Pump-LS400-LS500-manual-rev-5 062110

Pump-LS400-LS500-manual-rev-5 062110
OPERATION AND PARTS MANUAL
SERIES
MODELS LS400/LS500
CONCRETE PUMPS
(DEUTZ F4L2011, BF4L2011 DIESEL ENGINES)
Revision #5 (06/21/10)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Proposition
65 Warning
LS400/LS500 PUMP
— PROPOSITION
65 WARNING
Diesel engine exhaust and some of
PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
NOTES
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 3
LS400/LS500 PUMP —TABLE OF CONTENTS
MAYCO LS400/LS500
COMPONENT DRA
WINGS
DRAWINGS
CONCRETE PUMPS
Name Plate and Decals ..................................... 88-91
Frame Assy......................................................... 92-93
Axle Assy. ........................................................... 94-95
Brake Line Assy. ................................................. 96-97
Brake Lights Assy. .............................................. 98-99
Trailer Hitch Assy. ........................................... 100-101
Battery Assy. .................................................. 102-103
Hopper Assy. .................................................. 104-105
Hopper Attachment Assy. ............................... 106-107
Hopper Interior Assy....................................... 108-109
Shuttle Cylinder Assy...................................... 110-111
Lubrication Pistons Assy. ............................... 112-115
Fuel Tank Assy. .............................................. 116-117
Heat Exchanger Assy. .................................... 118-119
Accumulator Assy. .......................................... 120-121
Remixer Control Assy. .................................... 122-123
Lubrication Panel Assy. .................................. 124-125
Engine Cover Assy. ........................................ 126-127
Hydraulic Tank Assy. ....................................... 128-129
Engine Assy. ................................................... 130-131
Throttle Assy................................................... 132-133
Water Separator Assy..................................... 134-135
Hydraulic Pump Assy...................................... 136-137
Manifold Assy.................................................. 138-139
Control Box Assy. ........................................... 140-141
Control Box Harness Assy. ............................. 142-143
Remote Control Cable Assy. .......................... 144-145
Hydraulic Stabilizer Assy. (Optional) .............. 146-147
Proposition 65 Warning ............................................. 2
Table of Contents ...................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Message Alert Symbols .............................. 6-7
Rules for Safe Operation ..................................... 8-10
Specifications .......................................................... 12
Dimensions ............................................................. 13
Important Hand Signals .......................................... 14
General Information ...........................................15-16
How it Works ........................................................... 17
Pump Components ............................................18-19
Digital Control Panel Components .......................... 20
Digital Readout Screen ........................................... 21
Engine Components ............................................... 22
Inspection ...........................................................23-25
Set-Up ..................................................................... 26
Start-Up Procedure ................................................. 27
Operation ...........................................................28-31
Pumping Information ..........................................32-35
Maintenance (Pump) .........................................36-43
Maintenance (Trailer) .........................................44-46
Trailer Safety Guidelines ....................................47-61
Troubleshooting (Pump).....................................62-64
Troubleshooting (Engine) ........................................ 65
Troubleshooting (Brake System)............................. 66
Troubleshooting (Electrical) ...............................67-69
Wiring Diagram (Control Box) ............................70-73
Wiring Diagram (Digital Readout Screen)............... 74
Wiring Diagram (Optional Hopper Vibrator) ............ 75
Hydraulic System Diagram ..................................... 76
Manifold Block Ports ................................................ 77
Appendix - Concrete Mix Information ................78-79
Appendix - Slump Test Procedure........................... 80
Appendix - Recommended Shotcrete System ...... 82-83
Appendix - Recommended Shotcrete Accessories .... 84-85
Explanation Of Codes In Remarks Column ............ 86
Suggested Spare Parts ........................................... 87
Terms and Conditions of Sale - Parts ................... 148
Mayco Pump Warranty .......................................... 149
Specification and part number are subject
to change without notice.
PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 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.
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:
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
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards 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.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
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.
WARNING - BURN HAZARDS
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
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.
You CAN be injured if you do not follow directions
PAGE 6 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep fingers,
hands, hair and clothing away from all
moving parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
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.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory
settings of the engine governor or
settings. Personal injury and damage
to the engine or equipment can result
if operating in speed ranges above
maximum allowable.
CAUTION - RESPIRATORY HAZARDS
ALWAYS wear approved respiratory
protection.
CAUTION - SIGHT AND HEARING HAZARDS
This machine is capable of
producing noise levels above 85 dB.
Hearing protection is required.
Always wear eye protection.
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout
this manual to help prevent damage to your concrete
pump, other property, or the surrounding environment.
This pump , other property, or the
surrounding environment could be damaged
if you do not follow instructions.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — 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
■ DO 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
well due to fatigue, illness or taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or pump.
■ 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.
■ ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool.
■ NEVER 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.
■ 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.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Manufacture does not assume responsibility for any
accident due to equipment modifications.
■ NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
■ 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. #5 (06/21/10)
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 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
lbs. load.
■ If unit is equipped with ball hitch coupler, use only 2" all
steel ball rated for minimum of 6,000 lbs. 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 ON.
■ 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.
MAINTENANCE SAFETY
■ 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 containers to dispose of hazardous
waste.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 9
LS400/LS500 PUMP — RULES FOR SAFE OPERATION
BATTERY
EMERGENCIES
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:
■ ALWAYS know the location of the
nearest fire extinguisher.
■ ALWAYS know the location of the
nearest and first aid kit.
■ 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 in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
■ In emergencies always know the 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.
PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
NOTES
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 11
LS400/LS500 PUMP — SPECIFICATIONS
TABLE 1. PUMP SPECIFICATIONS
Model
LS-400
LS-500
Pumping Rate
Up to 40 cu.
yds. per hour*
Up to 50 cu.
yds. per hour*
Pumping Method
Reciprocating Piston
Maximum Aggregate Size
1-1/2 in. minus (38mm)
Ver tical Pumping Height
Up to Excess of 250 ft. (76m)
Piston Face Pressure
1150 psi
Horizontal Pumping Distance
1000 ft. (305m)*
Cylinder Lubrication Box Capacity
2 Gallons (7.6 Liters)
Hydraulic Fluid Capacity
50 Gallons (189 Liters)
Fuel Tank Capacity
40 Gallons (76 Liters)
Hopper Capacity
10 cu. ft. with optional fwd/rev remixer
Material Hose
3 in., 4 in., 5 in. dia.
(76.2mm, 101.6 mm, 127 mm)
Deutz Diesel
F4L2011
Engine Model
Deutz Turbo
Diesel BF4L2011
Weight (with fluids)
4,760 lbs. (2,159 kg)
Weight (dry/shipping)
4,560 lbs. (2,068 kg)
Tire Size
7.35 in. x 14 in. (187 mm x 356 mm)
Options
Wireless Remote Control, Hopper Screen Vibrator,
Hydraulic Rear Stabilizer
* Volume output will vary depending on mix design, slump, line size used and job site condititons
TABLE 2. ENGINE SPECIFICATIONS
Model
Deutz F4L2011F
Diesel Engine
Deutz BF4L2011F
Diesel Engine
Type
4 stroke, Air-cooled Diesel
No. of Cylinders
4
Bore x Stroke
4.19 in. x 5 in.
(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
Lube Oil Capacity
9.5 gal. (2.5 liters)
Fuel Type
#2 Diesel Fuel
Battery
12V DCV Group 27
PAGE 12 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — DIMENSIONS
TABLE 3. DIMENSIONS
REF.
DIMENSIONS
A
43 in. (109.2 cm.)
B
172 in. (437 cm.)
C
24 in. (61 cm.)
D
70 in. (177.8 cm.)
E
68 in. (172.2 cm.)
Figure 1. Dimensions
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 13
LS400/LS500 PUMP — IMPORTANT HAND SIGNALS
Figure 2 displays the basic hand signals commonly used in concrete pumping operations.
Figure 2. Operation Hand Signals
PAGE 14 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — GENERAL INFORMATION
CONCRETE MIX DESIGN
Mix design 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 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. By pumping excessively wet mixes which do not have
enough cohesion to hold together.
2. By pumping 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.
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
affect the 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. #5 (06/21/10) — 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 area.
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 a 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 lbs. 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 lbs. of cement/cu yd for 4000 p.s.i. concrete after 28
days.
4. Admixture pump-aid if necessary.
5. The proper 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. Pea rock (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.)
3. “Mud Jacking”, high pressure grouting.
PAGE 16 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HOW IT WORKS
The following is a brief explanation of how the concrete cylinders,
hydraulic cylinders, shuttle tube, valves and hopper work in
sequence to pump concrete.
The hydraulic pressure is generated by a variable volume,
pressure compensated, axial piston pump that is driven by a
diesel engine. The rod sides of the drive cylinders are
hydraulically connected together creating a “slave circuit,” which
allows hydraulic oil to transfer from one piston to the other.
The two 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
and the 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.
HIGH PRESSURE
OIL FROM PUMP
TO TANK
PROXIMITY
SWITCH
HYDRAULIC
CYLINDERS
SLAVE
Figure 4. Pumping Cycle 2
OIL
CONCRETE
CYLINDERS
A
B
SHUTTLE TUBE MOTION
PISTON
CUP
SHUTTLE TUBE
In the first cycle, hydraulic pressure is applied to cylinder (B),
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. 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.
Figure 3. Pumping Cycle 1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 17
LS400/LS500 PUMP — PUMP COMPONENTS
Figure 5. Major Pump Components
PAGE 18 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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:
1. Tow Hitch Coupler – Requires a 2-inch ball hitch or a
3-inch pintle. Capable of towing 6,000 lbs.
2. Documentation Box – Contains engine and pump
operation, parts and maintenance information.
3. Manifold Access Door– Release latch and lift door to
access the Hydraulic Manifold Block.
4. Hydraulic Manifold Block – Manifold block that
controls the flow of hydraulic pressure to the
components required to control the pump.
5. Hopper Discharge Sleeve – Connect hoses or steel
pipes to the discharge sleeve for pouring concrete.
6. Pump End Jack Stand – Use this jack stand to level
and support the rear end of the pump. NEVER deploy
on un-level ground and always check for firmness of
ground.
7. Shuttle Cylinder – Under pressure, the shuttle cylinder
shears concrete passing from the concrete cylinder to
the delivery line during the cycle phase.
8. 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.
9. Battery – This unit uses a +12 VDC type battery.
ALWAYS use gloves and eye protection when handling
the battery.
10. Hydraulic Pump – This unit incorporates an axial
variable displacement hydraulic piston pump.
11. 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.
12. 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.
13. Remixer Control Lever – Controls the forward/reverse
motion of the hopper remixer paddles.
14. 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 temperature of the hydraulic oil.
15. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic
fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if
level is low.
16. Accumulator Pressure Gauge– Used to monitor
accumulator pressure. Pressure should read at least
1750 psi for correct pump operation.
17. Pumping Pressure Gauge – Used to monitor pressure
in the concrete cylinders and shuttle tube.
18. Control Box – Contains the electrical components
required to run the pump. See Control Box Components
section for component callouts.
19. 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.
20. Hydraulic Oil Filter – This in-tank return hydraulic
filter 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.
21 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.
22. Rear Running Lights – ALWAYS check and make
sure both the right and left running lights are functioning
correctly before towing the pump.
23. Remixer Motor – Drives the remixer paddles inside
the hopper. The motor direction is controlled by the
remixer control lever.
24. Hopper/Hood – Lift hood to fill. Concrete from a RediMix 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.
25. 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. #5 (06/21/10) — PAGE 19
LS400/LS500 PUMP — DIGITAL CONTROL PANEL COMPONENTS
5
3
1
4
12
E
12
SCROLL
50
75
GENCY ST
O
ER
M
P
RESET
1000
0
500
1500
20
00
0
SET
11
VOLUME
OFF
ON
START
INCREASE
DECREASE
2
ACCUMULATOR
PRESSURE
13
IGNITION
7
12
50
75
1000
0
FLOW
DIRECTION
FORWARD
CONTROL
500
1500
8
CENTER
OFF
CYLINDER STROKE
20
00
0
REMOTE
LOCAL
REVERSE
JOG
AUTOMATIC
JOG “B”
JOG “A”
PUMPING
PRESSURE
REMOTE
9
10
6
Figure 6. Pump Digital Control Panel Components
1.
2.
3.
4.
5.
6.
7.
8.
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.
Direction 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.
10.
11.
12.
13.
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 or
decreases the number of strokes per minute of the
pump.
Accumulator Pressure Gauge – This gauge monitors
the internal pressure of the Accumulator 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. #5 (06/21/10)
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)
INDICATES
BATTERY
CHARGE
1
LS 400 OFF
0000 ENG RPM
BATTERY 12.5 V
LOW OIL PSI
INDICATES
ENGINE RPM
INDICATES
ELECTRIC
MALFUNCTION
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
CIRCUIT IS OFF
INDICATES
MAIN B
CIRCUIT IS OFF
INDICATES
PROXIMITY A
CIRCUIT IS OFF
Screen 2
Displays the position of theVOLUME CONTROL switch by indicating
whether the increase or decrease position is on or off.
INDICATES
UNLOADER
CIRCUIT IS OFF
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.
OF HOURS
ENGINE HAS
BEEN USED
E HRS: 00000.0 3
PMP HRS: 00000.0
FAULTS: 00000000
RESET TO CLEAR
MESSAGE OR
INSTRUCTION
INDICATES NO.
OF HOURS
PUMP HAS
BEEN USED
INDICATES A
RUNNING
COUNT OF
NO. OF STROKES
INDICATES
THROTTLE
IS ON
INDICATES THE
NO. OF YARDS
PER HOUR
6
PROX A OFF
PROX B ON
FUEL SOL OFF
UNLOADER OFF
INDICATES
PROXIMITY B
CIRCUIT IS ON
INDICATES
FUEL SOLENOID
CIRCUIT IS OFF
THROTTLE ON 7
STROKES: 20
STROKES/MIN 8.2
YDS/HR 10.7
INDICATES THE
NUMBER OF
STROKES
INDICATES THE
NO. OF STROKES
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 control panel.
INSTRUCTION
OR MESSAGE
8
TO TEST FUEL
SOL PRESS RESET
FUEL SOL OFF
INDICATES THE
FUEL SOLENOID
IS 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.
4
STROKE CTR: 0000
PRESS RESET TO
ZERO STROKE CTR
MESSAGE OR
INFORMATION
INDICATES
MAIN A
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 NO.
OF FAULTS
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.
MAIN A OFF
MAIN B OFF
Screen 6
Displays the ON/OFF electrical signal status for the
Proximity Switch A, Proximity Switch B, Engine Fuel
Solenoid, and Unloader Solenoid.
