Multiquip LS500, LS400 User Manual

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OPERATION AND PARTS MANUAL

SERIES

MODELS LS400/LS500

CONCRETE PUMPS

(DEUTZ F4L2011, BF4L2011 DIESEL ENGINES)

Revision #6 (09/19/11)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

LS400/LS500 PUMP — PROPOSITION 65 WARNING

Proposition 65 W arning

Diesel engine exhaust and some of

PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

NOTES

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 3

LS400/LS500 PUMP —TABLE OF CONTENTS

MAYCO LS400/LS500

CONCRETE PUMPS

Proposition 65 Warning ............................................. 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 (Optional Hopper Vibrator) ............ 74

Hydraulic System Diagram ..................................... 75

Manifold Block Ports ............................................... 76

Appendix - Concrete Mix Information ................77-78

Appendix - Slump Test Procedure........................... 79

Appendix - Recommended Shotcrete System ...... 80-81

Appendix - Recommended Shotcrete Accessories .... 82-83

Explanation Of Codes In Remarks Column ............ 84

Suggested Spare Parts ........................................... 85

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Name Plate and Decals ..................................... 86-89

Frame Assy. ....................................................... 90-91

Axle Assy. ........................................................... 92-93

Brake Line Assy. ................................................ 94-95

Brake Lights Assy. .............................................. 96-97

Trailer Hitch Assy. ............................................... 98-99

Battery Assy. ..................................................100-101

Hopper Assy. .................................................. 102-103

Hopper Attachment Assy. .............................. 104-105

Hopper Interior Assy. ..................................... 106-107

Shuttle Cylinder Assy. .................................... 108-109

Lubrication Pistons Assy. ............................... 110-111

Fuel Tank Assy. .............................................. 112-115

Heat Exchanger Assy. .................................... 116-117

Accumulator Assy........................................... 118-119

Remixer Control Assy. .................................... 120-121

Lubrication Panel Assy. .................................. 122-123

Engine Cover Assy. ........................................ 124-125

Hydraulic Tank Assy. ...................................... 126-127

Engine Assy. ................................................... 128-129

Throttle Assy. ................................................. 130-131

Water Separator Assy. ................................... 132-133

Hydraulic Pump Assy. .................................... 134-135

Manifold Assy. ................................................ 136-137

Control Box Assy. ...........................................138-139

Control Box Harness Assy. ............................ 140-141

Remote Control Cable Assy. .......................... 142-143

Hydraulic Stabilizer Assy. (Optional) .............. 144-145

Terms and Conditions of Sale - Parts ................... 146

Mayco Pump Warranty.......................................... 147

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

N View Parts Diagrams

N Order Parts N Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Par ts

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact your District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

When ordering parts, please supply:

R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R Quantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Tr uc k  N Ground N Next Day N Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 5

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 to the engine manufacturers instructions for data relative to its safe operation.

Before using this pump , ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential 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.

LS400/LS500 Concrete

pump. Refer

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

WARNING - EXPLOSIVE FUEL

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.

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.

Diesel fuel

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 extremely flammable, and

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

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

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hands, hair

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.

and clothing away from all

fingers

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

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.

ALWAYS wear approved protection.

This machine is capable of producing noise levels above 85 dB. Hearing protection is required.

Always wear eye protection.

respiratory

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. #6 (09/19/11) — PAGE 7

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

■

DANGER - READ OPERATION AND PARTS

Failure to follow instructions in this manual may lead to

death!

serious injury or even 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.

This equipment is to be

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 cause serious burns.

■

The engine section of this pump requires an adequate free flow of cooling air. 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 carbon monoxide gas.

■

ALWAYS refuel in a well-ventilated area, away from sparks and open flames.

hot!

components can

NEVER

DEADLY

■

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.

■

ALWAYS check the machine for loosened threads or bolts before starting.

■

ALWAYS wear proper respiratory (mask),

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.

hearing

and

■

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool.

NEVER machine. Fire or explosion could result from

fuel vapors

engine. NEVER operate the pump in an explosive atmosphere or

near combustible materials. An explosion or fire could result causing severe

Topping-off to filler port is dangerous, as it tends to spill fuel.

ALWAYS remove the unattended.

ALWAYS block the slope.

ALWAYS maintain this equipment in a safe operating condition at all times.

