property damage injury or death PAGE 44 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP MAINTENANCE TRAILER Periodically check the actuator mounting fasteners for damage or loosening Inspect the actuator for worn or dam aged parts As you are towing your trailer be aware of any changes in braking quality This could be an early warning of brake or actuator malfunction and requires immediate attention Consult a certified brake specialist to make necessary adjustment or repairs Adjustable Channel Your trailer may be equipped with an adjustable channel Figure 47 that allows the coupler to be raised or lowered to a desired height Periodically check the channel bolts for damage or loosening ADJUSTABLE CHANNEL 5 8 X 11 X5 SSS BOLT NYLOC 5 8 FLAT NUT 2 or 2 5 16 BALL WASHER COUPLER Figure 47 Adjustable Channel With Pintle Eye Coupler Wheel Bearings Hubs Wheel bearings Figure 48 must be inspected and lubri cated once a year or 12 000 miles
115. ing job askthe driver of the redi mix truck to see the concrete ticket and note the admixtures that exist and take the proper action DOWNHILL PUMPING Downhill pumping can be a difficult procedure on some jobs The slurry procedure would be the same as explained PrimingThe PumpWith Slurry Mixture section of this manual It is suggested that a sponge approximately 2 x 4 x 6 in size be placed in the hose before the start of pumping Wetthe sponge before placingitin the hose to keep the slurry from running too far ahead of the concrete which will reduce the possibility of separation When the pump is stopped the material can flow slowly down due to gravity and cause the hose to collapse When pumping is resumed you can expect blockage at the point of hose collapse To prevent this from happening the hose can be kinked off at the discharge end when the pump is stopped to prevent the gravity flow of the material in the hose The use of stiffer mixes when pumping downhill will decrease gravity flow of the material in the hose and will assure a smoother operation between the cam roller bearing andcam plate As with any job make sure that the hose and the couplings are in good workable shape VERTICAL PUMPING When pumping vertically up the side of a building above 40 feet we would recommend the installation of steel pipe securely fastened at intervals as necessary to support the pipe Ninety degree long radius pipe swe
116. inings if necessary electrolyte level is to the bottom of the vent well Figure 39 If necessary add only distilled water in a well ventilated area BATTERY ELECTROLYTE LEVEL DO NOT fill the master cylinder reservoir with used brake fluid DO NOT fill the reservoir beyond 2 from top DO NOT overfill brake fluid will damage paint Wheel bearings and seals should be inspected and packed at this time VENT WELL Figure 39 Battery Electrolyte Levels PAGE 38 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP MAINTENANCE PUMP CYLINDER LUBRICATION BOX AX WARNING FREEZING CONDITIONS When using the pump during freezing conditions completely drain the water box and cover the hopper after pumping Frozen liquid will restrict the piston travel and cause severe damage to the pump AX CAUTION SAFETY GUIDELINES Before checking lubrication level follow lock out tag out procedures Stop the engine and remove the engine starter key 1 The lubrication level should be checked everyday prior to pumping and maintained at a height of 5 inches or about 7 the concrete cylinder height We recommend using a 30 weight motor oil 2 Asthe rubber piston cups naturally wear fine cement particles will accumulate in the box Once the concrete paste reaches a height of about 12 inch from the bottom of the box drain and clean the lubrication
117. ion and subsequent jamming at that point MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 31 LS400 LS500 PUMP PUMPING INFORMATION REMIXTURES Remixtures that are designed into the concrete mix by the redi mix company or an architectural engineering company This section lists common admixtures and a brief explana tion of their functions A Pozzolith 300 or the equivalent acts as a water retarder anda lubricant On a lean mix long pushes stiff mixes and vertical pushes Pozzolith 300R helps pumpability B MBVR air entraining acts as a lubricant C Calcium Chloride commonly referredto as C C is used an accelerator When pumping a load with calcium chloride it is recommended that you wash out if the waiting time between delivery trucks becomes too long D Super Plasticizers acts as an accelerator The concrete will look very wet after the super plasticizer is added but will begin to set up very fast Wash out immediately if you do nothave atruck waiting Super plasticizers are used mainly on commercial jobs E Red Label acts as a water retarder and an accelerator Red label will be used mainly on com mercial jobs Fly Ash is used to help increase the strength of the concrete and decrease the cement content per yard This is one of the most common admixtures used All admixtures will be shown on the redi mix concrete ticket Before starting the pump
118. 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 3 Check the oil level in the lubrication box lf low fill 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 TOP Figure 14 Filling the Lubrication Box MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 25 15400 5500 PUMP SET UP 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 INCORRECT CORRECT 1 Locate both the left and right rear stabilizer jacks Figure 17 Rear Stabilizer Stand Deployment Figure 15 REAR 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 Pushup the middle control lever see Figure 18 to retract the right hydraulic rear stabilizer 3 Push down the rightmos
119. ives at risk and may be illegal Coupling to the Tow Vehicle Follow all of the safety precautions and instructions in this manual to ensure safety of persons equipment and satis factory life of the trailer Always use an adequate tow ve hicle and hitch If the vehicle or hitch is not properly se lected and matched to the Gross Vehicle Weight Rating GVWR of your trailer you can cause an accident that could lead to death or serious injury If you already have a tow vehicle know your vehicle tow rating and make certain the trailers rated Capacity is less than or equal to the tow vehicle s rated tow ing capacity If you already have or plan to buy a trailer make certain that the tow rating of the tow vehicle is equal to or greater than that of the trailer The trailer VIN tag contains the critical safety information for the use of your trailer Again be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer AX WARNING Coupler Selection Condition Proper selection and condition of the coupler and hitch are essential to safely towing your trailer A loss of coupling may result in death or serious injury Be sure the hitch load rating is equal to or greater than the load rating of the coupler Be sure the hitch size matches the coupler size Observe the hitch for wear corrosion and cracks before coupling Replace worn corroded or cracked hitch components before coupling the tr