SECONDARY SCREENS
INDICATES VOLUME
SWITCH IS NOT IN
THE - POSITION
5
SWING A OFF
IINSTRUCTION
OR MESSAGE
RADIO ADDRESS 9
COMMUNICATING
PRESS RESET TO
LEARN A NEW ONE
INDICATES
THAT RADIO
REMOTE IS ON
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — 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.
2.
Oil Filter – Prevents dirt and other debris from entering
the engine. Service the oil filter as recommended in
the maintenance section of this manual.
3.
Crankcase Drain Plug – Remove this plug to drain
engine oil from the engine crankcase. For best results
drain engine oil when oil is warm.
4.
Dip Stick – Remove dipstick to determine if the engine
oil level is low. If low add oil as specified in Table 4.
5.
V-Belt Cover – Remove this cover to gain access to
the V-belt. When replacing V-belt, use only recommended
type V-belt.
6.
Alternator – Provides power to the electrical system.
Replace with only manufacturers recommended
replacement parts.
7.
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.
8.
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.
9.
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. #5 (06/21/10)
LS400/LS500 PUMP — INSPECTION
CAUTION - GENERAL SAFETY GUIDELINES
FUEL CHECK
1.
NEVER operate the pump in a
confined area or enclosed area
structure that does not provide ample
free flow of air.
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
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.
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.
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
maintenance service on the pump.
See Figures 5, 6, and 7 for the location of
any control or component referenced in this
section.
Figure 8. Fuel Cap Gauge
BEFORE STARTING
1. Read safety instructions at the
beginning of manual.
2.
If fuel is low, remove fuel filler cap and fill with #2
diesel fuel (Figure 9).
2. Clean the entire pump, removing dirt and dust, particularly the engine cooling air inlet, and heat exchanger.
3. Check the air filter for dirt and dust. If air filter is dirty,
replace air filter with a new one as required.
4. Check fastening nuts and bolts for tightness.
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.
Figure 9. Adding Diesel Fuel
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 23
LS400/LS500 PUMP — INSPECTION
ENGINE OIL CHECK
1.
Remove the engine oil dipstick from its holder
(Figure 10).
6. The oil listed in Table 4 is recommended to ensure better
engine performance. Use class CD or higher grade motor
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
HYDRAULIC OIL TEMPERATURE
MINIMUM OIL LEVEL
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. If 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. #5 (06/21/10)
LS400/LS500 PUMP — INSPECTION
2. If the hydraulic oil level 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. If 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.
Figure 14. Filling the Lubrication Box
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 25
LS400/LS500 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:
1. Locate both the left and right rear stabilizer jacks
(Figure 15).
Figure 17. Rear Stabilizer Stand Deployment
HYDRAULIC REAR STABILIZER JACKS (OPTIONAL)
REAR
STABILIZER
JACKS
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. Push up the middle control lever (see Figure 18) to retract
the right hydraulic rear stabilizer.
3. Push down the rightmost control lever (see Figure 18)
to extend the left hydraulic rear stabilizer.
Figure 15. Locating Rear Stabilizer Jacks
4. Push up the rightmost control lever (see Figure 18) to
retract the left hydraulic rear stabilizer.
2. Remove the cotter pin from the handle tee bolt eye,
and then pull the handle tee to release the stabilizer
jack (Figure 16).
3. Position both rear stabilizers jacks on firm (not loose)
level ground (Figure 17).
4. Align the hole on the stabilizer jack with the hole on the
frame body and insert handle tee bolt.
5. Insert the cotter pin into handle tee bolt eye to lock the
stabilizer jack.
COTTER
PIN
HANDLE
T-BOLT
REAR
STABILIZER
STAND
MIDDLE CONTROL LEVER
(CONTROLS RIGHT
HYDRAULIC STABILIZER)
RIGHT HYDRAULIC
STABILIZER JACK
LEFT HYDRAULIC
STABILIZER JACK
RIGHTMOST
CONTROL LEVER
(CONTROLS LEFT
HYDRAULIC
STABILIZER)
Figure 18. Control Levers for Hydraulic Rear Stabilizers
WARNING - REAR STABILIZER SAFETY
BOLT EYE
NEVER place feet under jack while operating.
ALWAYS retract rear stabilizer jacks prior to towing.
Figure 16. Rear Stabilizer Jack
ALWAYS retract rear stabilizer jacks prior to servicing to
relieve load (working pressure).
PAGE 26 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — START-UP PROCEDURE
4. Place the Direction Control Switch to the FORWARD
position (Figure 22).
STARTING PROCEDURE
WARNING - GENERAL SAFETY GUIDELINES
DO NOT attempt to operate this concrete pump until
the Safety, General Information and Inspection
sections have been read and understood.
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.
e nc y S
erg
to
p
Em
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.
FORWARD
Figure 23. Ignition Switch
Figure 19. Emergency Stop Switch
If the Emergency Stop switch is in the
CLOSED position (stop), engine will not start.
To star t 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).
AUTOMATIC
JOG
Figure 20. Cylinder Stroke
Control Switch (Automatic)
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.
1
LS 400 OFF
0000 ENG RPM
BATTERY 12.5 V
LOW OIL PSI
1
LS 400 OFF
0000 ENG RPM
BATTERY 12.5 V
LOW RPM FAULT
1
LS 400 OFF
0000 ENG RPM
BATTERY 12.5 V
END OF MESSAGE
Figure 24. Primary Screen (Ignition Key ON)
3. Place the Pumping Control Switch to the CENTER
OFF position (Figure 21) for normal pumping operation.
REMOTE
LOCAL
7. 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.
CENTER
OFF
Figure 21. Pumping Control Switch (OFF)
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — 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.
PUMPING
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.
Before concrete is discharged into the hopper, it is 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 operations 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. Connect the entire delivery system to the pump. Pour 5
gallons of water and a bag of raw cement into the hopper.
2. Place the Direction Control Switch to the REVERSE
position (Figure 25). This will mix the water and cement
into slurry.
FORWARD
REVERSE
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.
REMOTE
LOCAL
CENTER
OFF
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.
_
DECREASE
VOLUME
+
INCREASE
VOLUME
Figure 27. Volume Control
Figure 25. Direction Control Switch (REVERSE)
3. Mix 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.
A thumping sound (cylinder stroke) should be heard.
The thumping sound represents the number of strokes
per minute (volume) of the pump.
3. 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. #5 (06/21/10)
LS400/LS500 PUMP — OPERATION
4. Let the pump cycle until the hydraulic oil temperature
(Figure 29) is approximately 50° to 60° F.
HYDRAULIC OIL
TEMPERATURE
Figure 32. Hopper Remixer Blades (Rotation)
Figure 29. Hydraulic Oil Temperature Gauge
5. The Accumulator Pressure Gauge (Figure 30) should
read approximately 1750 pounds per square inch (psi).
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.
CAUTION - HOSE/LINE 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.
Figure 30. Accumulator
Pressure Gauge
6. 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 a clockwise direction (FORWARD). To turn the blades
in a counterclockwise direction (REVERSE), push the
Hopper Remixer Control lever UPWARD (Figure 31).
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 it is 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 in volume
compared to shorter lines and wetter mixes
due to the change in valve efficiency or
cavitation.
Figure 31. Hopper Remixer Control Lever
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 29
LS400/LS500 PUMP — OPERATION
REMOTE CONTROL (OPTIONAL)
4. Reinstall the control panel and tighten the 2 screws.
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.
5. On the top of the unit, to the right of the control box
(Figure 36), hammer out the knock-out hole and install
the remote antenna.
ANTENNA
Radio Remote Control
Installation of the Radio Remote Control Assembly
KNOCK-OUT
HOLE
1. Remove the two screws on the digital control panel of
the pump. See Figure 33.
SCR
OLL
RES
ET
SET
CONTROL BOX
DEC
REA
SE
VO
LU
ME
EMERGENC
Y
S
ANTENNA
CONNECTOR
CABLE
REAR OF
CONTROL BOX
O
T
P
INCR
EAS
E
DIRFLO
FOR
EC W
WAR
TIO
D
N
REV
ERS
E
AUT
OMA
TIC
LOC
AL
JOG
CO
NT
RO
L
CEN
TER
OFF
JOG
CYL
INDE
R
“A”
OF
F
ON
REM
OTE
STA
RT
IGN
ITIO
N
STR
OKE
CONTROL BOX
CONNECTOR
JOG
“B”
RE
MO
TE
REMOVE 2 SCREWS
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.
Figure 36. Antenna Installation
6. Connect the 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.
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.
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.
SCREWS AND NUTS
ELECTRONIC
CONTROL
UNIT
BATTERY LED
WIRELESS
REMOTE
MODULE
CONNECTOR
Figure 35. Installing Remote Control Module
E-STOP
ON
OFF
PUMP
REV
PUMP
ON/OFF
VOLUME
VOLUME
POWER LED
NOTE: OLDER MODELS
MAY INDICATE FLOW
INSTEAD OF VOLUME
Figure 37. Radio Remote Control
PAGE 30 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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
The cable remote control (Figure 38) has the following
controls.
1. Press the ON/OFF button on the radio (wireless) remote
control to turn on the power. Hold down the RESET
switch. The display will now show:
RADIO ADDRESS 9
NOW SCANNING
FOR NEW
TRANSMITTER
2.
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.
PUMP ON/OFF - Starts and stops the forward pumping.
PUMP REV - starts pumping in reverse direction.
WARNING - TRANSPORTING PUMP
After 5 seconds, the display will show:
RADIO ADDRESS 9
COMMUNICATING
PRESS RESET TO
LEARN A NEW ONE
3. The remote control is now ready for use.
Cable Remote Control
Installation of the Cable Remote Control Assembly
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 separation and subsequent jamming at that point.
Connect the cable to the front panel of the control box (See
Figure 38).
CABLE REMOTE CONTROL UNIT
25 FT. CABLE
PUMP REV
PUMP ON/OFF
TO CONTROL BOX
CONNECTOR
Figure 38. Cable Remote Control
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — 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 explanation of their functions:
A. Pozzolith 300 – or the equivalent acts as a water
retarder and a 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 referred to as C.C.,
is used as 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 not have a truck 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 commercial jobs.
F. 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 pumping
job, ask the 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.
Wet the sponge before placing it in 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 and cam
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 sweeps 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 at the 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 90º 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. #5 (06/21/10)
LS400/LS500 PUMP — PUMPING INFORMATION
The use of 2 -1/2” I.D. hose in these extreme cases reduces
line pressures or the addition of slight amounts of water to the
mix, if permissible, will permit easier pumping. The use of
certain pumping admixtures may help.
If it is 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:
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.
A. How old is the concrete?
SNAP-JOINT COUPLINGS
C. The temperature of the day, 80, 90, degrees?
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 gasket in water before coupling the
hose will make for easier installation.
D. How much system you have out and how stiff was
the mix you were pumping?
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 do the same by making an adapter to 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:
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.
B. Is there an accelerator, calcium chloride, red label,
etc., in the concrete?
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 suggestions are offered:
1. Leave the 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 separation of the concrete in the hopper.
2. If the shutdown 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.
3. If it is necessary to wait 10 minutes or more for another
load of concrete, it is wise to start the pump and pump
6 or 8 strokes every 5 minutes to 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. When the 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. #5 (06/21/10) — 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
on harsh mixes, vertical pushes, stiff concrete, shotcrete,
long pushes, that a 2 -1/2” line be used as far 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 adequate 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.
4. If waiting time is excessive, it would be wise to wash out
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
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.
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.
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 of the 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.
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 of the hose. This
will assure that all of the separation is out of the hose.
Damaged hoses with internal restrictions can
cause blockages.
PAGE 34 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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.
WARNING - SHUTTLE TUBES
DO NOT open any of the delivery system joint clamps.
E. Chip the concrete out of the reducer with the pry
bar.
F. 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.
G. Chip the blockage out with the pry-bar.
H. Flush the shuttle tube with water.
I. Before resuming operation of the pump, perform the
“Reverse” Pumping Procedure to relieve pressure
on the shuttle tubes.
“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. Remix the 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.
WARNING - ACCUMULATOR PRESSURE
Make sure the accumulator pressure gauge reads
ZERO psi. prior to performing any maintenance or
inspection.
SHUTTLE TUBE INSPECTION PROCEDURE
A. Stop the pump. Switch off the engine.
B The senior or most experienced operator must 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.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 35
LS400/LS500 PUMP — MAINTENANCE (PUMP)
TABLE 5. MAINTENANCE CHECK SCHEDULE
Daily
Engine Oil
Hourly Weekly Monthly
X
X
Engine Air Filter
X
Fuel Filter
X
Hydraulic Oil Level
erational
6-Months OpH
ours
X
Lubrication Box
500 hrs.
X
Replace Hydraulic Oil
Clean Hydraulic Filters
Axle Crank
X
2100 hrs.
X
Grease Shuttle Tube Zerk Points
X
2 h rs
Check System Pressure
X
40 hrs.
Check Hardware for Tightness
X
40 hrs.
Check Cutting Ware Ring
X
Check Trailer Brakes Function
X
Check Brake Lights
X
Check Tire Conditions
X
Inspect Saftey Devices / Decals
X
Check Wheel Bearings
X
Check Battery
X
Inspect Brake Lining
Visually Check for Oil Leaks
X
X
DANGER - AMPUTATION RISK
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, 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 relieve the accumulator
circuit to zero pressure
prior to performing any
maintenance on the
pump.
CLEANING THE PUMP AND DELIVERY SYSTEM
Cleaning the pump is a very important operation as it
determines how the machine will pump the next time it is
used.
At the end of every pour, or because of long delays during a
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
and line or in the shuttle tube (using the Shuttle Tube
Inspection Procedure). If a blockage exists, clear it.
2. Pump concrete until the opening of the concrete cylinder
intake in the hopper is visible.
3. Stop the pump.
4. Carefully disconnect the first hose joint at the shuttle
tube discharge elbow.
PAGE 36 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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. Fill hopper 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, ½" minus) or mixes with high fines
content (60% 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 the shuttle tube
inspection plate (follow the Shuttle Tube Inspection
Procedure) and remove all remaining concrete.
9. When the pump has been used to pump large aggregate
concrete (" to 1 (" follow the instructions in step 8 once
per week.
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 equivalent). The above steps
must be followed or severe damage to the main axial piston
pump can occur.
1.
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 2½" diameter clean-out hook
when back-pumping into redi-mix truck. Use
a safety 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.