ALWAYS stop the engine before servicing, adding fuel or oil.

smoke

around or near the

, or if fuel is spilled on a

bodily harm or even death.

ignition key

wheels

when leaving the pump

on the unit when using on a

hot!

PAGE 8 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

■

NEVER run engine without air filter. Severe engine damage may occur.

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using pump.

■

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■

DO NOT operate this equipment unless the hopper grate, guards and safety devices are attached and in place.

■

CAUTION must be exercised while servicing this equipment. Rotating and moving parts can cause injury if contacted.

■

Keep all 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.

inexperienced

and

unauthorized

people away

TRANSPORTING

■

Towing

■

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.

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,

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.

always

have rear tail lights ON.

■

Check all fasteners periodically for tightness. Also check towing tongue bolt, lock nut and wheel lug nuts for wear.

■

Test the test is to shut down the engine.

■

Refer to the 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.

pump's ON/OFF

DEUTZ Engine Owner's Manual

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 9

switch. The purpose of this

for engine

LS400/LS500 PUMP — RULES FOR SAFE OPERATION

MAINTENANCE SAFETY

DANGER - AMPUTATION RISK

During routine maintenance or removing material blockage, you will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at

EXTREME RISK

engine is running or if pressure is in the hydraulic system.

Prior to performing any maintenance on the pump, follow described lock out-tag out procedures. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The pressure reading on the accumulator pressure gauge ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump.

■

NEVER lubricate components or attempt service on a running pump .

MUST

of injury or

read

AMPUTATION

if the

■■

■

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 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.

EMERGENCIES

clothing or skin

, rinse skin or clothing

■

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.

BATTERY

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

always

wear safety glasses.

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

■

In emergencies nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

fire extinguisher

first aid kit

always

know the location of the

keep a phone on the job site

and

fire department

. This

PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

NOTES

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

LS400/LS500 PUMP — SPECIFICATIONS

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ledoM004-SL005-SL

etaRgnipmuP

dohteMgnipmuPnotsiPgnitacorpiceR

eziSetagerggAmumixaM )mm83(sunim.ni2/1-1

thgieHgnipmuPlacitreV )m67(.tf052fossecxEotpU

erusserPecaFnotsiPisp

ecnatsiDgnipmuPlatnoziroH *)m503(.tf0001

yticapaCxoBnoitacirbuLrednilyC )sretiL6.7(snollaG2

iulFciluardyH )sretiL981(snollaG05

SeriT )mm653xmm781(.ni41x.ni53.7

yticapaCd

yticapaCknaTleuF )sretiL67(snollaG04

yticapaCreppoH reximerver/dwflanoi

esoHlairetaM

ledoMenignE

)sdiulfhtiw(thgieW )gk951,2(.sbl067,4

)gnippihs/yrd(thgieW )gk860,2(.sbl065,4

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obruTztueD

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snoitpO

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rezilibatSraeRciluar

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snotitidnocetisbojdnadesuezisenil,pmuls,ngisedximnognidnepedyravlliwtuptuoemuloV*

.2ELBATSNOITACIFICEPSENIGNE

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mpr0003@PH06mpr0003@PH97

)L37.2(.ni.uc761

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)sretil5.2(.lag5.9

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yrettaB

72puorGVCDV21

PAGE 12 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — DIMENSIONS

SNOISNEMID.3ELBAT

.FERSNOISNEMID

A).mc2.901(.ni34

B).mc734(.ni271

C).mc16(.ni42

D).mc8.771(.ni07

E).mc2.271(.ni86

Figure 1. Dimensions

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 13

LS400/LS500 PUMP — IMPORTANT HAND SIGNALS

Figure 2 displays the basic hand signals commonly used in concrete pumping operations.

Figure 2. Operation Hand Signals

PAGE 14 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — GENERAL INFORMATION

CONCRETE MIX DESIGN

Mix 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 section of this manual.

Operation

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 15

LS400/LS500 PUMP — GENERAL INFORMATION

REGIONAL DIFFERENCES

Concrete is made by mixing locally available rock and sand with cement and water. For this reason there are great differences in the pumpability of concrete from one region of the country to another.

It is impossible to define a specific mix for each region that the concrete pump be will working in. Therefore, the mixes listed in Appendix - Concrete Mix Information will provide a basic guideline for establishing the proper mix design for your 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.

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.

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.

PAGE 16 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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.