120. k Cutting Ware Ring and Plate gt gt x HE m Check Trailer Brakes Function Check Brake Lights Check Tire Conditions Inspect Saftey Devices Decals Check Wheel Bearings a X m Inspect Brake Lining X e E 5 lt Visually Check for Oil Leaks CLEANING THE PUMP AND DELIVERY SYSTEM Cleaning the pump is a very important operation as it During routine maintenance or removing material determines how the machine will pump the next time it is blockage you will be required to put your hand in the used concrete cylinders or near the shuttle tube You are at e At the end of every pour or because of long delays during a 2 pour the pump and delivery system must be thoroughly cleaned by removing all concrete material 1 Following the Clearing Concrete Blockage operating procedure ensure that there is no blockage in the hose engine by turning off the ignition switch and remove and line or in the shuttle tube If a blockage exists clear the starter key Place a DO NOT OPERATE tag over the switch and disconnect the battery The 2 Pumpconcrete until the opening of the concrete cylinder pressure reading on the intake in the hopper is visible accumulator pressure 3 Stop the pump gauge MUST read S ZERO ALWAYS make sure the accumulator Circuit pressure reads zero prior to performing any maintenance on the pump AX DANGER AMPUTATI
121. l fuel Engine oil too thick Refill engine crankcase with correct type of oil for winter environment Throttle lever in STOP position Reposition throttle lever to RUN position Engine fires but stops soon 28 c blocked Replace fuel filer starter is switched off Fuel supply blocked Check the entire fuel system Engine stops by itself during Fuel tank empty Add fuel normal operation Fuel filter blocked Replace fuel filter Fuel tank empty Replace fuel filter Fuel filter clogged Replace fuel filter Low engine power output and Fuel tank venting is inadequate Ensure that tank is adequately vented speed P Speed control lever does not remain in See engine manual for corrective action selected position Engine oil level too full Correct engine oil level Air filter blocked Clean or replace air filter Low engine power output and low Pe Incorrect valve clearances Adjust valves per engine specification speed black exhaust smoke MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 65 15400 5500 PUMP TROUBLESHOOTING TRAILER 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
122. lent The above steps must be followed or severe damage to the main axial piston pump can occur 1 When changing the hydraulic oil or topping off the reservoir use only the following type Reservoir capacity 50 gal Hydraulic oil Shell Oil Tellius 68 or Mobil DFE 26 Texaco Rand HDC AX WARNING HYDRAULIC OIL DO NOT mix oil brands This may impair quality 2 Lubrication Grease daily Hour Recommended after each Pour Main hydraulic cylinders 2 Place Axle crank 1 Place B Shuttle cylinders 2 Place 95 tube outlet flange 3 Place GreaseType Lithium Based EP Texaco Multitak 20 Lubriplate ED 2 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 37 LS400 LS500 PUMP MAINTENANCE PUMP BATTERY MAINTENANCE BRAKE SYSTEM The brake system should be periodically checked Look for fluid leaks worn or cracked hoses Check the reservoir for Wear safety glasses or face mask proper fluid levels The Atwood surge brake should be protective clothes and rubber gloves when 42 checked for damage Make sure that all links and pivots working with battery kept lubricated 1 Keep all links and pivots lubricated to prevent rusting and ensure ease of operation Using SAE 30 oil lubricate di inside the release handle and inside the actuator body This be reached from the underside the actuator Mishandling of the battery shortens the service life
123. level and support the rear end of the pump NEVER deploy on un level ground and always check for firmness of ground Shuttle Cylinder Under pressure the shuttle cylinder shears concrete passing from the concrete cylinder to the delivery line during the cycle phase 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 50 psi cold 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 Battery This unit uses a 12 VDC type battery ALWAYS use gloves and eye protection when handling the battery Hydraulic Pump This unit incorporates an axial variable displacement hydraulic piston pump 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 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 Remixer Control Lever Controls the forward reverse motion of the hopper remixer paddles 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 tempera
124. location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency ALWAYS know the location of the nearest and first aid kit aln LU AMBULANCE IITE or FIRE DEPARTMENT PAGE 10 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 15400 5500 PUMP SPECIFICATIONS TABLE 1 PUMP SPECIFICATIONS LS 400 Up to 40 cu yds per hour Model LS 500 Up to 50 cu Pumping Rate yds per hour Pumping Method Reciprocating Piston Maximum Aggregate Size 1 1 2 in minus 38mm Vertical Pumping Height Up to Excess of 250 ft 76m 1150 psi 1000 ft 305m 2 Gallons 7 6 Liters 50 Gallons 189 Liters 40 Gallons 76 Liters Piston Face Pressure Horizontal Pumping Distance Cylinder Lubrication Box Capacity Hydraulic Fluid Capacity Fuel Tank Capacity Hopper Capacity 10 cu ft with optional fwd rev remixer 3 in 4 in 5 in 76 2mm 101 6 mm 127 mm Engine Model Deutz Diesel Deutz Turbo 9 F4L2011 Diesel BF4L2011 Weight with fluids 4 760 Ibs 2 159 kg 4 560 Ibs 2 068 kg Material Hose Weight dry shipping Tire Size 7 35 in x 14 in 187 mm