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
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
■
Shuttle cylinders
- 2 Place
■
“S” tube outlet flange
- 3 Place
Grease Type:
Lithium Based EP
Texaco Multitak 20
Lubriplate ED-2
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 37
LS400/LS500 PUMP — MAINTENANCE (PUMP)
BATTERY MAINTENANCE
CAUTION - BATTERY MAINTENANCE SAFETY
Wear safety glasses or face mask ,
protective clothes, and rubber gloves when
working with battery.
Mishandling of the battery shortens the service life of the
battery and adds to maintenance cost. When handling the
battery do the following:
 Be careful not to let the battery electrolyte come in
contact with your body or clothing.
 Always wear eye protection and rubber gloves, since
the battery contains sulfuric acid which burns skin and
eats through clothing.
 Always check the battery terminals periodically to
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.
 If the pump will not be in operation for a long period of
time, store in cool dry place and check the battery charge
level every month to maintain the performance of the
battery.
 Check the battery regularly and make sure that each
electrolyte level is to the bottom of the vent well
(Figure 39). If necessary add only distilled water in a
well-ventilated area.
BRAKE SYSTEM
The brake system should be periodically checked. Look for
fluid leaks worn or cracked hoses. Check the reservoir for
proper fluid levels. The Atwood surge brake should be
checked for damage. Make sure that all links and pivots are
kept lubricated.
1. Keep all links and pivots lubricated to prevent rusting
and ensure ease of operation. Using SAE 30 oil, lubricate
inside the release handle and inside the actuator body.
This can be reached from the underside of the actuator.
Lubricate the hitch ball with conventional
automotive grease or a lubricant made for
hitch balls.
2. Check for any leaks in the brake system. Periodic checks
should be made on all hoses to guard against cuts and
worn hoses which may cause failure (leaks, rupturing
under pressure, and collapsing). Replace defective hoses.
CAUTION - MASTER BRAKE CYLINDER
DO NOT fill the master cylinder reservoir with used
brake fluid. DO NOT fill the reservoir beyond ½" from
top. DO NOT overfill; brake fluid will damage paint.
3. Check the brake fluid level in the master cylinder reservoir.
Keep it filled to within ½" from the top of the reservoir.
4. At the beginning of each year, inspect the brakes for
excessive wear, replace the linings if necessary.
Wheel bearings and seals should be
inspected and packed at this time.
Figure 39. Battery Electrolyte Levels
PAGE 38 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — MAINTENANCE (PUMP)
CYLINDER LUBRICATION BOX
ACCUMULATOR CIRCUIT
WARNING - FREEZING CONDITIONS
DANGER - ACCUMULATOR CHARGING
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.
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.
CAUTION - SAFETY GUIDELINES
Before checking lubrication level, 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 ½ the concrete cylinder height. We recommend a
using a soluble type oil (water & oil mixture)
2. As the rubber piston cups naturally wear, fine cement
particles will accumulate in the box. Once the concrete
paste reaches a height of about ½ inch from the bottom
of the box, drain and clean the lubrication box.
CLEANING THE LUBRICATION BOX
1. Remove the top cover and the drain plug (Figure 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.
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
When 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. Start the engine and stroke the pump. The accumulator
pressure gauge (Figure 30) should read 1750 PSI.
Figure 40. Cleaning the Lubrication Box
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. #5 (06/21/10) — 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 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
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.
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
58%%(5
(1(5*,=(5
&877,1*
5,1*
:($5
3/$7(
4. Unusual frequent material packs in the Shuttle tube
6+877/(78%(
,16,'(+233(5
*22'6($/
/($.,1*
Figure A. Wear Plate and Cutting Ring
PAGE 40 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — MAINTENANCE (PUMP)
CHANGING THE CONCRETE CYLINDER PISTON CUPS
6.
The Rubber piston cups will occasionally require replacement
depending on the following factors.
Remove the three 3/8 – 16 x 3” bolts from the piston.
Remove the front faceplate.
7.
Install two the 3/8’ 16x3” bolts back into the piston –
do not tighten. Use the two bolts as leverage to remove
the rubber piston cup and rear components.
8.
Obtain two 3/8 16x7” full thread studs (these studs will
be used to assist in assembly alignment) insert the
two studs into the piston adapter. Coat the concrete
cylinder with grease.
9.
Install the “O” Ring around the oiler plate. Install the
plate into the concrete cylinder utilizing the studs for
alignment.
■
The fluid level and cleanliness of the lubrication box.
■
The size and type of aggregate.
■
The type of concrete being pumped.
It is time to replace the cups when increasingly large particles
of sand and cement pass into the lubrication box. Do not
allow the cups to become so worn that they begin to pass
lubrication into the material cylinders. If the liquid level of
the lubrication box becomes to low, the rubber cups will
severely deform due to excessive heat. Whenever
replacement is due, both cylinder cups should be replaced.
WARNING - AMPUTATION RISK
To prevent accidental cycling of any pump
components, ALWAYS relieve the accumulator circuit
to ZERO pressure prior
to performing any
maintenance on the
pump.
CYLINDER CUP REPLACEMENT PROCEDURE
1.
Remove the two hydraulic hoses connected to the remix
motor. Plug the ports with fittings (not provided) to
prevent hydraulic hose leakage.
2.
Remove the hopper discharge nipple and loosen sleeve
seal. Inspect and replace if wear is excessive.
3.
Remove the two tie rod nuts and the four eyebolt nuts
securing the hopper to the pump frame.
4.
Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.
5.
Start the engine and turn on the pressure test switch.
Cycle pump in reverse until hydraulic system obtains
maximum pressure, then turn pump and engine
off.
Felt ring must be saturated with 30 wt. oil
prior to installation.
10. Install the felt holder over the oiler plate. Install felt ring
into felt holder. Install the bronze ring.
11. Using silicon sealant place a small bead of sealant
material on the front of the rubber piston cup and the
rear of the face plate. Install over alignment studs and
into concrete cylinders.
12. Insert one 3/8” 16x3” bolt into the open bolt hole, remove
the alignment studs one at a time and install the
remaining 3/8” 16x3” bolts.
Before installing 3/8” bolt, coat the back of
bolt heads with silicon sealant.Torque all three
bolts equal at 55 ft. lbs. each.
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.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 41
LS400/LS500 PUMP — MAINTENANCE (PUMP)
CHANGING THE WEAR PLATE AND RING
Wear Plate Installation
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.
1.
Install the two cylinder “O” 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 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.
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.
3.
Remove the two tie rod nuts and the four eyebolt nuts
securing the hopper to the pump frame.
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.
4.
Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.
HEAT EXCHANGER COOLING FAN
Remove the four 1/2” 1-¼” bolts that hold the shuttle
tube to the nun-plate and remove shuttle tube.
This section is intended to make sure the fan is working
properly. Under normal conditions the fan should be running
any time the engine is turned on.
5.
Using two small pry bars remove the rubber energizer
ring, steel insert ring and wear ring.
CAUTION - HYDRAULIC OIL TEMPERATURE
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 nunplate area with a wire brush.
7.
Inspect the wear components for indications of wear.
The wear plate has two wear surfaces.
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. #5 (06/21/10)
LS400/LS500 PUMP — MAINTENANCE (PUMP)
WHEEL BEARINGS
PRESSURE TEST
After every 6 months of operation inspect the wheel bearings.
Once a year, or when required, disassemble the wheel hubs
remove the old grease and repack the bearings forcing grease
between rollers, cone and cage with a good grade of high
speed wheel bearing greases (never use grease heavier than
265 A.S.T.M. penetration “No. 2.”).
1. To determine the pressure of the Hydraulic System, set
the Cylinder Stroke Control Switch (Figure 42) to the
JOG position.
1. Fill the wheel hub with grease to the inside diameter of
the outer races and also fill the hub grease cap.
2. Reassemble the hub and mount the wheel. Then tighten
the adjusting nut, at the same time turn the wheel in
both directions, until there is a slight bind to be sure all
the bearing surfaces are in contact.
Figure 42. Cylinder Stroke Control Switch (JOG)
2. Turn and hold the Manual Cylinder Jogging Switch
(Figure 43) to either JOG “A” or JOG “B” position to
test the pressure of that cylinder.
3. Back off the adjusting nut 1/6 to 1/4 turn or to the nearest
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.
4. Install the cotter pin and dust cap, and tighten all
hardware.
EXTENDED STORAGE INSTRUCTIONS
The following preventative maintenance is recommended
for extended periods of storage.
Figure 43. Manual Cylinder Jogging Switch
13. The Pumping Pressure Gauge (Figure 44) should read
approximately 4400 ± 50 PSI.
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
boot on forward end of brake wheel cylinder. Avoid
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. #5 (06/21/10) — 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 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, inspect 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.
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.
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. Note: 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.
6. Replace the adjusting-hole cover.
7. Repeat the above procedure on all brakes.
8. Lower the trailer to the ground.
Figure 45. Hydraulic Brake Components
Hydraulic Brake Actuator
The hydraulic brake actuator (Figure 46) is the mechanism
that activates the trailer’s 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
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. #5 (06/21/10)
LS400/LS500 PUMP — MAINTENANCE (TRAILER)
Periodically check the actuator mounting fasteners for
damage or loosening. Inspect the actuator for worn or damaged 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.
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
CONE
WHEEL
HUB
OIL
SEAL
COTTER
PIN
BEARING
CUP
DUST
CAP
LUG
NUT
SPINDLE
WASHER
Figure 47. Adjustable Channel
With Pintle Eye Coupler
Wheel Bearings (Hubs)
Wheel bearings (Figure 48) must be inspected and lubricated once a year or 12,000 miles to insure safe operation
of your trailer.
If a 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.
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 adjust.
 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.
 Install a 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. #5 (06/21/10) — PAGE 45
LS400/LS500 PUMP — MAINTENANCE (TRAILER)
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!
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 bracket’s fasteners to the trailer
frame, no other suspension maintenance is required on the
axles.
5/8”-18 X 2”
MOUNTING
BOLT
DANGER - Trailer Inspection
When performing trailer inspection and maintenance activities, 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 inside of the perimeter strip on the supporting structure to
which the axles are attached.
MOUNTING
BRACKET
AXLE
TUBE
SPINDLE
TORSION
ARM
TORSION
BAR
5/8”-18
NYLOC NUT
GRADE C
Figure 49. Torsion Suspension
WARNING - Trailer Impact
If the trailer is involved in an accident have it inspected
immediately by qualified personnel. In addition, the trailer
should be inspected annually for signs of wear or
deformations.
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.
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.
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.
PAGE 46 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
TRAILER SAFETY INFORMATION
■ ALWAYS use lower gears for climbing and descending
grades.
Safety precautions should be followed at all times when
operating this equipment. Failure to read, understand and
follow the Operating Instructions could result in injury to
yourself and others. Loss of control of the trailer or tow vehicle can result in death or serious injury.
■ 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.
Common Causes for Loss of Trailer
■ Slow down for bumps in the road. Take your foot off the
brake when crossing the bump.
■ 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
city driving.
■ To conserve fuel, don’t use full throttle to climb a hill.
Instead, build speed on the approach.
■ 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. There is appropriate slack in the breakaway
switch pullpin cable.
E. Tires are not visibly low on pressure.
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. #5 (06/21/10) — PAGE 47
LS400/LS500 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 hitting 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.
WARNING - Transporting Personnel
DO NOT transport people on the trailer. The transport of people puts
their lives 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 satisfactory life of the trailer. Always use an adequate tow vehicle and hitch. If the vehicle or hitch is not properly selected 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 trailer’s rated
capacity is less than or equal to the tow vehicle’s rated towing 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.
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 trailer to the
tow vehicle
Be sure the hitch components are tight before coupling
the trailer to the tow vehicle.
WARNING - Coupler Connection
An improperly coupled trailer can result in death or serious
injury.
DO NOT move the trailer until:
• The coupler is secured and locked to hitch
• The safety chains are secured to the tow vehicle
• The trailer jack(s) are fully retracted
DO NOT tow the trailer on the road until:
•
•
•
•
•
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
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.
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.
PAGE 48 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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 addition to notifying us.
Trailer Towing Tips
Driving a vehicle with a trailer in tow is vastly different from
driving the same vehicle without a trailer in tow. Acceleration, maneuverability and braking are all diminished with a
trailer in tow.
If NHTSA receives similar complaints, it may open an
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.)
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.
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.
WARNING - Checking Taillights/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:
•
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.
Because of the significant differences in all aspects of maneuverability 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 combination
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. #5 (06/21/10) — PAGE 49
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
Some drivers place their hands at 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.
PSIC: The tire pressure (Pounds per Square Inch)
measured when Cold.
If you are towing a bumper hitch rig, be careful not to allow
the trailer 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.
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.
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.
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 shipping documents list average or standard weights and your
trailer may be equipped with options.
SAFETY WARNING LABELS ON YOUR TRAILER
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.
Figure 51. VIN Tag Location
GVWR: The maximum allowable gross weight of the trailer
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 (Maximum 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.
PAGE 50 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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, detachable extended mirrors are necessary. Check with your
dealer or the 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 Connector
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 vehicle 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 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”.
WARNING
An improperly coupled trailer can result in death or serious
injury.
DO NOT move the trailer until:
• The coupler is secured and locked to hitch;
• The safety chains are secured to the tow vehicle
• The trailer jack(s) are fully retracted.
DO NOT tow the trailer on the road until:
•
•
•
•
•
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. #5 (06/21/10) — PAGE 51
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
Coupler Types
The trailer is shipped from the factory with a 2-inch ball coupler.
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.
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 ESSENTIAL 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.
Figure 52. Ball Hitch Coupler
Adjustable Tongue
Before each tow, coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation. 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.
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.
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. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
WARNING - Defective Hitch Ball
A worn, cracked or corroded hitch ball can fail while towing, and may
result in death or serious injury.
2-INCH
TRAILER
COUPLER
TOW
VEHICLE
Before coupling trailer, inspect the hitch ball for wear, corrosion and
cracks.
Replace worn or damaged hitch ball.
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 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 support 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
BALL
Figure 53. Ball Hitch Coupling Mechanism
 Lower the trailer (Figure 53) until the coupler fully engages the hitch ball.
 Engage the coupler locking mechanism. In the engaged
position, the locking mechanism securely holds the
coupler to the hitch ball.
 Insert a pin or lock through the hole in the locking
mechanism.
 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 position.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 53
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
Attaching Safety Chain
TOW
VEHICLE
TRAILER
TONGUE
IMPORTANT!
SAFETY CHAIN
MASTER LINK
Breakaway Brake System
If the coupler or hitch fails, a properly connected and working breakaway brake system (Figure 55) will apply the hydraulic 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
Tow Vehicle
Breakaway Lever
CROSS BOTH
SAFETY CHAINS
Figure 54. Safety Chain Arrangement
for a Bumper Pull Trailer (Ball Hitch)
Hydraulic Actuator
 Visually inspect the safety chains and hooks for wear
or damage. Replace worn or damaged safety chains
and hooks before towing.