TO TANK

HYDRAULIC CYLINDERS

SLAVE

OIL

SHUTTLE TUBE MOTION

HIGH PRESSURE

OIL FROM PUMP

PROXIMITY

SWITCH

CONCRETE CYLINDERS

PISTON

CUP

SHUTTLE TUBE

Figure 4. Pumping Cycle 2

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. #6 (09/19/11) — PAGE 17

LS400/LS500 PUMP — PUMP COMPONENTS

Figure 5. Major Pump Components

PAGE 18 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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 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.

50 psi cold

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.

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.

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

23. Remixer Motor – Drives the remixer paddles inside

24. Hopper/Hood – Lift hood to fill. Concrete from a Redi-

25. Tow End Jack Stand – Use this jack stand to level

the hopper. The motor direction is controlled by the remixer control lever.

Mix truck is poured into this hopper. The hopper can hold 10 cu. ft of concrete with optional forward/reverse mixer. NEVER put hands or any other parts of you body into the hopper.

and support the tow end of the pump.

LS400/LS500 PUMP — DIGITAL CONTROL PANEL COMPONENTS

ACCUMULATOR

PRESSURE

PUMPING

PRESSURE

DECREASE

FORWARD

AUTOMATIC

RESET

SET

VOLUME

FLOW

DIRECTION

INCREASE

REVERSE

JOG

SCROLL

Figure 6. Pump Digital Control Panel Components

1. Emergency Stop Button – Press emergency stop

9. Cylinder Stroke Control Switch – This 2-position

button to stop pump in an emergency. Turn knob counterclockwise to disengage the stop button.

2. 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.

3. Digital Readout Screen – Displays and monitors the various functions of the machine.

10. Manual Cylinder Jogging Switch – This 2-position

4. Scroll Switch – Allows the operator to scroll the various readout screens.

5. Reset Switch – Allows the operator to reset the stroke counter.

6. Remote Cable Connector – Insert the remote control input cable into this connector.

7. Direction Control Switch – This 2-position switch

11. Stroke Volume Control Switch – Increases or

controls the direction of flow for any mix in the pump. The

leftmost

forward and the

position sets the pumping direction to

rightmost

position sets the pumping

12. Accumulator Pressure Gauge – This gauge monitors

direction to reverse.

8. Pumping Control Switch – This 3-position switch controls the pumping of the pump. The position (REMOTE) is for use with the remote control unit, the pumping operation, and the

leftmost

position (LOCAL) is for normal

centermost

rightmost

13. Main Pressure Gauge – This gauge monitors the

position

(CENTER OFF) prevents pumping.

OFF

START

CONTROL

REMOTE

LOCAL

CENTER

OFF

CYLINDER STROKE

JOG “B”

JOG “A”

switch controls the pumping function. The position (AUTOMATIC) sets the pump to

cycling

. Set the switch to this position for normal pump

IGNITION

REMOTE

leftmost

automatic

operation. The

rightmost

automatic to to be manually cycled using the

Jogging Switch

position (JOG) changes the pump from

manual cycling

. This allows the cylinders

Manual Cylinder

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

rightmost

position jogs Cylinder “A” and the

position jogs Cylinder “B”.

decreases the number of strokes per minute of the pump.

the internal pressure of the Accumulator tank. Normal internal pressure should read approximately 1750 PSI during pumping.

system pressure while pumping material. The maximum pressure rating is 4400 PSI ± 50.

PAGE 20 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — DIGITAL READOUT SCREEN

PRIMARY SCREEN

Screen 5

Displays the ON/OFF electrical signal status of the various

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.

12 volt solenoids (Swing A circuit, Main A circuit, Main B circuit).

INDICATES

SWING A CIRCUIT IS OFF

Indicates electrical malfunction - Refer to Troubleshooting section.

INDICATES STATUS OF PUMP ( ON OR OFF)

INDICATES BATTERY CHARGE

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW OIL PSI

SECONDARY SCREENS

INDICATES ENGINE RPM

INDICATES ELECTRIC MALFUNCTION

INDICATES

MAIN B CIRCUIT IS OFF

Screen 6

Displays the ON/OFF electrical signal status for the Proximity Switch A, Proximity Switch B, Engine Fuel Solenoid, and Unloader Solenoid.

INDICATES

PROXIMITY A CIRCUIT IS OFF

Screen 2

Displays the position of the VOLUME CONTROL switch by indicating whether the increase or decrease position is on or off.