125. lons of water and a bag of raw cement into the hopper 2 Placethe Direction Control Switch to the REVERSE position Figure 25 This will mix the water and cement into slurry FORWARD lt gt REVERSE Figure 25 Direction Control Switch REVERSE 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 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 PUMPING AX WARNING SAFETY GLASSES Safety glasses MUST be worn at all times when operating the pump Failure to follow safety guidelines can result in serious injury A well planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job 1 Place the Pumping Control Switch to the LOCAL position Figure 26 for normal pumping operation LOCAL 3 REMOTE Figure 26 Pumping Control Switch LOCAL 2 Slide the Volume Control Switch Figure 27 to the right to increase the volume to approximately 10 strokes per minute Sliding the volume control to the left will decrease pump volume INCREA
126. ls throughout the discharge of the mixer or truck DO NOT take samples at the beginning or end of the discharge Dampen the inside of the cone and place it on a smooth moist nonabsorbent level surface large enough to accommodate both the slumped concrete and the slump cone Stand on the foot pieces throughout the test procedure to hold the cone firmly in place Fill the cone 1 3 full by volume Figure 68 A and rod 25 times with a 1 2 dia x 24 Ig bullet pointed steel rod Thisis a specific requirement which will produce non standard results unless followed exactly Dis tribute rodding evenly over the entire cross section of the sample BULLET POINTED STE 1 2 DIAMETER 24 INCHES LONG Figure 68 A Slump Test 1 3 Full 5 Fill cone to overflowing Figure68 C Rod this layer 25 times with rod penetrating into but not through the second layer Distribute rodding evenly over the entire cross section of this layer Figure 68 C Slump Test Full Overflow 6 Remove the excess concrete Figure 68 D from the top of the cone using the tamping rod as a screed Figure 68 0 Slump Test Removing Excess Concrete 7 Lift the cone vertically Figure 68 with a slow even motion DO NOT jar the con crete or tilt the cone during this process Invert the withdrawn cone and place it next to but not touching the slumped con crete 4 Fillcone another 1 3 Figure 68 B which will make the cone 2
127. m securely holds the coupler to the hitch ball insert a pin or lock through the hole in the locking mechanism m Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jackstand verify that you can raise the rear of the tow vehicle by 1 inch after the coupler is locked to the hitch lower the trailer so that its entire tongue weight is held by the hitch Raise the jackstand to a height where it will not interfere with the road Overloading can damage the tongue jack DO NOT use the tongue jack to raise the tow vehicle more than 1 inch If the coupler cannot be secured to the hitch ball do not tow the trailer Call your dealer for assistance Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted posi tion MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 53 15400 5500 PUMP TRAILER SAFETY GUIDELINES Attaching Safety Chain TOW VEHICLE TRAILER TONGUE CROSS BOTH SAFETY CHAINS MASTER LINK Figure 54 Safety Chain Arrangement for a Bumper Pull Trailer Ball Hitch Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing m Attach the safety chains so
128. meter clean out hook when back pumping into redi mix truck Use asafety chain to secure the clean out hook 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 Deutz Model F4L2011F BFL2011F Diesel Engine This pump is equipped with either a Deutz F4L2011F or Deutz BF4L2011F turbo diesel engine For information concerning the procedure in checking removing cleaning etc of the various engine parts or any other information on the engine not contained herein refer to the engine manufacturer s instruction manual HYDRAULIC OIL SYSTEM MAINTENANCE The Mayco pump is equipped with an in tank return hydraulic filter with a 10 micron cleanable filter The element has been designed to remove all particles large enough to cause wear and job break down Under normal conditions we recommend replacement every 6 month The most important factor to keep in mind is the effect of cold weather on the hydraulic oil The viscosity thickness of the hydraulic oil will be much heavier ALWAYS run machine until oil temperature reaches a minimum of 50 F before pumping Damage to the main piston pump will occur if the machine is cycled too fast before the oil temperature reaches the minimum of 50 F Cycle the machine at 6 8 strokes per minute at approximately 1 3 throttle In areas where the weather normally remains under 50 F use Shell Oil Tellus 46 or the equiva
129. mmer out the knock out hole and install the remote antenna ANTENNA KNOCK OUT HOLE ANTENNA CONNECTOR CABLE REAR OF CONTROL BOX CONTROL BOX CONNECTOR Figure 36 Antenna Installation 6 Connectthe antenna cable to the connector on the rear of the control box Figure 36 Radio Remote Control Buttons Operation 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 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 POWER LED BATTERY LED Figure 37 Radio Remote Control PAGE 30 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP OPERATION Radio Remote Control Programming Before starting operation of the Radio Remote Control go to Screen 9 of the Digital Readout Screen RADIO ADDRESS 9 NO RADIO PRESS RESET TO LEARN A NEW ONE 1 Press the ON OFF button on the radio wireless remote control to tu
130. mposition and Materials Used The number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indi cate the materials in the tire which include steel nylon poly ester and others Maximum Load Rating This number indicates the maxi mum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions Uniform Tire Quality Grading Standards UTQGS Treadwear Number This number indicates the tire s wear rate The higher the treadwear number is the longer it should take for the tread to wear down For example a tire graded 400 should last twice as long as a tire graded 200 Traction Letter This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade Traction is graded from highest to lowest as and Temperature Letter This letter indicates a tire s resistance to heat The temperature grade is for a tire that is inflated properly and not overloaded Excessive speed underinflation or excessive loading either separately or in combination can cause heat build up and possible tire failure
131. n volume compared to shorter lines and wetter mixes due to the change in valve efficiency or cavitation MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 29 15400 5500 PUMP OPERATION 4 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 radio or a hardwire method which utilizes a 25 ft extension cable Contact MQ Sales Department to order remote control Radio Remote Control Installation of the Radio Remote Control Assembly 1 Remove the two screws on the digital control panel of the pump See Figure 33 CONTROL BOX REMOVE 2 SCREWS L 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 FRONT PANEL ELECTRONIC CONTROL UNIT 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 ELECTRONIC CONTROL UNIT WIRELESS REMOTE MODULE CONNECTOR Figure 35 Installing Remote Control Module Reinstall the control panel and tighten the 2 screws On the top of the unit to the right of the control box Figure 36 ha