 Attach the safety chains so 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.
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.
• 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.
Figure 55. Breakaway Brake System
Breakaway Cable Surge Brake System
The breakaway brake system includes a brake cable connected to the tow vehicle on one end and to the emergency
brake lever located on the hydraulic actuator on the other
end.
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 manufacturer.
PAGE 54 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
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 lever).
WARNING - 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, before 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 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.
WARNING - Lug Nut Tightening
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. #5 (06/21/10) — PAGE 55
LS400/LS500 PUMP — TRAILER 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.
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.
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 trailers 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 certification label described above. This placard provides tire and loading information. In addition, this
placard will show a statement regarding maximum cargo
capacity.
TIRE AND LOADING INFORMATION
WARNING - Improper Lug Nut Torque
The weight of cargo should never exceed XXX kg. Or XXX lbs.
TIRE
Improper lug nut torque can cause a wheel parting from
the trailer, leading to death or serious injury.
FRONT
Be sure lug nuts are tight before each tow.
REAR
SPARE
WARNING - Tire Pressure
Improper tire pressure can result in a 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.
SIZE
COLD TIRE PRESSURE
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
Figure 56. Tire and Loading Information Placard
If additional work items (hoses, tools, clamps etc.) are going 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 PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
Step 1.
Locate the statement, “The weight of cargo should never
exceed XXX kg or XXX lbs.,” 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 available equipment load capacity. The trailer’s Tire Information
Placard is attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer.
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.
Determining Load Limit of Tow Vehicle
 Improve fuel economy
Step 1.
Locate the statement, “The combined weight of
occupants and cargo should never exceed XXX lbs.,” on
your vehicle’s placard.
 Increase the tire life
Step 2.
Determine the combined weight of the driver and passengers 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 e q u a l s
1400 lbs. and there will be five 150 lb.
passengers in your vehicle, the amount of available cargo and
luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
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 standardized information on the sidewall of all tires (Figure 57). This
information identifies and describes the fundamental characteristics of the tire and also provides a tire identification
number for safety standard certification and in case of a
recall.
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 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.
Figure 57. Standard Tire Sidewall Information
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 57
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
P: The “P” indicates the tire is for passenger vehicles.
Next number: 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: The “R” 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.
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 Composition 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 indicate the materials in the tire, which include steel, nylon, polyester, and others.
Next number: This two- or three-digit number is 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.
Maximum Load Rating: This number indicates the maximum load in kilograms and pounds that can be carried by
the tire.
M+S:
The “M+S” 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 capability.
Uniform Tire Quality Grading Standards (UTQGS)
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
Q
99 mph
R
106 mph
S
112 mph
T
118 mph
U
124 mph
H
130 mph
V
149 mph
W
168* mph
Y
186* mph
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.
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 “AA”,”A”, “B”, and “C”.
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. From highest to lowest, a tire’s resistance to heat is graded as “A”,
“B”, or “C”.
PAGE 58 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
Reference Figure 58 for additional tire information for light
trucks.
 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.
 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.
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 (lbs) at kPa (psi) Cold: This information 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 (lbs) 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 capabilities and its inflation limits.
Tire Safety Tips
 Slow down if you have to go over a pothole or other
object in the road.
 DO NOT run over curbs or other foreign objects in the
roadway, and try not to strike the curb when parking.
 Check tire inflation pressure weekly during use to insure the maximum tire life and tread wear.
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 the causes and solutions of
tire wear problems.
TABLE 7 TIRE WEAR TROUBLESHOOTING
CAUSE
WEAR PATTERN
SOLUTION
Center Wear
Over Inflation
Adjust pressure to
particular load per
tire manufacturer.
Edge Wear
Under Inflation
Adjust pressure to
particular load per
tire manufacturer.
Side Wear
Loss of chamber
or overloading.
Make sure load does
not exceed axle rating.
Align wheels.
Toe Wear
Incorrect toe-in
Align wheels.
Cupping
Out-of balance
Check bearing adjustment and balance tires.
Flat Spots
Wheel lockup &
tire skidding.
Avoid sudden stops
when possible and
adjust brakes.
 DO 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.
 Remove bits of glass and foreign objects wedged in the
tread.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 59
LS400/LS500 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.
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 loose, 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.
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug 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. Check to see if the lug nuts are tight after the first 10, 25
and 50 miles of driving and before each tow thereafter.
TABLE 8. TIRE TORQUE REQUIREMENTS
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
NEVER! use an pneumatic air gun
to tighten wheel lug nuts.
WARNING - Lug Nut Tightening
Over-tightening lug nuts will result in breaking the studs
or permanently deforming the mounting stud holes in the
wheels.
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.
Figure 59. Wheel Lug Nuts Tightening Sequence
PAGE 60 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES
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.
Replace any broken or burned-out lamps as necessary.
Check the wire harness for cuts, fraying or other damage. If
it needs replacing, contact your dealer.
WARNING - Trailer Lights
Improper operating taillights, stoplights and turn signals
can cause collisions.
Check all lights before each tow.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 61
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP)
The hydraulic troubleshooting procedures listed below are intended for use by individuals equipped 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
WARNING - HYDRAULIC SYSTEM HAZARD
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.
DO NOT open hydraulic lines or loosen hydraulic fittings
while the engine is running! Hydraulic fluid under pressure
can penetrate the skin, blind, cause burns or create other
potentially dangerous hazards.
Prior to performing any maintenance on the pump, 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 relieve the
accumulator circuit to zero
pressure prior to performing
any maintenance on the
pump.
TABLE 9. PUMP TROUBLESHOOTING
Problem
Possible Problem
To Troubleshoot
Incorrect System Operating
Pressure
Check the pump pressure gage. Verify
it is approx. 4400 PSI
Incorrect Engine RPM setting
Verify the engine's high RPM speed is
set to 2550
Contaminated Main Relief Valve
Check the manifold for a contaminated
Relief Valve
Obstructed Material Cylinders
check for obstructions (dried material)
inside the cylinders
Incorrect Directional Control
Operating Pressure
Verify the Directional Control operating
pressure is approx. 1000 PSI
Contaminated Relief Valve
Check the manifold for a contaminated
Relief Valve
Broken Shaft Coupler Key
Check the Hopper Remixer shaft
coupler for a broken key
Loose Shaft Retaining Set Collar
Check the Shaft Retaining Set Collar
for tightness
Main Hydraulic Cylinder will
not cycle
Hopper Remix Paddles will
not rotate
PAGE 62 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP)
TABLE 9. PUMP TROUBLESHOOTING (CONTINUED)
Problem
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
contaminated Relief Valve
Shuttle Cylinder does not stroke
Check for burned out solenoid and
Swing Solenoid not energizing
12V signal voltage
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 approx. 4400 PSI
Check the manifold for contaminated
Contaminated Swing Relief Cartridge
Swing Relief Cartridge
Shuttle Cylinder slow to complete
Check the accumulator pressure
stroke
Low Accumulator System Pressure
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. #5 (06/21/10) — PAGE 63
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP)
TABLE 9. PUMP TROUBLESHOOTING (CONTINUED)
Problem
Possible Problem
To Troubleshoot
Check oil level and for closed suction
Insufficient oil
strainer
Check for aeration reservoir
Air in system
Main Hydraulic Pump Noisy
Vacuum leak in suction line
Excessive pump wear
Repair or replace
Excessive engine speed
Check for correct engine RPM
Low engine speed
Check engine RPM
Main relief cartridge set to low
Adjust relief cartridge
Engine bogs down
Decrease volume control on main
pump
Engine overloaded when pumping
Material hose pack
Low engine speed
Check engine RPM
Machine does not deliver volume and Volume control set to low
Adjust control to full open setting
pressure
Check for proper pressure or for
Main hydraulic pressure too low
contaminated relief cartridge
Check fan electrical connection or for
burnt fan motor.
Cooling fan
Fan rotating 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
set too low
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
Replace
PSI
coil
Unloader cartridge coil not energizing Check for 12 Volt signal voltage
Defective gear pump
Replace pump
Worn or defective urethane cups or
Concrete slurry in lubrication box
Replace
worn material cylinder
Material cylinder piston cups squeel Low on lubrication
Check oil level
Excessive amount of hydraulic on
Inspect cylinder. Check values for
cylinder rod side
contamination or faulty spring
Cylinders not completely extended
(short stroke)
Hydraulic cylinder piston head seal
Replace seals
leaking
PAGE 64 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 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
SYMPTOM
Engine will not star t or star t is
delayed, although engine can be
turned over.
At low temperatures engine
will not star t.
Engine fires but stops soon as
star ter is switched off.
Engine stops by itself during
normal operation.
Low engine power, output and
speed.
Low engine power output and low
speed, black exhaust smoke.
POSSIBLE PROBLEM
SOLUTION
Speed control lever is in "STOP" position
Set speed control lever to "START" position.
No fuel reaching injection pump
Add fuel. Check entire fuel system.
Defective fuel pump
Replace fuel pump.
Fuel filter clogged
Replace fuel filter and clean tank.
Faulty fuel supply line
Replace or repair fuel line.
Compression too low
Check piston, cylinder and valves. Adjust or
repair per engine repair manual.
Fuel injector not working correctly
Repair or replace injector in accordance with
engine repair manual.
Oil pressure too low
Check engine oil pressure.
Low star ting temperature limit exceeded
Comply with cold star ting instructions and
proper oil viscosity.
Fuel separates has inadequate resistance to
low temperatures
Check whether clear (not turbid) fuel emerges
from the fuel line (detach from injection
pump). If the fuel is turbid or separated, warm
up the engine or drain the complete fuel
supply system. Refuel with winter grade diesel
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.
Fuel filter blocked
Replace fuel filter.
Fuel supply blocked
Check the entire fuel system.
Fuel tank empty
Add fuel.
Fuel filter blocked
Replace fuel filter.
Fuel tank empty
Replace fuel filter.
Fuel filter clogged
Replace fuel filter.
Fuel tank venting is inadequate
Ensure that tank is adequately vented.
Speed control lever does not remain in
selected position
See engine manual for corrective action.
Engine oil level too full
Correct engine oil level?
Air filter blocked
Clean or replace air filter.
Incorrect valve clearances
Adjust valves per engine specification.
Malfunction at injector
See engine manual.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 65
LS400/LS500 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 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.
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.
Seized actuator
Replace or rebuild actuator.
Broken return spring
Replace spring.
Brakes improperly adjusted
Check adjustment.
Break-away cable system
par tially activated
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.
Brakes squeak, chatter or chuck.
Brakes overheah, fail to operate,
pull to the side, or function poorly
PAGE 66 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)
Refer to Figure 61 for the location of components for troubleshooting.
TABLE 12. ELECTRICAL TROUBLESHOOTING
MALFUNCTION
READING
(Screen 1)
PROBABLE CAUSE
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted directly to
ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the ground.
Correct connection.
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted directly to
ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the ground.
Correct connection.
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted directly to
ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the ground.
Correct connection.
MAIN A OPEN
MAIN A SHORTED
SOLUTION
MAIN B OPEN
MAIN B SHORTED
SWING OPEN
SWING SHORTED
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 67
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)
TABLE 12. ELECTRICAL TROUBLESHOOTING (continued)
MALFUNCTION
READING
(Screen 1)
PROBABLE CAUSE
SOLUTION
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted
directly to ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the
ground.
Correct connection.
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted
directly to ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the
ground.
Correct connection.
Burnt 12 V cycling solenoid.
Measure solenoid coil resistance. It should
read 6 ohms. Replace burnt solenoid.
Wire connection broken.
Replace broken wire.
The 12-volt cycling solenoid is shor ted
directly to ground.
Measure solenoid coil resistance. It should
read 6 ohms. Replace shor ted solenoid.
Wire connection is shor ted directly to the
ground.
Correct connection.
ALTERNATOR FAILURE
Defective alternator.
Replace alternator.
V-BELT BREAKAGE
Engine blower cooling fan V-belt is broken
requiring replacement.
Replace v-belt.
THROTTLE SOLENOID
OPEN
THROTTLE SOLENOID
SHOR TED
FUEL SOLENOID OPEN
FUEL SOLENOID
SHOR TED
UNLOADER SOLENOID
OP E N
UNLOADER SOLENOID
SHOR TED
PAGE 68 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)
MAIN “A”
SOLENOID
MAIN “B”
SOLENOID
SWING
SOLENOID
UNLOADER
SOLENOID
PROXIMITY
SWITCH “B”
SCRO
LL
RESET
SET
DECR
EASE
VOL
UME
EMERGENC
Y
S
O
T
P
INCRE
ASE
FORW
ARD
FLO
DIRE
W
CTIO
N
REVER
SE
AUTOM
LOCAL
ATIC
CON
TRO
L
OFF
ALTERNATOR
ON
REMO
JOG
CENTE
TE
OFF R
CYLIN
IGNI
TION
DER
JOG
“A”
STROK
STAR
T
E
JOG
“B”
REM
OTE
E
F
V-BELT
PROXIMITY
SWITCH “A”
THROTTLE
SOLENOID
INTERNAL
FUEL
SOLENOID
Figure 61. Location of Components for Electrical Troubleshooting
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 69
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)