INDICATES VOLUME SWITCH IS NOT IN

THE - POSITION

FLOW DEC OFF FLOW INC ON

INDICATES VOLUME SWITCH IS IN THE + POSITION

INDICATES UNLOADER 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 THROTTLE IS ON

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 PUMP HAS BEEN USED

INDICATES NO. OF FAULTS DETECTED

INDICATES NO. OF HOURS ENGINE HAS BEEN USED

MESSAGE OR INSTRUCTION

E HRS: 00000.0 PMP HRS: 00000.0 FAULTS: 00000000 RESET TO CLEAR

Screen 4

Displays the number of strokes the main hydraulic cylinders have gone through. This indicator can be reset to zero by the RESET switch on the control panel.

INDICATES THE NO. OF YARDS PER HOUR

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.

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,

INDICATES A RUNNING COUNT OF NO. OF STROKES

STROKE CTR: 0000

PRESS RESET TO ZERO STROKE CTR

MESSAGE OR INFORMATION

use the reset switch on the control panel.

IINSTRUCTION OR MESSAGE

SWING A OFF

MAIN A OFF MAIN B OFF

PROX A OFF PROX B ON FUEL SOL OFF UNLOADER OFF

THROTTLE ON STROKES: 20 STROKES/MIN 8.2 YDS/HR 10.7

TO TEST FUEL SOL PRESS RESET FUEL SOL OFF

RADIO ADDRESS COMMUNICATING PRESS RESET TO LEARN A NEW ONE

INDICATES

MAIN A CIRCUIT IS OFF

INDICATES PROXIMITY B CIRCUIT IS ON

INDICATES

FUEL SOLENOID CIRCUIT IS OFF

INDICATES THE NUMBER OF STROKES

INDICATES THE NO. OF STROKES PER MINUTE

INSTRUCTION

OR MESSAGE

INDICATES THAT RADIO REMOTE IS ON

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 21

LS400/LS500 PUMP — ENGINE COMPONENTS

Figure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components

INITIAL SERVICING

The engine (Figure 7) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1. Fuel Filter – Service the fuel filter as recommended in the maintenance section of this manual.

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.

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.

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.

PAGE 22 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — INSPECTION

CAUTION - GENERAL SAFETY GUIDELINES

NEVER operate the pump in a

confined area or enclosed area structure that does not provide ample

free flow of air

NEVER operate the pumps's engine

with the engine hood removed. The possibility exists of and

clothing

the V-belt, causing injury and bodily harm.

NEVER place hands or feet inside the ALWAYS make while the engine is running. ALWAYS

shut down the engine before performing any kind of maintenance service on the pump.

ALWAYS wear approved

hearing

operating the pump .

hands, long hair

becoming entangled with

protection before

eye

and

hopper

FUEL CHECK

1. 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

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.

is extremely flammable, and

See Figures 5, 6, and 7 for the location of any control or component referenced in this section.

BEFORE STARTING

1. Read safety instructions at the beginning of manual.

2. Clean the larly the engine cooling air inlet, and heat exchanger.

3. Check the 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 can be dangerous if refueling. DO NOT attempt to refuel pump if the engine is hot or running. ALWAYS allow engine to refueling.

entire pump

air filter

, removing dirt and dust, particu-

for dirt and dust. If air filter is dirty,

mishandled. DO NOT

flammable

smoke

cool

before

and

while

Figure 8. Fuel Cap Gauge

2. If fuel is low, remove fuel filler cap and fill with

diesel fuel

(Figure 9).

Figure 9. Adding Diesel Fuel

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 23

LS400/LS500 PUMP — INSPECTION

ENGINE OIL CHECK

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.

3. Pull the engine oil dipstick (Figure 11) from its holder.

HYDRAULIC OIL CHECK

1. Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass (Figure 12).

Figure 11. Engine Oil Level

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. #6 (09/19/11)

NORMAL OIL LEVEL

HYDRAULIC OIL TEMPERATURE

MINIMUM OIL LEVEL

Figure 12. Hydraulic Oil Sight Glass

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

LS400/LS500 PUMP — INSPECTION

3. Check the oil level in the

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

lubrication box

. If low, fill

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 25

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:

LS400/LS500 PUMP — SET-UP

1. Locate both the left and right rear stabilizer jacks (Figure 15).

REAR STABILIZER JACKS

Figure 17. Rear Stabilizer Stand Deployment

HYDRAULIC REAR STABILIZER JACKS (OPTIONAL)

If your pump comes equipped with hydraulic rear stablizers, they can be controlled as follows:

1. Push down the middle control lever (see Figure 18) to extend the right hydraulic rear stabilizer.

2. 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.