132. nnector An Electrical Connector connects the light and brake systems on the trailer to the light and brake controls on the towing vehicle Emergency Flares and Emergency Triangle Reflectors It is wise to carry these warning devices even if you are not towing a trailer It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the battery is running both the trailer lights and tow vehicle lights Safety Chains If the coupler connection comes loose the safety chains can keep the trailer attached to the tow vehicle With properly rigged safety chains it is possible to keep the tongue of the trailer from digging into the road pavement even if the coupler to hitch connection comes apart Trailer Lighting and Braking Connector A device that connects electrical power from the tow ve hicle to the trailer Electricity is used to turn on brake lights running lights and turn signals as required In addition if your trailer has a separate braking system the electrical connector will also supply power to the brakes from the tow vehicle Breakaway System If the trailer coupler connection comes loose the breakaway system can actuate emergency electric or hydraulic brakes depending on the type of actuator on the trailer The breakaway cable must be rigged to the tow vehicle with appropriate slack that will activate the system if the
133. nut is solid against the lock washer and hitch frame Wipe the inside and outside of the coupler Clean and visually inspect it for cracks and deformations Feel the inside of the coupler for worn spots and pits Be sure the coupler is secured tightly to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame The bottom surface of the coupler must be above the top of the hitch ball Use the tongue jackstand to sup port the trailer tongue Wood or concrete blocks may also be used Coupling the Trailer to the Tow Vehicle Ball Coupler Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler Using the jackstand at the front of trailer tongue turn the jackstand crank handle to raise the trailer If the ball coupler does not line up with the hitch ball adjust the position of the tow vehicle Open the coupler locking mechanism Ball couplers have a locking mechanism with an internal moving piece and an outside handle In the open position the coupler is able to drop fully onto the hitch ball 2 INCH TRAILER COUPLER TOW gt VEHICLE Figure 53 Ball Hitch Coupling Mechanism W Lower the trailer Figure 53 until the coupler fully en gages the hitch ball Engage the coupler locking mechanism In the engaged position the locking mechanis
134. ol panel OR MESSAGE TO TEST FUEL SOL PRESS RESET FUEL SOL OFF INDICATES THEY FUEL SOLENOID 15 OFF Screen 9 Displays the communication status of the optional radio remote control To activate a new remote control connection use the reset switch on the control panel INDICATES THAT RADIO RADIO ADDRESS 9 REMOTE IS ON COMMUNICATING PRESS RESET TO LEARN A NEW ONE IINSTRUCTION OR MESSAGE 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 Oil Filter Prevents dirt and other debris from entering the engine Service the oil filter as recommended in the maintenance section of this manual Crankcase Drain Plug Remove this plug to drain engine oil from the engine crankcase For best results drain engine oil when oil is warm Dip Stick Remove dipstick to determine if the engine oil level is low If low add oil as specified in Table 4 V Belt Cover Remove this cover to gain access to the V belt When replacing V belt use only
135. or incorrect inflation Tires with too little tread will not provide adequate tracking on wet roadways and can result in loss of control leading to death or serious injury Improper tire pressure causes an unstable trailer and can result in a tire blowout and loss of control Therefore before each tow you must also check the tire pressure Tire pressure must be checked when tires are cold Allow 3 hours cool down after driving as much as 1 mile at 40 m p h before checking tire pressure NOTE Trailer tires will be inflated to higher pressures than passenger vehicle tires Since trailer wheels and lug nuts or bolts are subjected to greater side loads than automobile wheels they are more prone to loosen Before each tow check to make sure they are tight The proper tightness torque for lug nuts is listed in the lug nut tightening section of this manual Use a torque wrench to tighten the lug nuts If you do not have a torque wrench use a lug wrench from your tow vehicle and tighten the nuts as much as you can Then have a service garage or trailer dealer tighten the lug nuts to the proper torque AX WARNING Lug NutTightening Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off leading to death or serious injury Tighten lug nuts before each tow MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 55 5400 5500 PUMP TRAIL
136. ose worn or damaged wheel bearing is the most common cause of brakes that grab To check wheel bearings jack trailer and check wheels for side to side looseness If the wheels are loose or spin with a wobble the bearings must be serviced or replaced Check inflation pressure weekly during use to insure the maximum tire life and tread wear Most trailer axles are built with sealed bearings that are not serviceable Sealed bearings must be replaced as complete units NEVER use an pneumatic air gun to tighten wheel lug nuts AX WARNING Lug Nut Tightening Over tightening lug nuts will result in breaking the studs or permanently deforming the mounting stud holes in the wheels AX WARNING Lug Nut Inspection Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check all wheel lug nuts periodically 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 fas teners matched to the cone angle of the wheel Proper pro cedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torquealllug nuts in sequence See Figure 59 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 9 3 Checkto see if the lug nuts are tight after the first 10 25 and 50 miles of driving and before each tow thereafter