J1
GND
1
2
3
DIGITAL READOUT
MODULE
J4
4
5
L
TRO
CON REAR
X
BO W
VIE
6
7
+12VDC IN
A
A
8
9
10
J1
J2
J3
J4
J5
11
12
+12VDC OUT
E-STOP
1 2 3 4
5 6 7 8
1 2 3 4
YELLOW
WHITE
YELLOW
WHITE
YELLOW
J3
J2
30 AMP
FUSE
E-STOP
+12VDC OUTPUT
J1
J1
YELLOW
8 7 6 5
4 3 2 1
8 7 6 5
4 3 2 1
J2
J2
WHITE
8 7 6 5
4 3 2 1
8 7 6 5
4 3 2 1
A
2
1
2
1
INSIDE
CONTROL
BOX
FUEL SOLONOID
1
2
P1
10 AWG RED
EMERGENCY
STOP
SWITCH
12 AWG RED (+12VDC)
FUSE
HOLDER
5 6 7 8
12 AWG RED
OUTSIDE
CONTROL
BOX
W
D
SOLENOID
10 AWG RED
H
P1
4
3
2
1
8
7
6
5
INSIDE
CONTROL
BOX
12 AWG RED
BATTERY
10 AWG BLK
14 AWG PINK/BLK (STARTER SOLENOID)
16 AWG GREEN
16 AWG YELLOW
16 AWG ORANGE
14 AWG RED
1
14 AWG BLACK (GND.)
2
A
15/54
58
J
OIL PRESSURE
SWITCH
17
30
I
ALTERNATOR
G
A
OUTSIDE
CONTROL
BOX
1
2
3
4
5
6
7
8
A
A
J1 MALE
INTERFACE
CONNECTOR
(YELLOW)
STARTER
F
K
50A
FUEL SOLENOID
(SHUT-DOWN)
19
IGNITION
SWITCH
CIRCUIT ACTIVE = +12VDC
CIRCUIT OFF = GND
+12VDC POWER IN
ENGINE CRANK
A
LOW BATTERY
TACH INPUT
J2 MALE
INTERFACE
CONNECTOR
(WHITE)
P2
P2
LOW OIL INPUT
SWING A
CYL A
CYL B
THROTTLE
BRN
RED
+12VDC POWER OUT GROUND
RED
GRN
WHT/BLK
BLK
FUEL SOLENOID
(SHUT-DOWN)
CONTROLLER
BLACK
POTTED
BOX
C
4
3
2
1
8
7
6
5
1
2
3
4
5
6
7
8
BLK
GND
MAIN B
A
INSIDE
CONTROL
BOX
14 AWG RED
B
D
MAIN A
DEUTZ 10-PIN
ENGINE
CONNECTOR
14 AWG BRN
E
14 AWG RED
14 AWG GRAY
SWING A
14 AWG RED
MA
14 AWG YEL
NI
FO
LD
14 AWG RED
14 AWG WHITE
OUTSIDE
CONTROL
BOX
TH
R
BLOTT
OC LE
K
ENGINE SPEED
SOLENOID
L
Figure 62. Connections to Digital Control Box - J1 and J2 Connectors ( 1 of 2)
PAGE 70 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)
F
C
D
B
E
H
G
A
SCRO
LL
RESET
SET
DECR
EASE
VOL
UME
EMERGENC
Y
S
O
T
P
INCRE
ASE
FORW
ARD
FLO
DIRE
W
CTIO
N
REVER
SE
AUTO
LOCAL
MATIC
CON
TRO
L
I
OFF
ON
REMO
JOG
CENT
CENTE
TE
OFFER
R
CYLIN
“A”
STA
RT
IGNI
TION
DER
JOG
STRO
KE
JOG
“B”
REM
OTE
E
F
L
K
J
Figure 62. Connections to Digital Control Box - J1 and J2 Connectors ( 2 of 2)
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 71
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)
A
A
L
TRO
CON REAR
BOX EW
VI
YELLOW
WHITE
YELLOW
WHITE
YELLOW
J1
J2
J3
J4
J5
+12 VDC
J3
J3
YELLOW
8 7 6 5
4 3 2 1
8 7 6 5
4 3 2 1
J4
J4
WHITE
8 7 6 5
4 3 2 1
8 7 6 5
4 3 2 1
INSIDE
CONTROL
BOX
P3
J3 MALE
INTERFACE
CONNECTOR
(YELLOW)
OUTSIDE
CONTROL
BOX
4
3
2
1
8
7
6
5
INSIDE
CONTROL
BOX
A
B
P3
1
2
3
4
5
6
7
8
A
UNFUSED 35A, 1 SEC SUPPLY ENGINE SOLENOID
OUTSIDE
CONTROL
BOX
PROXIMITY
SWITCH “B”
C
16 AWG WHITE
16 AWG BLUE
NOT USED
SIGNAL
16 AWG BROWN
SIGNAL
16 AWG GREEN
NOT USED
16 AWG BLUE
NOT USED
16 AWG BROWN
G
INDICATOR “RED” ACTIVE
BETWEEN GND. 800 mV
+12 VDC
GND.
A
PROXIMITY
SWITCH “A”
F
BLACK
BROWN
BLUE
ENG SOL POWER 35A 1 SEC
OVER TEMP
PROX A
NOT USED
PROX B
PROX C
NOT USED
HEAT EXCHANGER
“COOLING FAN”
PROX D
POWER
B
GROUND
NOT USED
AUTO LUBE
FLOW A 12VDC
FLOW B 12VDC
CONTROLLER
BLACK
POTTED
BOX
+12 VDC
14 AWG RED
1
UNLOADER
C
P4
ORANGE
BLUE
12VDC
BLUE
A
15/54
30
IGNITION
SWITCH
58
50A
19
H
P4
4
3 A
2 B
1
8
7
6 16 AWG RED 12VDC
5 16 AWG BLACK
1
2
3
4
5
6
7
8
A
17
INSIDE
CONTROL
BOX
D
FLOW CONTROL
BROKEN FAN BELT
OUTSIDE
CONTROL
BOX
J4 MALE
INTERFACE
CONNECTOR
(WHITE)
A
E
+12
V-BELT BREAK
SWITCH
1
GND.
14 AWG BLACK
2
NOTE:
WHEN MEASURING VOLTAGE
AT CONNECTOR P4 PINS 2 AND 3.
1 PLACE NEGATIVE LEAD OF
VOLTMETER TO FLOW CONTROL
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. #5 (06/21/10)
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)
B
E
C
A
SCRO
LL
RESET
SET
VOL
DECR
EMERGENC
UME
EASE
Y
S
O
T
P
INCRE
ASE
FORW
ARD
FLO
DIRE
W
CTIO
N
REVER
SE
CON
AUTOM
OFF
TRO
LOCAL
ATIC
L
ON
REMO
JOG
CENTE
TE
STA
OFF R
RT
CYLIN
IGNI
DER
JOG
“A”
TION
STROK
E
JOG
“B”
REM
OTE
E
F
H
D
F
G
Figure 63. Connections to Digital Control Box - J3 and J4 Connectors ( 2 of 2)
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 73
LS400/LS500 PUMP — WIRING DIAGRAM (DIGITAL READOUT SCREEN)
BROWN (DECREASE)
GREEN (INCREASE)
RED (IGNITION +12VDC)
BLUE (UNLOADER SOLENOID)
RED (FUEL SOLENOID)
RED/BLACK
J1
RED
WHITE
YELLOW
GREEN
6
+12VDC IN
DIGITAL READOUT
MODULE
4
5
6
7
8
8
9
10
RED
3
BROWN
BLACK
7
11
WHITE
1
2
CONTROLLER
BLACK POTTED
BOX
BLUE
4
5
J4
RED
BLACK
1
2
3
BLACK
GND
12
E-STOP
1 2 3 4
RADIO
REMOTE
CONTROL
CONNECTOR
+12VDC OUT
5 6 7 8
1 2 3 4
5 6 7 8
J3
J2
BROWN
BLACK
PURPLE
BLK
RED
RED
1
1
2
2
ORANGE
3
3
NC 1 NC 1 NC 1
SCROLL
RESET/SET
GRAY
2
2
2
VOLUME
1 2
(-)
3
(+)
RED
YELLOW (REV)
RED/BLK
1
RED
CONTROL
2
GRN
RED
WHITE
(LOCAL)
BLUE
(FWD)
3
(REMOTE)
FLOW
DIRECTION
RED
15/54 50A
RED
BLACK
REMOTE
CONNECTOR
GRN/YEL
AUTOMATIC/JOG
IGNITION
SWITCH
BLK
BLUE
(JOG A) 1
2
WHITE
3 (JOG B)
CYLINDER
STROKE
1
2
3
ORANGE
Figure 64. Connections to Digital Readout Screen
PAGE 74 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — WIRING DIAGRAM (HOPPER VIBRATOR)
Figure 65. Optional Hopper Vibrator Wiring Diagram
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 75
LS400/LS500 PUMP — HYDRAULIC SYSTEM DIAGRAM
STA-2
STA-1
A
P
B
T
A
B
P
T
MANIFOLD
T3
T1
P2
A1
A2
1750 PSI
B2
B1
ACC
ACCUMULATOR
GAUGE
T2
P1
1000 PSI
T
P
OUT
RELIEF
T
LS
4400 PSI
RELIEF
1000 PSI
T
P
IN
OPTIONAL AGITATOR AND
HYDRAULIC OUTRIGGERS
7CC
14CC
MAIN
PRESSURE
GAUGE
Figure 66. Hydraulic System Diagram
PAGE 76 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — MANIFOLD BLOCK PORTS
MANIFOLD BLOCK PORTS
ACC
Connect to Accumulator Tank
A1
Connect to Shuttle Cylinder
A2
Connect to Hydraulic Cylinder
B1
Connect to Shuttle Cylinder
B2
Connect to Hydraulic Cylinder
GA
Connect to Accumulator Gauge
P1
Connect to Secondary Hyd. Pump
P2
Connect to Flow Control Valve
T1
Connect to Hydraulic Tank
T2
Connect to Heat Exchanger
T3
Connect to Tank, Relief Heat Exchanger
Figure 67. Manifold Block Ports
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 77
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 lbs. in 28 days
Gallons per sack
7.1
Washed Sand-#200 wash
1.3
Organic matter-OK
Specific gravity (SSD)
Sand-2.58; Pea Gravel-2.60
Sieve analysis-percent passing
Material
1.5”
1”
3/4”
3/8”
#4
#8
#16
#30
#50
#100
#200
W.C. Sand
100
99.7
79.1
60.4
36.5
14.3
4.0
1.1
Pea Gravel
100
3.0
% Comb.
100
66
51
39
23
9
3
1.0
DESIGN FOR ONE YARD OF CONCRETE (SATURATED & SURFACE DRY):
Absolute volume of aggregate in one cu. yard:
17.78 cu. ft.
Specific gravity of aggregates in one cu. yard:
2.58
Weight of aggregates in one cu. yard batch:
2850 lbs.
%
BATCH
SPEC. GRAVITY
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
ABS. VOL.
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.
PAGE 78 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
APPENDIX — CONCRETE MIX INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 79
APPENDIX — SLUMP TEST PROCEDURE
1. To obtain a representative sample (concrete), take
several samples at three or more regular intervals
throughout the discharge of the mixer or truck. DO
NOT take samples at the beginning or end of the
discharge.
2. 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.
3. Fill the cone 1/3 full by volume (Figure 68-A) and rod
25 times with a 1/2” dia x 24” lg. bullet-pointed steel
rod. (This is a specific requirement which will produce
non-standard results unless followed exactly.) Distribute rodding evenly over the entire cross section of
the sample.
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.
FULL
(OVERFLOW)
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-D. Slump Test
(Removing Excess Concrete)
BULLET POINTED
STEEL ROD
1/3 FULL
1/2 DIAMETER
24 INCHES LONG
FOOT
PIECE
Figure 68-A. Slump Test (1/3 Full)
4. Fill cone another 1/3 (Figure 68-B) which will make the
cone 2/3 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.
2/3 FULL
7. Lift the cone ver tically
(Figure 68-E) with a slow even
motion. DO NOT jar the concrete or tilt the cone during this
process. ( Invert the withdrawn
cone, and place it next to, but
not touching the slumped concrete.
Figure 68-E. Slump Test
(Cone Invert)
8. Lay a 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 complete in a maximum elapsed
time of 1-½ minutes. Discard
the concrete. DO NOT use it in
another tests.
Figure 68-B. Slump Test (2/3 Full)
Figure 68-F. Slump Test (Measurement)
PAGE 80 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
NOTE PAGE
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 81
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
Figure 69. Recommended Shotcrete System
PAGE 82 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
NO.
1
PART NO.
EM28906
PART NAME
COUPLING, 5” H-D “CF”
2
EM25837
ELBOW, 5"x4”x90°
3
EM28905
COUPLING, 4” H-D w/GASKET & PIN
4
EM402552
REDUCER, 4”x2.5”x53” H-D ENDS
5
EM28061
PIPE, 2.5”x120w x 10’ H-D
6
EM289035
COUPLING, 2.5” H-D w/GASKET & PIN
7
EM28001DD
REDUCER, 2.5”x2”x36” H-D
8
EM23815D
REDUCER, 2.5”x2” w/AIR VIBRATOR
9
EM28902
COUPLING, 2” H-D w/GASKET & PIN
10
EM23101
AIR VIBRATOR ASSY.
11
EM28131D
2"x2" ELBOW 90º
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”
QTY.
REMARKS
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. #5 (06/21/10) — PAGE 83
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
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 nozzle 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 84 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
NO.
1
2
3
4
5
6
7
8
9
10
11
11
11
12
*
13
*
14
*
15
*
16
*
17
*
18
*
19
*
20
21
PART NO.
EM26107
EM23101
EM132
EM23407
EM23408
EM23411
EM912073
EM23409
EM923346
EM406
EM23818
EM24841
EM23845
EM23802
EM23803
EM20816
EM23804
EM23805
EM23806
EM23807
EM911076
EM23808
PART NAME
QTY.
REMARKS
HOPPER SCREEN ......................... 1 .......... W/AIR VIBRATOR MOUNTING
AIR VIBRATOR
1
BOLT, 1/2-13X2
2
AIR HOSE
1
BUSHING
1
VALVE
1
NIPPLE
2
COUPLING
1
WASHER, 1/2 LOCK
2
NUT, HEX 1/2-13
2
2"X25' GROOVED HOSE
2"X25' RAISED HOSE
2"X50' GROOVED HOSE
VIC ADAPTER / EM23802D H.D 1
GUN BODY
1
“O” RING
1
AIR INSERT
1
NOZZLE CLAMP
1
NOZZLE TIP, 1-3/8", SHORT
1
NOZZLE TIP, 1-1/4", LONG
1
STREET ELBOW
1
AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO
NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES ITEMS W/
*
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 85
LS400/LS500 PUMP — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
remarks used in the Parts section of this manual. 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
NO.
1
2%
2%
3
4
PART NO. PART NAME
QTY. REMARKS
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
12347
WASHER, 3/8 IN....1 .....MQ-45T ONLY
12348
HOSE ..................A/R ...MAKE LOCALLY
12349
BEARING ..............1 .....S/N 2345B AND ABOVE
NO. 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.
Unique Symbols — All items with same unique
symbol
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
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 that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
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 XXXX”
“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 washers 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 86 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — SUGGESTED SPARE PARTS
LS400/LS500
CONCRETE PUMP
1 Unit
Qty.
P/N
1 .......... EM16462 ..............
4 .......... EM98050 ..............
4 .......... EM16493 ..............
1 .......... EM98033 ..............
2 .......... EM14408 ..............
2 .......... EM16145 ..............
1 .......... EM98021 ..............
2 .......... EM16816-1A ........
1 .......... EM16816-2 ...........
2 .......... EM98065 ..............
1 .......... EM98022 ..............
1 .......... EM98065 ..............
2 .......... EM14407 ..............
1 .......... 34507 ...................
2 .......... EM20763 ..............