4. Push up the rightmost control lever (see Figure 18) to

Figure 15. Locating Rear Stabilizer Jacks

2. Remove the and then

cotter pin

pull

the handle tee to release the stabilizer

from the handle tee bolt eye,

retract the left hydraulic rear stabilizer.

jack (Figure 16).

3. Position both rear stabilizers jacks on firm (not loose)

level

ground (Figure 17).

MIDDLE CONTROL LEVER (CONTROLS RIGHT

HYDRAULIC STABILIZER)

LEFT HYDRAULIC STABILIZER JACK

4. Align the hole on the stabilizer jack with the hole on the frame body and

5. Insert the cotter pin into handle tee bolt eye to lock the

insert

handle tee bolt.

RIGHT HYDRAULIC STABILIZER JACK

stabilizer jack.

COTTER PIN

REAR STABILIZER STAND

Figure 18. Control Levers for Hydraulic Rear Stabilizers

HANDLE T-BOLT

BOLT EYE

NEVER place feet under jack while operating. ALWAYS retract rear stabilizer jacks prior to towing. ALWAYS retract rear stabilizer jacks prior to servicing to

Figure 16. Rear Stabilizer Jack

PAGE 26 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

relieve load (working pressure).

RIGHTMOST CONTROL LEVER (CONTROLS LEFT HYDRAULIC STABILIZER)

WARNING - REAR STABILIZER SAFETY

LS400/LS500 PUMP — START-UP PROCEDURE

STARTING PROCEDURE

4. Place the position (Figure 22).

WARNING - GENERAL SAFETY GUIDELINES

DO NOT attempt to operate this concrete pump until

FORWARD REVERSE

the Safety, General Information and Inspection sections have been read and understood.

Figure 22. Direction Control Switch (FORWARD)

5. To start the engine, insert the key (Figure 23) into the

1. Locate the Emergency Stop Switch (Figure 19) on the

ignition switch and turn the key to the ON position.

Hydraulic Pump Control Box. Turn the Emergency Stop switch clockwise and release (open). This will allow the engine to start.

Figure 19. Emergency Stop Switch

If the Emergency Stop switch is in the

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.

CLOSED position (stop), engine will not start. To start the engine, make sure the Emergency Stop switch is in the OPEN position (fully extended).

Direction Control Switch

to the FORWARD

Figure 23. Ignition Switch

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW OIL PSI

2. Turn the

Cylinder Stroke Control Switch

to the

AUTOMATIC position (Figure 20).

AUTOMATIC JOG

Figure 20. Cylinder Stroke

Control Switch (Automatic)

3. Place the

Pumping Control Switch

to the CENTER

OFF position (Figure 21) for normal pumping operation.

LOCAL

CENTER

OFF

REMOTE

Figure 21. Pumping Control Switch (OFF)

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW RPM FAULT

LS 400 OFF 0000 ENG RPM BATTERY 12.5 V END OF MESSAGE

Figure 24. Primary Screen (Ignition Key ON)

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.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 27

LS400/LS500 PUMP — OPERATION

HOSE LUBRICATION

Before pumping, it is necessary to lubricate the hose.

PUMPING

WARNING - SAFETY GLASSES

This procedure prevents separation and blockages in the hose. Inspect the lines at all times to prevent problems.

Before concrete is discharged into the hopper, 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.

1. Place the

PRIMING THE PUMP WITH SLURRY MIXTURE

position (Figure 26) for normal pumping operation.

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.

Safety glasses MUST be worn at all times when operating the pump. Failure to follow safety guidelines can result in

A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job.

Pumping Control Switch

LOCAL

serious

injury.

to the LOCAL

REMOTE

Failure to properly prepare the pump and system will result in a “dry pack” of concrete, blocking the shuttle valve tube or delivery line.

Figure 26. Pumping Control Switch (LOCAL)

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

2. Slide the right to increase the volume to approximately 10 strokes

per minute. Sliding the volume control to the left will

decrease

into slurry.

FORWARD

Figure 25. Direction Control Switch (REVERSE)

REVERSE

thumping

The thumping sound represents the number of strokes

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

per minute (volume) of the pump.