137. ow vehicle on one end and to the emergency brake lever located on the hydraulic actuator on the other end AX WARNING Brakeaway Cable An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or ball hitch fails Connect the breakaway cable to the tow vehicle and NOT to the hitch ball or support Before towing the trailer test the function of the breakaway brake system If the breakaway brake system is not working DO NOT tow the trailer Have it serviced or repaired DO NOT tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure Replace the breakaway brake battery if equipped at intervals specified by manu facturer PAGE 54 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP TRAILER SAFETY GUIDELINES Connecting Trailer Lights Connect the trailer lights to the tow vehicle s electrical system using the electric connectors at the front of the trailer tongue Refer to the wiring diagram shown in the trailer wiring diagram section of this manual Before towing the trailer check for the following Running lights turn on tow vehicle headlights Brake Lights step on tow vehicle brake pedal Backup Lights place tow vehicle gear shift in reverse Turn Signals activate tow vehicle directional signal le ver A WARNI
138. ped with the proper tools and equipment and are familiar with hydraulic systems and safe shop practices Use the Pump Troubleshooting Table Table 8 to identify possible causes for the pump s malfunction Contact the Multiquip Service department for the proper repair procedure DANGER AMPUTATION RISK AX WARNING HYDRAULIC SYSTEM HAZARD During routine maintenance or removing material DO NOT open hydraulic lines or loosen hydraulic fittings blockage you will be required to put your hand in the while the engine is running Hydraulic fluid under pressure concrete cylinders or near the shuttle tube You are at can penetrate the skin blind cause burns or create other EXTREME RISK of injury or AMPUTATION if the potentially dangerous hazards 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 TABLE 9 PUMP TROUBLESHOOTING Possible Problem To Troubleshoot Incorrect System Operating Check the pump pressure gage Verify Pressure it is approx 4400 PSI Incorrect Engine RPM setting Verify x engine s h
139. pprox 4400 PSI Contaminated Swing Relief Cartridge Check the manifold for contaminated Swing Relief Cartridge Shuttle Cylinder slow to complete Check he aceumtlatorpressute trok reading Verify it is approx 1750 PSI Hopper Discharge Nipple Seal Check the Hopper Discharge Nipple improperly lubricated Seal for seizing and lack of lubricant Misaligned hopper creating excessive Realign hopper ensuring S tube is friction on the outlet nipple bearing rotating in the center of the hopper sleeve outlet Lack of lubrication Grease Nun Plate Bushing Pump Engine will idle but not increase Throttle Control Block Solenoid not Check for burned out solenoid and to full operating speed energizing 12V signal voltage Blown out fuse Check the fuse Battery voltage falls below 12VDC on Dead battery Check the charge on the battery digital display causing engine not to Check the wiring connections and start Wiring connection inside Control Box verify power is reaching ignition switch MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 63 LS400 LS500 PUMP TROUBLESHOOTING PUMP TABLE 9 PUMP TROUBLESHOOTING CONTINUED Possible Problem To Troubleshoot m Check oil level and for closed suction Main Hydraulic Pump Noisy Air in system Engine bogs down Decrease volume control on main Engine overloaded when pumping pump Material hose pack Low engine speed Check engine RPM
140. r and its contents The gross weight of the trailer includes the weight of the trailer and all of the items within it such as the pump and other items GVWR is sometimes referred to as GTWR Gross Trailer Weight Rating or MGTW Maxi mum Gross Trailer Weight GVWR GTWR and MGTW are all the same rating The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer because some of the trailer load is to be carried by the tow vehicle rather than by the trailer axle s The total weight of the cargo and trailer must not exceed the GVWR and the load on an axle must not exceed its GAWR PSIC The tire pressure Pounds per Square Inch measured when Cold VIN The Vehicle Identification Number EMPTY WEIGHT Some information that comes with the trailer such as the Manufacturer s Statement of Origin is not a reliable source for empty or net weight The ship ping documents list average or standard weights and your trailer may be equipped with options To determine the empty or net weight of your trailer weigh it on an axle scale To find the weight of the trailer using an axle scale you must know the axle 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 vehicle axles Figure 51 VIN Tag Location PAGE 50 MAYCO LS400 LS500 PUMP
141. r upon inspection at such point to have been defective in material or workmanship This warranty does not obligate Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair of the defective parts This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated to any pump which has been repaired with other than Genuine Mayco Parts nor to any pump which has been altered repaired or used in such manner as to adversely affect it s performance nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer Due to the abrasive nature of concrete Mayco does not cover natural component wear THIS WARRANTY AND MANUFACTURER S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 147 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Multiquip Corporat
142. r tank Normal internal pressure should read approximately 1750 PSI during pumping Main Pressure Gauge This gauge monitors the 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 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 Indicates electrical malfunction Refer to Troubleshooting section INDICATES STATUS OF PUMP ON OR OFF LS 400 OFF INDICATES 0000 ENG RPM ENGINE REM INDICATES BATTERY 12 5 V BATTERY LOW OIL PSI CHARGE INDICATES ELECTRIC MALFUNCTION SECONDARY SCREENS Screen 2 Displays the position ofthe 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 2 FLOW INC ON INDICATES VOLUME SWITCH IS IN THE POSITION 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 INDICATES NO OF HOURS OF HOURS ENGINE HAS SR PUMP HAS BEEN USED E HRS 00000 0 BEEN USED PMP HRS 00000 0 FAULTS 00000000 RESET TO CLEAR