1 .......... P53712 .................
3 .......... 01174416 .............
3 .......... 01174696 .............
3 .......... 1319257 ...............
3 .......... 1880870 ...............
1 .......... EM98163 ..............
1 .......... EM98121 ..............
...........................................
1 .......... EM98275 ..............
...........................................
Description
FELT HOLDER
PISTON CUP, ORANGE
FELT RING
OIL PLATE
BRONZE RING
BUSHING, SWING AXLE (BRONZE )
WEAR PLATE
ENERGIZER RING
INSERT RING
SLEEVE SEAL
WEAR RING
RUBBER RING
O-RING
CAP, FUEL
FILTER, FUEL (IN LINE)
CARTRIDGE, WATER SEPARATOR
FILTER, OIL (ENGINE)
FILTER, FUEL (ENGINE)
INSERT, AIR FILTER
AIR CARTRIDGE, SAFETY
PROXIMITY SWITCH
ELEMENT, RETURN OIL
S/N 281100 AND BELOW
ELEMENT, RETURN OIL,
S/N 281101 AND ABOVE
LS400/LS500
CONCRETE PUMP
3 Units
Qty.
P/N
1 .......... EM16459 ..............
2 .......... EM25801 ..............
4 .......... EM16462 ..............
6 .......... EM98050 ..............
8 .......... EM16493 ..............
4 .......... EM98033 ..............
4 .......... EM14408 ..............
4 .......... EM16145A ............
3 .......... EM98021A ............
4 .......... EM16816-1A ........
2 .......... EM16816-2 ...........
4 .......... EM98065 ..............
6 .......... EM98022 ..............
3 .......... EM98065 ..............
6 .......... EM14407 ..............
2 .......... EM16174 ..............
2 .......... EM98163 ..............
6 .......... 510265 .................
1 .......... 34507 ...................
6 .......... EM20763 ..............
3 .......... P53712 .................
9 .......... 01174416 .............
9 .......... 01174696 .............
9 .......... 1319257 ...............
9 .......... 1180870 ...............
2 .......... EM98121 ..............
...........................................
2 .......... EM98275 ..............
...........................................
Description
PIN
CONCRETE CYLINDER
FELT HOLDER
PISTON CUP, ORANGE
FELT RING
OIL PLATE
BRONZE RING
BUSHING, SWING AXLE (BRONZE )
WEAR PLATE
ENERGIZER RING
INSERT RING
SLEEVE SEAL
WEAR RING
RUBBER RING
O-RING
O-RING
SWITCH, PROXIMITY
BOLT, HEX HEAD 3/8 NC x 3-1/4 IN. G8
CAP, FUEL
FILTER, FUEL
CARTRIDGE, WATER SEPARATOR
FILTER, OIL (ENGINE)
FILTER, FUEL (ENGINE)
INSERT, AIR FILTER
AIR CARTRIDGE, SAFETY
ELEMENT, RETURN OIL
S/N 281100 AND BELOW
ELEMENT, RETURN OIL
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. #5 (06/21/10) — PAGE 87
LS400/LS500 PUMP — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
1
1
3
2
LEVER OPERATING INSTRUCTIONS
HOPPER REMIXER
REMIX LEVER
PULL UP TO
OPERATE. PUSH
DOWN TO REVERSE
3
PULL UP TO OPERATE
NEUTRAL
NEUTRAL
RIGHT REAR HYDRAULIC
STABILIZER LEVER
PULL UP TO EXTEND
PUSH DOWN TO RETRACT
LEFT REAR HYDRAULIC
STABILIZER LEVER
PULL UP TO EXTEND
PUSH DOWN TO RETRACT
PUSH DOWN TO REVERSE
CIP972
15
AMPUTATION DANGER!
KEEP HANDS CLEAR
5 2
SHUTTLE TUBE PIVOTS RAPIDLY AND WILL CRUSH
OR CUT. DO NOT PUT ANY BODY PARTS INTO
THE HOPPER UNTIL MACHINE IS COMPLETELY
SHUT DOWN AND THE ACCUMULATOR
PRESSURE GAUGE READS ZERO
P/N: DCL301
14
12
DIG
ITA
L
4 1
SCRO
LL
CO
NT
RO
LP
AN
EL
RESE
T
SET
VOL
DECR
EMERGENC
UME
EASE
Y
S
O
T
P
INCRE
ASE
FORW
ARD
FLO
DIRE
W
CTIO
N
REVE
RSE
CON
AUTO
OFF
TRO
LOCA
MATIC
L
L
ON
REMO
JOG
CENT
TE
OFFER
IGNI
DER
“A”
STA
RT
CYLIN
JOG
TION
STRO
KE
JOG
“B”
REM
OTE
13
6
E
F
Engine RPM Setting
(without change)
8
RPM
Low RPM:
RPM
USE DIESEL
FUEL ONLY
WARNING
(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.
11
High RPM:
7
P/N 35137
3
CAUTION
9
NOTES:
EM98000
10
800-30-MAYCO
1
PLACE DECAL ON LS400 MODELS ONLY.
2
PLACE DECAL ON LS500 MODELS ONLY.
3
USE THIS DECAL (OPTION) WHEN
HYDRAULIC STABILIZER JACKS
ARE INSTALLED.
CAUTION
9
EM98000
PAGE 88 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
EM970
DECAL, HOPPER REX MIXER
1
1
TBD
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 LS400 LOGO ....................... 1 .......... USED ON LS400 MODELS
5
517641
DECAL, MQ/MAYCO LS500 LOGO ....................... 1 .......... USED ON LS500 MODELS
6
513580
DECAL, ENGINE RPM SETTING
1
7
EM97084
DECAL, MAINTENANCE
1
8
EM995
DECAL, CAUTION DIESEL FUEL
1
9
EM98000
DECAL, CAUTION - GREASE 2 HOURS
2
10
511709
DECAL, 800-30-MAYCO
1
11
35137
DECAL, CAUTION READ MANUAL
1
12
517907
DIGITAL CONTROL PANEL LOGO
1
13
EM955
DECAL, DANGER CHARGING ACCUM.
1
14
DCL304
DECAL, DANGER IMPROPER CHARGING
1
15
DCL301
DECAL, SHUTTLE TUBE DANGER
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 89
LS400/LS500 PUMP — NAMEPLATE AND DECALS
PAGE 90 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
TBD
DECAL, IMPACT HAZARD
1
2
EM97070
DECAL, ACCUMULATOR PRESSURE .................. 1 .......... INCLUDED W/ITEM 4
3
EM985
DECAL, HYDRAULIC OIL ONLY
1
4
EM97070
DECAL, PUMPING PRESSURE DECAL ............... 1 .......... 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 ....................... 1 .......... USED ON LS400 MODELS
8
517642
DECAL, MQ/MAYCO LS500 LOGO ....................... 1 .......... 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
SERIAL PLATE ...................................................... 1 .......... CONTACT MQ PARTS DEPT.
13
TBD
DECAL, TIRE LOADING
1
14
49002
DECAL, WARNING COUPLER
1
15
TBD
DECAL, VIN IDENTIFICATION
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 91
LS400/LS500 PUMP — FRAME ASSY.
FRAME ASSY.
PAGE 92 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — FRAME ASSY.
FRAME ASSY.
NO.
PART NO.
1
514355
2
EM516581
3
EM25610
5
EM744
8
EM491686
10
EM491744
11
509562
12
0166 A
13
503112
14
3019092
15
EM969013
16
517985
17
504456
18
6109180
19
517113
20
492376
21
0166 A
23
EM969013
24
517124
25
EM923350
26
517092
27
517095
PART NAME
QTY.
REMARKS
FRAME, MAIN
1
CHAIN, TRAILER HITCH, 3/8 X 40", GRADE 40
2
JACK STAND, FRONT
1
CLEVIS PIN
2
PIN
2
RIVET, POP AM-44
2
BOLT, 3/8" NC X 5/8" G5
2
LOCK, WASHER 3/8" ................................................ 2 ......... REPLACES 492624
BOLT 3/8" X 2-3/4"
1
WASHER 3/8" ........................................................... 2......... REPLACES 492598
NUT 3/8" ................................................................... 1......... REPLACES 492583
FENDOR, BOLT ON
2
BOLT 1/2" NC X 3/4" G5
12
WASHER, LOCK 1/2 IN. ........................................... 12 ....... REPLACES 492626
STABILIZER STAND
2
BOLT 3/8" NC X 1-1/4" G5
2
WASHER, LOCK 3/8" ................................................4 ........ REPLACES 492624
NUT 3/8" ....................................................................2 ........ REPLACES 492583
BOLT 3/4" NC X 1" G5
10
WASHER, LOCK 3/4 IN. ........................................... 10 ....... REPLACES EM492628
SUPPORT PLATE, RIGHT
1
SUPPORT PLATE, LEFT
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 93
LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT)
AXLE ASSY. (RIGHT/LEFT)
PAGE 94 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT)
AXLE ASSY. (RIGHT/LEFT)
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
EM98116
AXLE, TORSION BAR ASSY.
2
2
EM092305
BRAKE ASSY COMPLETE, RIGHT ................ 1.............. INCLUDES ITEMS W/#
2
EM092306
BRAKE ASSY COMPLETE, LEFT .................. 1.............. INCLUDES ITEMS W/%
.......................................................................................... 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 PRESS IN 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 HP
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 ......... 4.............. REPLACES 503982
17
0401450160
WASHER, FLAT 5/8 IN. ................................... 8.............. REPLACES 492602
18
EM969023
NUT, LOCK 5/8 IN. ........................................... 4.............. REPLACES 492586
RIGHT AND LEFT SIDE AXLE
ASSEMBLIES ARE IDENTICAL WITH
THE EXCEPTION OF THE BRAKE
ASSEMBLY.
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 95
LS400/LS500 PUMP — BRAKE LINE ASSY.
BRAKE LINE ASSY.
PAGE 96 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — BRAKE LINE ASSY.
BRAKE LINE ASSY.
NO.
PART NO.
1
34566
2
EM512877
3
EM512876
4
34565
PART NAME
KIT, MAIN BRAKE LINE
ADAPTOR, STRAIGHT
ADAPTOR, ELBOW
KIT, WHEEL BRAKE LINE
QTY.
1
2
2
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 97
LS400/LS500 PUMP — BRAKE LIGHT ASSY.
BRAKE LIGHT ASSY.
PAGE 98 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — BRAKE LIGHT ASSY.
BRAKE LIGHT ASSY.
NO.
1
2
PART NO.
29242
29207
PART NAME
BRAKE LIGHT ASSY.
HARNESS ASSY. W/RECEPTACLES
QTY.
2
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 99
LS400/LS500 PUMP — TRAILER HITCH ASSY.
TRAILER HITCH ASSY.
PAGE 100 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — TRAILER HITCH ASSY.
TRAILER HITCH ASSY.
NO.
PART NO.
PART NAME
QTY.
1
EM29228
COUPLING, TRAILER 2 IN.BALL, 6000 LBS
1
2
EM19067
ACTUATOR, BRAKE
1
3
EM503111
BOLT, HEX HEAD 1/2 NC X 4-1/2 IN.
3
4
EM492600
WASHER, FLAT 1/2 IN.
3
5
EM492584
NUT, LOCK 1/2 IN.
3
6
EM507658
BOLT, HEX HEAD 5/8 NC X 4-1/2 IN. G5
2
7
EM492586
NUT, LOCK 5/8 IN.
2
8
16137
TOW RING, 3 IN. LUNETTE EYE
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 101
LS400/LS500 PUMP — BATTERY ASSY.
PAGE 102 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
1
EM34506
2
EM16738
3
514856
4
513577
PART NAME
BATTERY BOX W/ BELT
BATTERY 12V 125A
BATTERY CABLE POSITIVE
BATTERY CABLE NEGATIVE
QTY.
1
1
1
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 103
LS400/LS500 PUMP — HOPPER ASSY.
HOPPER ASSY.
PAGE 104 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HOPPER ASSY.
HOPPER ASSY.
NO.
PART NO.
1
EM515980
2
EM16184
3
EM516779
4
EM200303
5
EM200301
6
EM516820
7
EM514339
8
510717
9
EM514338
10
EM514706
11
EM902153
12
EM200018
13
EM703
14
500264
16
EM511428
17
EM516780
18
EM98108
19
505989
20
6109180
21
EM25508
22
EM70860-1
23
EM50417
24
EM508830
25
492378
26
0166 A
29
EM514031
30
EM514032
31
EM514033
32
513454
33
6109180
34
492589
35
EM25483
36
EM70860
37
EM515460
39
516799
40
EM702
41
EM703
42%
516787
43
EM500264
44%
516776
45%
516775
46
EM516786
PART NAME
QTY.
REMARKS
HOPPER ASSY
1
HOPPER SEAL
1
REMIXER SHAFT
1
FOLLOWER RING
2
GRAPHITE SEAL
6
COMPRESSION SPRING
2
HOPPER SPRING SEAT
2
BOLT 1/2 X 1-3/4 IN.
4
SUPPORT, LEFT
1
END CAP, SHAFT SUPPORT
1
BEARING
2
SET COLLAR
1
SET SCREW ............................................ 2 ................ REPLACES 492470
KEY 3/8 IN.
1
BOLT 1/2 X 3-1/2 IN.
4
HOUSING
1
MOTOR, REMIX
1
BOLT 1/2 X 1-1/4 IN.
2
WASHER, LOCK 1/2 IN. ........................... 2 ................ REPLACES 492626
ADAPTER, FITTING
2
PISTON CUP HOLDER
1
PISTON CUP
1
HANDLE
1
BOLT 3/8 X 1-3/4 IN.
4
WASHER, LOCK 3/8 IN. ........................... 4 ................ REPLACES 492624
PADDLE ARM, END
2
PADDLE ARM, MOTOR END
2
PADDLE ARM, CENTER
2
BOLT 1/2 X 3-1/4 IN.
6
WASHER, LOCK 1/2 IN. ........................... 6 ................ REPLACES 492626
HEX NUT 1/2 IN. ...................................... 6 ................ REPLACES 507661
HOSE
2
HANDLE ASSY.
1
RETAINING RING
1
SPACER 6MM
1
DOG POINT SET SCREW 3/8"
1
SET SCREW 3/8"
3
REMIX SHAFT COUPLER
1
SQUARE KEY 3/8"
1
DRIVE MEMBER COUPLER
1
MOTOR SHAFT COUPLER
1
COUPLER ASSY ...................................... 1 ................ INCLUDES ITEMS W/%
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 105
LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY.
HOPPER ATTACHMENT ASSY.
PAGE 106 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY.
HOPPER ATTACHMENT ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
PART NO.