3. Scroll through the switch to go to Screen 7 (Figure 28). This screen will show the volume in strokes per minute.

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.

CENTER

OFF

Volume Control Switch

(Figure 27) to the

pump volume.

DECREASE

VOLUME

INCREASE

VOLUME

Figure 27. Volume Control

sound (cylinder stroke) should be heard.

Digital Readout Screen

THROTTLE ON

with the scroll

STROKES: 100 STROKES/MIN 10.0 YDS/HR 0.0

Figure 28. Strokes Per Minute Display

PAGE 28 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — OPERATION

4. 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).

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).

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 lines are

kinked

blocked

for any reason, or if the

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

move

in a manner

that could cause injury to personnel.

8. It is important that once the slurry procedure is completed, and concrete is flowing through the hose, DO NOT stop the pour until all the slurry is pumped out and the concrete has reached the end of the hose. The only time to stop the pump during the priming procedure is if a blockage occurs.

9. If 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. #6 (09/19/11) — PAGE 29

LS400/LS500 PUMP — OPERATION

REMOTE CONTROL (OPTIONAL)

The LS400/LS500 Concrete Pump has a remote control feature that allows the pump to be remotely controlled. If desired, the pump can be operated via a receiver/transmitter

4. Reinstall the control panel and tighten the 2 screws.

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.

(radio) or a hardwire method, which utilizes a 25-ft. extension cable. Contact MQ Sales Department to order remote control.

Radio Remote Control

KNOCK-OUT

Installation of the Radio Remote Control Assembly

HOLE

1. Remove the two screws on the digital control panel of the pump. See Figure 33.

REMOVE 2 SCREWS

SCR

OLL

RESET

SET

ECREA

CREASE

F L

WARD

C T

I O

REVE

RSE

TOM

LOCAL

TIC

JOG

MOT

CENT

T A

YLINDE

I G N

JOG“A”

RST

I T

I O

ROKE

JOG“B”

R E

O T E

CONTROL BOX

ANTENNA CONNECTOR CABLE

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.

6. Connect the antenna cable to the connector on the rear of the control box (Figure 36).

Radio Remote Control Buttons Operation

ANTENNA

REAR OF CONTROL BOX

CONTROL BOX CONNECTOR

Figure 36. Antenna Installation

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

WIRELESS REMOTE MODULE

CONNECTOR

Figure 35. Installing Remote Control Module

E-STOP

OFF

POWER LED

NOTE: OLDER MODELS MAYINDICATE

FLOW

INSTEAD OF

VOLUME

BATTERY LED

PUMP

ON/OFF

REV

VOLUME VOLUME

Figure 37. Radio Remote Control

PAGE 30 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — OPERATION

CABLE REMOTE CONTROL UNIT

25 FT. CABLE

PUMP REV

PUMP ON/OFF

TO CONTROL BOX CONNECTOR

Radio Remote Control Programming Before starting operation of the Radio Remote Control, go

to Screen 9 of the Digital Readout Screen:

RADIO ADDRESS NO RADIO PRESS RESET TO LEARN A NEW ONE

Cable Remote Control Operation Before using cable remote control, set the pumping volume

with the VOLUME switch on the control box then move the Pumping Control Switch on the control box to the REMOTE position.

The cable remote control (Figure 38) has the following controls.

1. Press the ON/OFF button on the radio (wireless) remote

PUMP ON/OFF - Starts and stops the forward pumping.

control to turn on the power. Hold down the RESET switch. The display will now show:

RADIO ADDRESS NOW SCANNING FOR NEW TRANSMITTER

PUMP REV - starts pumping in reverse direction.

It will be necessary at times to move your pump from

2. After 5 seconds, the display will show:

one job site location to another. Before moving the pump, make sure to pump the remaining concrete out

RADIO ADDRESS COMMUNICATING PRESS RESET TO LEARN A NEW ONE

3. The remote control is now ready for use.

of the hopper. Moving the pump with a concrete can cause the axle and axle springs, excess strain and pressure on the hub and bearing assembly.

WARNING - TRANSPORTING PUMP

full hopper

severe damage

or breakage of

Cable Remote Control

Installation of the Cable Remote Control Assembly Connect the cable to the front panel of the control box (See

Figure 38).

CABLE REMOTE CONTROL UNIT

Figure 38. Cable Remote Control

Leaking manifold seals or hose coupling gaskets which leak water can cause separation and subsequent jamming at that point.