143. r to turn too much because it will hit the rear of the tow vehicle To straighten the rig either pull forward or turn the steering wheel in the opposite direction Trailer VIN Tag Figure 50 below is a sample of the Vehicle Identification Number VIN Tag which is typically located on the left front of the trailer See Figure 51 MANUFACTURED BY FABRIQUE PAR 1 ME GVWR PNBV 1j i GAWR EACH AXLE PHBE CHAQUE ESSIEU Kl RIMS SANTA COLD INFL PRESS PRESS DEGONFL AFROID 62 HPAL CISINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE US FEDERAL MOTOR VEFILE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWA ABOVE THIS VEHICLE CONFORMS APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IV EFFECT ON TE DATE OF MANUFACTURE CE VEHICULE EST CONFORMEA TOUTES LES NORMES GUI LU SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE DE SA FABRICATION VLN TYPE TRAILER TRA REM FD 306 REV A 48 TIRES PEE Figure 50 Vehicle VIN Tag The trailer VIN Tag contains the following critical safety information for the use of your trailer GAWR The maximum gross weight that an axle can support It is the lowest of axle wheel or tire rating Usually the tire or wheel rating is lower than the axle rating and determines GAWR GVWR The maximum allowable gross weight of the traile
144. recommended type V belt Alternator Provides power to the electrical system Replace with only manufacturers recommended replacement parts 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 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 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 Starter Solenoid This engine uses a 12 VDC 2 7kW 3 7 HP starter motor with solenoid PAGE 22 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 AX CAUTION GENERAL SAFETY GUIDELINES 1 NEVER operate the pump ina ee confined area or enclosed area Med structure that does not provide ample free flow of air ALWAYS wear approved eye and hearing protection before operating the pump NEVER operate the pumps s engine with the engine hood removed The possibility exists of hands long hair and clothing becoming entangled with the V belt causing injury and bodily harm 4 Ao NEVER place hands or feet inside the hopper ALWAYS make while the engine is running ALWAYS shut down the engine before performing any kind of
145. rn on the power Hold down the RESET switch The will now show RADIO ADDRESS RADIO ADDRESS NOW SCANNING FOR NEW JTRANSMITTER 2 After 5 seconds the display will show 1 RADIO ADDRESS COMMUNICATING PRESS RESET TO LEARN A NEW ONE The remote control is now ready for use Cable Remote Control Installation of the Cable Remote Control Assembly Connect the cable to the front panel of the control box See Figure 38 CABLE REMOTE CONTROL UNIT 25 FT CABLE PUMP ON OFF TO CONTROL BOX connector Figure 38 Cable Remote Control Cable Remote Control Operation Before using cable remote control set the pumping volume with the VOLUME switch on the control box then move the Pumping Control Switch on the control box to the REMOTE position The cable remote control Figure 38 has the following controls PUMP ON OFF Starts and stops the forward pumping PUMP REV starts pumping in reverse direction WARNING TRANSPORTING PUMP It will be necessary at times to move your pump from one job site location to another Before moving the pump make sure to pump the remaining concrete out of the hopper Moving the pump with a full hopper of concrete can cause severe damage or breakage of the axle and axle springs excess strain and pressure on the hub and bearing assembly Leaking manifold seals or hose coupling gaskets which leak water can cause separa t
146. rs to dispose of hazardous waste BATTERY The battery contains acids that can cause injury to the eyes and skin To avoid eye irritation always wear safety glasses Use well insulated gloves when picking up the battery Use the following guidelines when handling the battery 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 contact with clothing or skin rinse skin or clothing immediately with plenty of water Incase the battery liquid dilute sulfuric acid comes contact with your eyes rinse eyes immediately with plenty of water then contact the nearest doctor or hospital and seek medical attention 4 2 EMERGENCIES ALWAYS know the location of the nearest fire extinguisher ona ANN N 6 OS KIT In emergencies always know the
147. sen sleeve seal Inspect and replace if wear is excessive 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 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 o
148. t control lever see Figure 18 to extend the left hydraulic rear stabilizer 4 Push up the rightmost control lever see Figure 18 to retract the left hydraulic rear stabilizer Figure 15 Locating Rear Stabilizer Jacks 2 Remove the cotter pin from the handle tee bolt eye and then pull the handle tee to release the stabilizer jack Figure 16 s A I MIDDLE CONTROL LEVER 3 Position both rear stabilizers jacks on firm not loose CONTROLS RIGHT level ground Figure 17 HYDRAULIC STABILIZER 4 Align the hole on the stabilizer jack with the hole on the frame body and insert handle tee bolt RIGHT HYDRAULIC 5 Insert the cotter pin into handle tee bolt eye to lock the stabilizer jack LEFT HYDRAULIC STABILIZER JACK RIGHTMOST CONTROL LEVER CONTROLS LEFT HYDRAULIC STABILIZER REAR STABILIZER STAND Figure 18 Control Levers for Hydraulic Rear Stabilizers A WARNING REAR STABILIZER SAFETY 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 relieve load working pressure PAGE 26 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 LS400 LS500 PUMP START UP PROCEDURE STARTING PROCEDURE AX WARNING GENERAL SAFETY GUIDELINES DO NOT attempt to operate this concrete pump until the Safety
149. t the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by S N XXXXX AND BELOW S N XXXX AND ABOVE S N XXXX TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by XXXXX ONLY NOT USED ON Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain w
150. te Your trailer maybe equipped with drop spindle axles See axle manual for your axle type You will need a modified adjusting tool for adjusting the brakes in these axles With drop spindle axles a modified adjusting tool with about an 80 degree angle should be used 5 Rotate the starwheel in the opposite direction until the wheel turns freely with a slight drag Replace the adjusting hole cover Repeat the above procedure on all brakes 8 Lower the trailer to the ground N O You must check the fluid level in the master cylinder reservoir at least every three months If you tow your trailer an average of 1 000 miles per month in a hot and dry environment you must check the brake fluid level once a month The brake fluid reservoir is located on the tongue of the trailer Always fill with clean uncontaminated DOT 4 brake fluid Figure 45 below displays the major hydraulic air surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 6 as referenced in the Manually Adjusting The Brakes section on this page See Table 11 Trailer Brake System Troubleshooting Anchor Post Retractor Springs 2 SS 5 S Plate Primary Shoe Adjuster Spring Adjuster Assembly Figure 45 Hydraulic Brake Components Hydraulic Brake Actuator The hydraulic brake actuator Figure 46 is the mechanism that activates the tra