EM514204
EM514620
EM491686
EM70134-2
EM505723
EM16166
505728
EM14165
EM619
EM968446
505121
EM968446
505123
492491
6109160
492379
3019092
515395
492584
EM969013
PART NAME
QTY.
REMARKS
SPLASH PLATE
1
HINGE PIN
1
COTTER PIN 1/8 X 1-1/2 IN.
1
PIN, SPLASH PLATE
1
COTTER PIN 5/32 X 1-1/2 IN.
1
TIE ROD
4
NUT, HEX 1 IN. NC
12
EYE BOLT 3/4 IN.
4
O-RING 3/4 IN.
4
NUT, HEX 3/4 IN.
4
BOLT 3/4 IN. X 3 IN.
4
HEX NUT 3/4 IN.
4
HEX BOLT 1/2 X 2-1/2 IN.
2
HEX BOLT 1/2 X 1-1/2 IN.
1
HEX NUT 1/2 IN. ................................................ 3 ............. REPLACES 492556
SCREW CAP 3/8"
2
WASHER FLAT 3/8"
4
BOLT 7/16 NC X 4" G5
2
NUT LOCK 1/2"
2
NUT NYLOC
2
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 107
LS400/LS500 PUMP — HOPPER INTERIOR ASSY.
HOPPER INTERIOR ASSY.
PAGE 108 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HOPPER INTERIOR ASSY.
HOPPER INTERIOR ASSY.
NO.
1
2
3
4
5
6
6A
7
8
8
9
10
11
12
13
14
15
17
18
19
20
21
25
26
27
28
29
30
31
32
PART NO.
EM16145A
EM284
EM16175
EM16170
EM16176
EM98022
EM16816-1A
EM16816-2
EM16804
EM16804A
EM104
EM923348
EM25803
EM98065
EM512212
491701
EM210
EM16811
EM25843
EM104
491719
EM923348
EM514357
EM98021
EM969023
EM265
EM923350
EM151
EM264
EM517700
PART NAME
QTY.
REMARKS
SWING AXLE BUSHING
2
STUD 1 IN. - 14 UNF
1
O-RING
1
RING SEAL, SHUTTLE AXLE
1
O-RING
1
WEAR RING HF
1
RING, ENERGIZER RUBBER
1
RING, INSERT STEEL
1
SLEEVE 5 IN. ............................................ 1 ............... JUNE 2008 AND BELOW
SLEEVE 5 IN. ............................................ 1 ............... JULY 2008 AND ABOVE
BOLT 5/8 X 2 IN. ........................................ 4 ............... REPLACES 503982
WASHER, LOCK 5/8 IN.
4
DISCHARGE PLATE BEARING
1
SEAL, RUBBER
1
DISCHARGE NIPPLE
1
GREASE FITTING
3
BOLT 5/8 X 2 IN.
6
SHUTTLE CYLINDER
1
NUN PLATE
1
BOLT, HEX HEAD 5/8 X 2 IN. .................... 4 ............... REPLACES 503982
PIN
1
WASHER, LOCK 5/8 IN.
4
HOPPER SCREEN
1
PLATE, WEAR HF
1
NUT, HEX 5/8 IN. NC INS. ......................... 2 ............... REPLACES 492586
BOLT, COUNTER SUNK 5/8-11 x 3 IN.
2
WASHER, LOCK 3/4 IN. ............................ 2 ............... REPLACES EM492628
BOLT, HEX HEAD 3/4-10 X 2 IN.
2
BOLT, COUNTER SUNK 1/2-13 x 3 IN.
2
O-RING
2
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 109
LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY.
SHUTTLE CYLINDER ASSY.
PAGE 110 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY.
SHUTTLE CYLINDER ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
EM16145
SWING AXLE BUSHING
2
2
EM510684
GREASE FITTING
1
3
EM16169
THRUST WASHER
1
4
EM25236
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
EM417
NUT 1 IN. 14NF
1
9
EM98106
SHUTTLE CYLINDER ASSY. ....................... 1 ............ INCLUDES ITEMS W/
*
9A
EM98106SK
SEAL KIT, SHUTTLE CYLINDER
1
10
EM254549
BRACKET, PIVOT
1
*
11
492397
BOLT 1/2 X 2-1/2 IN.
4
12
EM621
WASHER 1/2 IN.
4
13
6109180
WASHER, LOCK 1/2 IN. ............................... 4 ............ REPLACES 492626
14
492584
NUT 1/2 IN.
4
15
0820270000
CLEVIS PIN 3/4 IN.
2
* 0820270000
16
COTTER PIN
2
* 515249
18
JAM NUT
1
* 0509440000
19
FEMALE CLEVIS
2
* 3322
20
FITTING, ELBOW
2
21
EM514590
HOSE
1
22
EM514591
HOSE
1
23
517742
COVER, SHUTTLE CYLINDER
1
24
0202
BOLT ............................................................. 3 ............ REPLACES 492364
25
EM923023
WASHER, FLAT ............................................ 3 ............ REPLACES 492597
26
2105164
NUT, HEX ...................................................... 3 ............ REPLACES 492582
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 111
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
PAGE 112 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
NO.
PART NO.
PART NAME
QTY. REMARKS
1
EM510265
BOLT, HEX HEAD 3/8 NC X 3-1/2 IN., BLACK OXIDE G8 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
2
7
EM16462
FELT HOLDER
2
8
EM16461
OILER PLATE
2
9
EM14407
O- RING, OILER PLATE
2
10
EM25801
CYLINDER, CONCRETE
2
11
EM25110
RETAINER, CYLINDER
4
12
EM963610
BOLT, 3/8 NC X 1.3/4 IN. G5 ................................................... 8 ........ REPLACES 492375
13
0166 A
WASHER LOCK 3/8 IN. .......................................................... 8 ........ REPLACES 492624
14
3019092
WASHER, FLAT 3/8 IN. ......................................................... 22 ....... REPLACES 492598
16
EM514197
LUBRICATION BOX
1
17
EM507895
PLUG
1
18
EM515796
COVER, LUBRICATION BOX
1
19
EM514610
LATCH, COVER
1
20
491754
RIVET, AM-66
2
21
492378
BOLT, 3/8 NC X 1.3/4 IN. G5
6
22
0166 A
WASHER, LOCK 3/8” .............................................................. 6 ........ 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
EM98163
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. #5 (06/21/10) — PAGE 113
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
PAGE 114 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
NO.
PART NO.
PART NAME
QTY.
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
EM98211
CYLINDER, MAIN
2
42
EM514920
HOSE, MAIN HYD. CYLINDER
2
43
EM514202
EXTENSION, SPACER
2
6
44
EM185
BOLT, SOCKET HEAD 3/8 NC X 3 IN., BLACK OXIDE G8
45
EM25497
FITTING, 90°
4
46
EM25474
HOSE, HYDRAULIC SLAVE
1
47
EM16459
PIN, WRIST
2
48
EM505723
PIN, COTTER
4
49
EM491701
FITTING, GREASE
2
50
EM517126
LOCK WASHER
6
51
EM513352
SEAL, SQUARE
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 115
LS400/LS500 PUMP — FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 116 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — FUEL TANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
1
EM514084
2
514080
3
492362
4
EM923343
5
34507
6
EM514559
7
506208
8
EM514536
9
EM20426
10
EM514536
11
EM20763
PART NAME
QTY.
REMARKS
COVER, DIESEL TANK
4
GASKET
4
BOLT 5/16 X 5/8 IN.
56
WASHER, LOCK 5/16 IN. .................................. 56 ......... REPLACES 492623
CAP, FUEL W\GAUGE
1
ADAPTOR
1
CLAMP
5
HOSE, FUEL RETURN 5/16 IN.
A/R
ADAPTER
1
HOSE, FUEL FILTER 5/16 IN.
A/R
FILTER, FUEL
2
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 117
LS400/LS500 PUMP — HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
PAGE 118 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
NO.
PART NO.
1
EM98118
2
EM514175
3
EM963610
4
3019092
5
0166 A
6
0202
7
EM923023
8
2105164
9
EM25497
10
EM514607
11
EM25566
12
EM509345
13
EM514606
14
EM509401
15
EM514604
16
EM98264
PART NAME
QTY.
REMARKS
HEAT EXCHANGER
1
COVER, HEAT EXCHANGER
1
BOLT 3/8 IN. X 1 IN. ........................... 4 ..............REPLACES 492375
O-RING 3/8 IN. ................................... 4 ..............REPLACES 492598
WASHER, LOCK 3/8 IN. ..................... 4 ..............REPLACES 492624
BOLT 5/16 X 1 IN. .............................. 4 ..............REPLACES 492364
WASHER, FLAT 5/16 IN. .................... 8 ..............REPLACES 492597
NUT 5/16 IN. ....................................... 4 ..............REPLACES 492582
ADAPTER
1
HOSE 4000 PSI
1
ADAPTER
1
ADAPTER
1
HOSE 2000 PSI
1
ADAPTER
1
HOSE, 2000 PSI
1
MOTOR AND FAN ASSY
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 119
LS400/LS500 PUMP — ACCUMULATOR ASSY.
ACCUMULATOR ASSY.
PAGE 120 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — ACCUMULATOR ASSY.
ACCUMULATOR ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
PART NO.
EM97015
EM97016
EM9603055
3019092
0166A
EM509425
EM509353
EM514603
EM98009
EM98052
PART NAME
ACCUMULATOR 1 GAL.
BRACKET, ACCUMULATOR
BOLT, HHCS 3/8 IN. DIA.
WASHER, FLAT 3/8 IN.
WASHER, LOCK 3/8 IN. DIA.
FITTING, STRAIGHT
FITTING, 90° ELBOW
HOSE, ACCUMULATOR
ACCUMULATOR REPAIR KIT
ACCUMULATOR TEST/CHARGE KIT
QTY.
1
1
2
2
2
1
1
1
1
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 121
LS400/LS500 PUMP — REMIXER CONTROL ASSY.
REMIXER CONTROL ASSY.
PAGE 122 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — REMIXER CONTROL ASSY.
REMIXER CONTROL ASSY.
NO.
1
2
3
4
5
6
7
8
9
PART NO.
EM25495
515384
506195
EM25509
EM218
EM923343
2105164
EM98015
EM98014
PART NAME
QTY.
REMARKS
VALVE REMIXER W/ LEVER
1
ADAPTER FITTING, T
1
ADAPTER FITTING, 90° ELBOW
1
ADAPTER FITTING, STRAIGHT
2
BOLT 5/16 X 2-1/2 IN.
2
WASHER, LOCK 5/16 IN. .............................. 2 ................. REPLACES 492623
NUT, HEX 5/16 IN. ......................................... 2 ................. REPLACES 492553
COUPLING
1
TEST PORT
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 123
LS400/LS500 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
A ................................................. CLEVIS GREASE POINT ................................................ 34 in. (1.1 m)
B ................................................. SWING AXLE BUSHING GREASE POINT ...................... 26 in. (.85 m)
C................................................. PIVOT BRACKET GREASE POINT ................................. 41 in. (1.5 m)
PAGE 124 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — LUBRICATION PANEL
LUBRICATION PANEL ASSY.
NO.
1
2
3
4
5
PART NO.
EM491701
EM508812
EM510684
EM505516
EM510487
PART NAME
GREASE FITTING
CONNECTOR
CONNECTOR
HOSE, PLASTIC
HOSE, STEEL
QTY.
3
2
3
A/R
1
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 125
LS400/LS500 PUMP — ENGINE COVER ASSY.
ENGINE COVER ASSY.
PAGE 126 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — ENGINE COVER ASSY.
ENGINE COVER ASSY.
NO.
1
2
3
4
6
7
8
PART NO.
EM517737
492356
EM923057
2101402
EM517730
492541
TK6737260
PART NAME
QTY.
REMARKS
COVER, TOP
1
BOLT 1/4" NC X 3/4" G5
16
LOCK WASHER 1/4 IN. ........................................ 14 .......... REPLACES 492596
WASHER 1/4 IN. .................................................. 16 .......... REPLACES 492622
COVER, FRONT ENGINE
1
NUT 5/16" NC G2
2
DOCUMENT CYLINDER
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 127
LS400/LS500 PUMP — HYDRAULIC TANK ASSY.
HYDRAULIC TANK ASSY.
PAGE 128 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HYDRAULIC TANK ASSY.
HYDRAULIC TANK ASSY.
NO.
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30A
31
33
34
35
36
41
45
46
47
48
49
50
51
PART NO.
514040
0166 A
EM517295
EM251191
EM25184
492362
EM923343
EM98263
492267
16433
EM491189
EM18436
EM514605
EM514622
EM514597
EM491164
509784
517002
EM509369
491237
506094
EM98188
EM97066
EM97067
EM25523
EM509517
EM514602
EM16517
EM98112A
EM98275
516814
EM16513
492376
492598
509343
TBD
516813
409401
EM16414
16516
509344
514604
514604
PART NAME
QTY.
REMARKS
HYDRAULIC TANK, LS-S
1
LOCK, WASHER 3/8 IN. .......................................4 ........... REPLACES 492624
HANDLE
1
TANK COVER PLATE
1
RESERVOIR GASKET
1
BOLT 5/16 X 5/8 IN.
20
WASHER, LOCK 5/16 IN. .................................... 20 .......... REPLACES 492623
CAP ASSEMBLY
1
BOLT 3/16 X 5/8 IN.
6
TUBE
1
FITTING
1
90° MALE ADAPTER 2103-16-16
1
HOSE
1
FITTING 1 IN.
1
HOSE
1
ELBOW, 3/4 IN.
1
ADAPTER
1
HOSE
1
STRAIGHT MALE ADAPTOR , 0101-08-08
1
VALVE 1/2 IN.
1
CAP 1/2 IN.
1
GAUGE, LEVEL & TEMP. .....................................1 ........... REPLACES EM16478
GAUGE 3000PSI, ACCUMULATOR
1
GAUGE 5000 PSI, MAIN
1
ADAPTER
2
HOSE, 4000 PSI MAIN GAUGE
1
HOSE, 4000 PSI ACCUMULATOR GAUGE
1
STRAIGHT MALE ADAPTER 0102-24-16
1
RETURN FILTER ASSY. .......................................1 ........... S/N 281101 AND BELOW
ELEMENT, RETURN FILTER ................................1 ........... S/N 281102 AND ABOVE
90° FITTING
1
DIFFUSER
1
BOLT 3/8 X 1-1/4 IN.
4
WASHER, FLAT 3/8 IN.