151. that they A Cross underneath the coupler See Figure 54 B Loop around a frame member of the tow vehicle or holes provided in the hitch system DO NOT attach them to an interchangeable part of the hitch assembly C Have enough slack to permit tight turns but not be close to the road surface so if the trailer un couples the safety chains can hold the tongue up above the road AX WARNING Safety Chains Rigging Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle e Fasten chains to frame of tow vehicle DO NOT fasten chains to any part of the hitch 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 Breakaway Brake System If the coupler or hitch fails a properly connected and work ing breakaway brake system Figure 55 will apply the hy draulic brakes on the trailer The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailer s axles the trailer tow vehicle combination will come to a controlled stop Connect Cable to Breakaway Lever Tow Vehicle Hydraulic Actuator Figure 55 Breakaway Brake System Breakaway Cable Surge Brake System The breakaway brake system includes a brake cable con nected to the t
152. 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 loo
153. the pump and hoses and start over when the new truck arrives This can be avoided by being observant to the pump and system also taking into consideration the above actors A through D affecting the mix CLEARING CONCRETE BLOCKAGE AX WARNING BLOCKAGES If you repeatedly pull the throttle all the way out and try to force your pump to push through blockages due to separation of material in the hose or manifold you will soon have breakdowns and costly repairs which are not covered under warranty If a blockage occurs find 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 the hose until you find the point of trouble The hose will be soft immediately past the blockage To clear the blockage 1 Disconnect the hose at the first coupling past the blockage AX WARNING HOSE LINE PRESSURE Use extreme care The hose line is under pressure and can cause serious injury 2 Elevate the hose at that point with the blockage area hanging down 3 Using a hammer you can pound the downstream edge of the packed area until it is free to flow Shake all of the sand and gravel out to the end of the hose 4 Before reconnecting the hose start the pump and run a small amount of concrete out to the end ofthe hose This will assure that all of the separation is out of the hose Dam
154. tion responds Next make some right and left hand turns Watch in your side mirrors to see how the trailer follows the tow vehicle Turning with a trailer attached requires more room Stop the rig a few times from speeds no greater than 10 mph If your trailer is equipped with brakes try using different combinations of trailer electric brake and tow vehicle brake Note the effect that the trailer brakes have when they are the only brakes used When properly adjusted the trailer brakes will come on just before the tow vehicle brakes It will take practice to learn how to back up a tow vehicle with a trailer attached Take it slow Before backing up get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 49 LS400 LS500 PUMP TRAILER SAFETY GUIDELINES Some drivers place their hands the bottom of the steering wheel and while the tow vehicle is in reverse think of the hands as being on the top of the wheel When the hands move to the right counterclockwise as you would do to turn the tow vehicle to the left when moving forward the rear of the trailer moves to the right Conversely rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left while backing up If you are towing a bumper hitch rig be careful not to allow the traile
155. tion Control Switch This 2 position switch controls the direction of flow for any mix in the pump The leftmost position sets the pumping direction to forward and the rightmost position sets the pumping direction to reverse Pumping Control Switch This 3 position switch controls the pumping of the pump The rightmost position REMOTE is for use with the remote control unit the leftmost position LOCAL is for normal pumping operation and the centermost position CENTER OFF prevents pumping 9 Cylinder Stroke Control Switch This 2 position switch 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 pump from automatic to manual cycling This allows the cylinders to be manually cycled using the Manual Cylinder Jogging Switch Manual Cylinder Jogging Switch This 2 position 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 position jogs Cylinder A and the rightmost position jogs Cylinder B Stroke Volume Control Switch Increases decreases the number of strokes per minute of the pump Accumulator Pressure Gauge This gauge monitors the internal pressure of the Accumulato
156. tion label described above This plac ard provides tire and loading information In addition this placard will show a statement regarding maximum cargo capacity lt The weight of cargo should never exceed XXX kg Or XXX Ibs TIRE SIZE COLDTIRE PRESSURE Re AX WARNING Tire Pressure Improper tire pressure can result blowout and loss of control which can lead to death or serious injury Be sure tires are inflated to pressure indicated on side wall before towing trailer Figure 56 Tire and Loading Information Placard If additional work items hoses tools clamps etc are go ing to be added to the trailer be sure they are distributed evenly to prevent overloading front to back and side to side Heavy items should be placed low and as close to the axle positions as reasonable Too many items on one side may overload a tire Excessive loads and or underinflation cause tire overloading and as a result abnormal tire flexing occurs This situation can generate an excessive amount of heat within the tire Excessive heat may lead to tire failure It is the air pressure that enables a tire to support the load so proper inflation is critical The proper air pressure may be found on the certification VIN label and or on the Tire and Loading Information placard This value should never exceed the maximum cold inflation pressure stamped on the tire PAGE 56 MAYCO LS400 LS500 PUMP OPERATION AND PA
157. 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 pumping excessively wet mixes which do not have enough cohesion to hold together 2 Bypumping 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
158. ture of the hydraulic oil 15 16 20 21 22 23 24 25 Hydraulic Oil Tank Cap Remove cap to add hydraulic fluid Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if level is low Accumulator Pressure Gauge Used to monitor accumulator pressure Pressure should read at least 1750 psi for correct pump operation Pumping Pressure Gauge Used to monitor pressure in the concrete cylinders and shuttle tube Control Box Contains the electrical components required to run the pump See Control Box Components section for component callouts 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 Hydraulic Oil Filter This in tank return hydraulic filler 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 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 Rear Running Lights ALWAYS check and make sure both the right and left running lights are functioning correctly before towing the pump Remixer Motor Drives the remixer paddles inside the hopper The motor direction is controlled by the remix
159. ublication were in effect 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 reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is 44 MULTIQUIP
160. ures orthe addition of slight amounts of waterto the mix if permissible will permit easier pumping The use of certain pumping admixtures may help If excessive pulsation exists in the hose it is advisable to use burlap or some means of wear protection under the hose at points where the hose may wear through the outer cover e g over forms steel or sharp curbs SNAP JOINT COUPLINGS When using Snap Joint couplings with gaskets to join hose see that they are washed clean after each job Keeping the hose ends clean heavy duty is very important for the best job setup A thin coat of grease on the rubber gasket or dipping both coupling and gasketin water before couplingthe hose will make for easier installation NEW PUMPS All new pumps are water pressure tested at the factory This procedure permits a thorough inspection of entire drive system and valving under simulated full load conditions The pump owner can dothe same by making an adapterto couple to the end of the discharge cone e g the use of a standard 2 pipe cap with a 3 8 drilled hole in the center screwed on to the end of hinged cone or reducer at the pump Fill the hopper with water after making sure that all sand and rock have been removed from manifold Operate pump at full throttle and the 3 8 diameter hole restriction will create sufficient back pressure to make thorough inspection of all moving parts THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETE
161. ust warn all others to stand at least 20 feet away from the machine and turn their heads to face away from the pump C The operator will position himself beside the reducing elbow at the pump outlet Wearing safety glasses slip the end of a pry bar 24 length of reinforcing steel rod under the latch of the hose clamp and flip it up D Carefully knock the end of the hose away from the reducer E F Chip the concrete out of the reducer with the pry bar Remove the reducer From the discharge end chip the concrete out of the shuttle tube with the pry bar If concrete cannot be loosened from the outlet of the shuttle tube remove the clean out plug on the bottom of the hopper to discharge the concrete Chip the blockage out with the pry bar Flush the shuttle tube with water Before resuming operation of the pump perform the Reverse Pumping Procedure to relieve pressure on the shuttle tubes MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 35 LS400 LS500 PUMP MAINTENANCE PUMP TABLE 5 MAINTENANCE CHECK SCHEDULE Lees Pere a Y y ky ly hs Hours Ereol gt j Engine gt Fuet Fiter gt aaa am x Denmewenes x sos eom e Es Outlet Zerk Points Check System Pressure x Em ES gt Check Hardware for Tightness Chec
162. y driving grades DO NOT ride the brakes while descending grades they may get so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer To conserve fuel don t use full throttle to climb a hill Instead build speed on the approach Slow down for bumps in the road Take your foot off the brake when crossing the bump DO NOT brake while in a curve unless absolutely necessary Instead slow down before you enter the curve and power through the curve This way the towing vehicle remains in charge DO NOT apply the brakes to correct extreme trailer swaying Continued pulling of the trailer and even slight acceleration will provide a stabilizing force Anticipate the trailer swaying Swaying is the trailer reaction to the air pressure wave caused by passing trucks and buses Continued pulling of the trailer provides a stabilizing force to correct swaying DO NOT apply the brakes to correct trailer swaying Use lower gear when driving down steep or long grades Use the engine and transmission as a brake Do not ride the brakes as they can overheat and become ineffective Be aware of your trailer height especially when approaching roofed areas and around trees Make regular stops about once each hour Confirm that A Coupler is secure to the hitch and is locked B Electrical connectors are secure C There is appropriate slack in the safety chains D
163. zzle assembly thoroughly after each job Grease all threads before reassembly DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air passages clean PAGE 82 MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 APPENDIX RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES PARTNO PART NAME QTY REMARKS 1 26107 HOPPER SCREEN W AIR VIBRATOR MOUNTING 2 EM23101 AIR VIBRATOR 1 3 EM132 BOLT 1 2 13X2 2 4 EM23407 AIR HOSE 1 5 23408 BUSHING 1 6 EM23411 VALVE 1 EM912073 NIPPLE 2 8 EM23409 COUPLING 1 9 923346 WASHER 1 2 LOCK 2 10 EM406 NUT HEX 1 2 13 2 11 EM23818 2 X25 GROOVED HOSE 11 EM24841 2 X25 RAISED HOSE 11 EM23845 2 X50 GROOVED HOSE 12 23802 VIC ADAPTER EM23802DH D 1 13 23803 GUN BODY 1 14 20816 O RING 1 15 23804 AIR INSERT 1 16 23805 NOZZLE CLAMP 1 17 23806 NOZZLE TIP 1 3 8 SHORT 1 18 23807 NOZZLE TIP 1 1 4 LONG 1 19 911076 STREET ELBOW 1 20 AIRHOSE u Sunius NOT SUPPLIED BY MAYCO 2 EM23808 NOZZLE ASSEMBLY INCLUDES ITEMS W MAYCO LS400 LS500 PUMP OPERATION AND PARTS MANUAL REV 6 09 19 11 PAGE 83 15400 5500 PUMP EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual

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