4
TEE FITTING
1
BOLT
2
BUSHING
1
ADAPTOR 3903-16-16
1
VALVE NEEDLE
1
PIPE 1-1/2" ...........................................................1 ........... S/N 281101 AND BELOW
ADAPTOR 063T-16-16
1
HOSE
1
HOSE
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 129
LS400/LS500 PUMP — ENGINE ASSY.
LS-40TD/LS-50TD ENGINE ASSY.
PAGE 130 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — ENGINE ASSY.
ENGINE ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
*
13
*
14
*
15
*
16
*
17
*
18
*
19
*
24
25
26
27
28
29
30
31
32
33
PART NO.
EM98189
492401
6109170
6109180
EM511021
EM510725
EM511019
TBD
EM510888
22001301
22002183
01881280
01319257
01880870
01881413
EM492366
EM492623
EM492597
EM492553
EM514633
492371
EM923023
EM514714
EM923343
2105164
EM510897
01174416
01174696
EM516434
PART NAME
QTY.
REMARKS
ENGINE, DEUTZ TURBO 76 HP BF4L2011
1
BOLT1/2 IN.X 4 FT.
4
WASHER, FLAT 1/2 IN. ........................................... 4............ REPLACES 492600
WASHER, LOCK 1/2 IN. ......................................... 4............ REPLACES 492626
AIR DUCTING CLAMP
2
AIR DUCTING CLAMP
2
AIR DUCTING DUCTING
1
CLAMP
3
CONNECTOR, AIR FILTER
1
HOSE, ELBOW 90°
1
AIR CLEANER ASSY. ............................................. 1............ INCLUDES ITEMS W/
*
HOOD, AIR CLEANER
1
INSERT, AIR FILTER
1
CARTRIDGE, SAFETY AIR
1
DUST EJECTOR
1
BOLT 5/16 X 1-1/2 IN.
2
WASHER, LOCK 5/16 IN.
2
WASHER, FLAT 5/16 IN.
4
NUT, HEX 5/16 IN. G5
2
REDUCTION TUBE, EXHAUST
1
BOLT 5/16 NC X 3 IN. G5
2
WASHER, FLAT 5/16 IN. ......................................... 4............ REPLACES 492597
SPACER, EXHAUST
2
WASHER, LOCK 5/16 IN. ........................................ 2............ REPLACES 492623
HEX NUT 5/16 IN. G5 .............................................. 2............ REPLACES 492553
CAP, EXHAUST 2-1/2 IN.
1
FILTER, OIL (ENGINE)
1
FILTER, FUEL (ENGINE)
1
PIPE EXHAUST ASSY.
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 131
LS400/LS500 PUMP — THROTTLE ASSY.
THROTTLE ASSY.
PAGE 132 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — THROTTLE ASSY.
THROTTLE ASSY.
NO.
1
2
3
4
5
6
7
*
8
*
9
*
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART NO.
510792
492356
EM167
EM923057
2101402
EM16465
EM98233
EM98228
EM98232
EM25429
EM25511
EM25576
EM50449
EM25504
EM50463
EM50449
EM50462
EM50449
EMCC700
492581
515812
513213
EM501102
EM491089
510229
492366
2105164
EM98168
PART NAME
QTY.
REMARKS
SUPPORT
1
BOLT 1/4' X 3/4 IN.
3
BOLT 1/4 X 1-3/4 IN.
4
LOCK WASHER 1/4 IN. ..................................... 4 .............. REPLACES 492596
WASHER 1/4 IN. ............................................... 4 .............. REPLACES 492622
PISTON SPACER
2
BLOCK
1
COIL, 12V
1
VALVE
1
ELBOW ADAPTER 90° MALE
3
STRAIGHT ADAPTER
1
HOSE 20 IN.
2
ELBOW ADAPTER 90° MALE
1
ELBOW ADAPTER 90° MALE
1
HOSE 17-1/2 IN.
1
ELBOW ADAPTER 90° MALE
1
HOSE 10 IN.
1
ELBOW ADAPTER 90° MALE
1
HYDRAULIC CYLINDER
1
NUT, HEX 1/4 IN.
2
THROTLE CONTROL PLATE
1
THROTTLE CABLE GUIDE
1
SLEEVE, THROTTLE
1
BOLT 8 X 1/4 IN.
1
CABLE, THROTTLE
1
BOLT 5/16 X 1-1/2 IN.
1
HEX NUT 5/16 IN. ............................................. 1 .............. REPLACES 492553
THROTTLE BLOCK ASSY. ............................... 1 .............. INCLUDES ITEMS W/
*
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 133
LS400/LS500 PUMP — WATER SEPARATOR ASSY.
WATER SEPARATOR ASSY.
PAGE 134 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — WATER SEPARATOR ASSY.
WATER SEPARATOR ASSY.
NO.
1
2
3
3A
4
5
6
7
8
PART NO.
514340
TBD
EM16747
P53712
492364
2105164
EM514559
EM506208
EM514536
PART NAME
QTY.
REMARKS
BRACKET, WATER SEPARATOR
1
BOLT
2
WATER SEPARATOR ASSEMBLY
1
CARTRIDGE, WATER SEPARATOR
1
BOLT 5/16 X 1 IN.
3
HEX NUT 5/16 IN. ............................................. 3 .............. REPLACES 492582
ELBOW ADAPTER 90° MALE
2
CLAMP, HOSE
2
HOSE 5/16 IN.
TBD
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 135
LS400/LS500 PUMP — HYD. PUMP ASSY.
HYDRAULIC PUMP ASSY.
PAGE 136 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HYD. PUMP ASSY.
HYDRAULIC PUMP ASSY.
NO.
1
2
PART NO.
TBD
EM514719
PART NAME
QTY.
REMARKS
O-RING
1
FLANGE, SUCTION PIPE .......................................... 2 ............ INCLUDES ITEMS W/
3
EM492444
BOLT 1/2 X 1-1/4 IN.
4
5
6
7
8
9
10
11
12%
13
14
16
16
17
18
19
20
21
22
23
24
25
25
26
27
29
30
31
32
33
34
35
36$
37
39
40
6109180
EM514718
EM515207
EM514623
EM514627
EM514628
EM510902
6109180
WASHER, LOCK 1/2 IN. .............................................. 6 ............ REPLACES 492626
SUCTION PIPE ADAPTER, 40 SPECIAL
1
CLAMP 2 IN. ................................................................ 2
HOSE, SUCTION 2 IN.
1
ADAPTER, SUCTION PIPE 32
1
FLANGE, SUCTION PIPE .......................................... 1 ............ INCLUDES ITEMS W/%
BOLT 1/2 X 1-1/2 IN.
4
WASHER, LOCK 1/2 IN. .............................................. 4 ............ REPLACES 492626
O-RING
1
COUPLER, ENGINE ASSY.
1
BOLT 1/2 X 1-1/2 IN.
2
PUMP, MAIN 60CC, PARKER P1-60 SERIES ............ 1 ............ USED ON LS400 ONLY
PUMP, MAIN 75CC, PARKER P1-75 SERIES ............ 1 ............ USED ON LS500 ONLY
FLOW CONTROL VALVE
1
BOLT 7/16 X 3 IN.
4
GASKET
1
PUMP, SECONDARY
1
BOLT 3/8 X 1 IN. .......................................................... 2 ............ REPLACES 492375
WASHER, LOCK 3/8 IN. .............................................. 2 ............ REPLACES 492624
STRAIGHT ADAPTER
1
ELBOW ADAPTER
1
HOSE, 4000 PSI SENSOR ......................................... 1 ............ USED ON LS400 ONLY
HOSE, 4000 PSI SENSOR ......................................... 1 ............ USED ON LS500 ONLY
ELBOW ADAPTER
1
STRAIGHT ADAPTER
1
STRAIGHT ADAPTER
1
ELBOW ADAPTER 90° MALE
2
ELBOW ADAPTER
1
HOSE 2000 PSI, REMIX VALVE
1
MOTORIZED FLOW CONTROL MANIFOLD ASSY. 1
HOSE, MAIN MANIFOLD
1
ELBOW
1
VALVE, MAIN RELIEF
1
HOSE
1
ELBOW
1
ELBOW ADAPTER
1
*
EM98128
EM510902
EM517674
EM98256
EM98273
EM506953
EM16190
EM98107
EM963610
0166 A
EM25498
EM25429
EM514599
EM516875
EM25429
EM491372
EM25498
EM16524
506200
EM514601
EM517649
EM517038
EM509353
TBD
EM514608
EM25459
EM25429
4
*
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 137
LS400/LS500 PUMP — MANIFOLD ASSY.
MANIFOLD ASSY.
PAGE 138 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — MANIFOLD ASSY.
MANIFOLD ASSY.
NO.
1
2
3
4%
5%
6%
7%
8%
9%
10%
12%
12A%
13
14
15
16
17
18
19
20
21
22
23
24
25
PART NO.
EM963102
6109180
EM98261
EM98221
EMBK227
EM98223
EMBK2097
EM98220
EM98221
EM98227
EM98228
EM98229
EM25498
EM509401
EM514488
EM25459
EM98226
EM514231
EM514489
EM491372
506193
EM25462
EM509353
EM25429
TBD
PART NAME
QTY.
REMARKS
BOLT 1/2 X 1-1/4 IN. ................................................ 4 .......... REPLACES 492393
WASHER, LOCK 1/2 IN. ........................................... 4 .......... REPLACES 492626
MANIFOLD ASSY COMPLETE ............................... 1 .......... REPLACES EM98109
CYCLING VALVE, SWING W/PILOTS
1
BOLT, SHCS 1/2" x 2-1/4"
12
PILOT VALVE, SHUTTLE
1
BOLT, SHCS 1/2" X 1-1/4"
8
CYCLING VALVE, MAIN
1
PILOT VALVE, MAIN CYLINDER
1
CHECK VALVE
1
COIL, 12VDC ACCUMULATOR
1
ACCUMULATOR UNLOADER CARTRIDGE ASSY 1
ADAPTER
1
ADAPTER
3
ADAPTER
1
ADAPTER
2
UNLOADING RELIEF VALVE, SHUTTLE
1
ADAPTER
2
ADAPTER
2
ADAPTER
1
ADAPTER
1
ADAPTER
2
ADAPTER
3
ADAPTER
1
CHECK VALVE
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 139
LS400/LS500 PUMP — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 140 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
8A
12
13
14
15
18
19
20
21
PART NO.
517648
0202
EM923023
2105164
TBD
EM98206
EM98206K
EM517177
EM517186
EM98120
EM98119
EM98121
EM98122
EM97068
TBD
TBD
TBD
PART NAME
QTY.
REMARKS
CONTROL BOX ASSY
1
BOLT 5/16 X 1 IN. ............................................ 4 ................ REPLACES 492364
WASHER, FLAT 5/16 IN. .................................. 4 ................ REPLACES 492597
NUT 5/16 IN. .................................................... 4 ................ REPLACES 492582
OVERLAY, CONTROL PANEL
1
IGNITION SWITCH ASSY.
1
KEY, IGNITION
1
EMERGENCY STOP SWITCH ASSY.
1
CONTACT BLOCKS, EMERGENCY SWITCH 3
FLOW DIRECTION SWITCH ASSY.
1
MAIN CONTROL SWITCH ASSY.
1
AUTO/JOG SWITCH ASSY.
1
JOG A/B SWITCH ASSY.
1
RECEPTACLE, REMOTE
1
VOLUME SWITCH ASSY.
1
SCROLL SWITCH ASSY.
1
RESET SWITCH ASSY.
1
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 141
LS400/LS500 PUMP — CONTROL BOX HARNESSES ASSY.
CONTROL BOX HARNESSES ASSY.
PAGE 142 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — CONTROL BOX HARNESSES ASSY.
CONTROL BOX HARNESSES ASSY.
NO.
1
2
3
4
5
6
7
PART NO.
EM514635
344102000
EM514636
EM514637
EM514638
509588
16716
PART NAME
WIRE HARNESS 1
FUSE, 30 AMP
WIRE HARNESS 2
WIRE HARNESS 3
WIRE HARNESS 4
POLY FLEX TUBE 1/2 IN. BLACK
CONDUCTIVE DIVIDER 3/8 IN.
QTY.
1
1
1
1
1
AR
AR
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 143
LS400/LS500 PUMP — REMOTE CONTROL CABLE ASSY.
REMOTE CONTROL CABLE ASSY.
PAGE 144 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — REMOTE CONTROL CABLE ASSY.
REMOTE CONTROL CABLE ASSY.
NO.
1
*
2
*
2A
3
*
4
*
5
*
6
*
7
8
9
PART NO.
EM16753
EM16754
EM97075
EM491897
EM16756
EM26791
EM26790
EM26793
EM97065
EM97099
PART NAME
QTY.
REMARKS
JUNCTION BOX
1
SWITCH
1
SWITCH
1
CONNECTOR, RING 3/16 IN.
4
GUARD SWITCH - ALUMINUM
2
SEAL, GRIP CORD
1
CORD, MX P/E 25 FT.
1
ADAPTER, CORD GRIP 1/2 IN.
1
ADAPTER, CORD 100 FT.
1
COMPLETE CORD ASSY 25 FT .............. 1 ................ INCLUDES ITEMS W/
*
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 145
LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL)
PAGE 146 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10)
LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL)
OPTIONAL HYDRAULIC STABILIZER ASSY.
NO.
1
2
3
4
4A
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART NO.
TBD
TBD
TBD
EM98046
EM98047
506200
517101
517102
517103
517104
512655
25509
EM516382
517107
517105
517100
517106
517153
517154
490957
PART NAME
BOLT
WASHER
NUT
VALVE REMIXER W/ 3 LEVERS
HANDLE, DIRECTIONAL VALVE
FITTING 45°
HOSE
HOSE
HOSE
HOSE
FITTING 90°
FITTING STRAIGHT
HYDRAULIC STABILIZER
FITTING STRAIGHT
HOSE
HOSE
HOSE
BOLT
BOLT
SNAP RING
QTY.
2
2
2
1
3
5
1
1
1
1
7
3
2
1
1
2
1
2
2
8
REMARKS
MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #5 (06/21/10) — PAGE 147
MAYCO PUMP WARRANTY
MECHANICAL DRIVE MODELS
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 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 defective parts.
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 Manufacturer
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 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.
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. #5 (06/21/10) — PAGE 149
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
MQ Parts Department
Tel. (800) 421-1244
Fax (800) 537-3927
Mayco Parts
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
800-306-2926
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
800-421-1244, Ext. 279
310-537-3700, Ext. 279
Fax: 310-537-1173
Technical Assistance
800-421-1244
310-537-3700
Fax: 310-537-4259
800-478-1244
Fax: 310-631-5032
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Unit 2, Northpoint Industrial Estate,
Global Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
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 2010, 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 publication 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.
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