25 FT. CABLE

TO CONTROL BOX CONNECTOR

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 31

LS400/LS500 PUMP — PUMPING INFORMATION

REMIXTURES

Remixtures that are designed into the concrete mix by the redi-mix company or an architectural engineering company. This section lists common admixtures and a brief 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 com-

mercial 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

Priming The Pump With Slurry Mixture

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.

section of this manual.

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 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 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.

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.

steel pipe

all hose

It is strongly recommended that be used on all vertical pumping for safety and convenience.

, it is recommended

steel pipe

PAGE 32 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — PUMPING INFORMATION

The use of 2 -1/2” 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 excessive pulsation exists in the hose, it is advisable to use burlap or some means of wear protection under the hose at points where the hose may wear through the outer cover; e.g. over forms, steel or sharp curbs.

SNAP-JOINT COUPLINGS

When using Snap-Joint couplings with gaskets to join hose, see that they are washed clean after each job. Keeping the hose ends clean (heavy duty) is very important for the best job setup. A thin coat of grease on the rubber gasket or dipping both coupling and gasket in water before coupling the hose will make for easier installation.

NEW PUMPS

All new pumps are ‘water pressure tested” at the factory This procedure permits a thorough inspection of entire drive system and valving under simulated full load conditions. The pump owner can 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

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 ( affecting the concrete:

A. How old is the concrete?

B. Is there an accelerator, calcium chloride, red label,

C. The temperature of the day, 80, 90, degrees?

D. How much system you have out and how stiff was

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 much water into the hopper, as this could cause separation of the concrete in the hopper.

2. If the 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.

etc., in the concrete?

the mix you were pumping?

redi-mix

shutdown

period exceeds 2 to 3 minutes, turn off

A through D

driver wash too

)

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 33

LS400/LS500 PUMP — PUMPING INFORMATION

Using this procedure will make it easier to pump through the clean hose. Note: Once the concrete has reached the end of the hose, do not apply any more water in this manner as this procedure is used for starting only.

6. Hose sizing is very important: We strongly recommend 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 pump will not damage the bearing.

bearing

on your Mayco

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

If you repeatedly pull the throttle all the way out and try to force your pump to push through 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, the point of trouble. The hose will be soft immediately past the blockage. To clear the blockage:

WARNING - BLOCKAGES

walk the hose

blockages

until you find

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 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.

pressure

Damaged hoses with internal restrictions can cause blockages.

PAGE 34 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — PUMPING INFORMATION

CLEARING SHUTTLE TUBE BLOCKAGE

The shuttle tube is plugged if volume at the discharge end of the hose stops and the hydraulic oil pressure gauge reads 4400 PSI or more.

To clear a plug in the shuttle tube, great care must be taken as a dangerous condition will exist from pressure build-up inside the shuttle tube. (With the shuttle valve, the concrete can be pumped in reverse.) Use the following procedures to clear the shuttle tubes.

WARNING - SHUTTLE TUBES

DO NOT open any of the delivery system joint clamps.

“REVERSE” PUMPING PROCEDURE

A. Switch the pump into REVERSE. With pump speed

at a medium-slow (approx. 12 strokes per min.) try to pull the “pack” back into the hopper with 5 or 6 reverse strokes.

B. Remix the concrete in the hopper.

E. Chip the concrete out of the reducer with the pry

F. Remove the reducer. From the discharge end, chip

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

bar.

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.

“Reverse” Pumping Procedure to relieve pressure on the shuttle tubes.

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. You must follow lock out-tag out procedures.

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 slip the end of a pry bar (24" length of reinforcing steel rod) under the latch of the hose clamp and flip it up.

safety glasses

D. Carefully knock the end of the hose away from the

reducer.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 35

LS400/LS500 PUMP — MAINTENANCE (PUMP)

TABLE 5. MAINTENANCE CHECK SCHEDULE

Hour-lyWee-

Daily

Engine Oil X X

Engine Air Filter X

Fuel Filter X

Hydraulic Oil Level X 500 hrs.

Lubrication Box X

Replace Hydraulic Oil 1000 hrs.

Clean Hydraulic Filters X 500 hrs.

Axle Crank X 2 hrs

Grease Shuttle Tube and Hopper Outle t Zerk Points

Check System Pressure X 40 hrs.

Check Hardware for Tightness X 40 hrs.

Check Cutting Ware Ring and Plate 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 X

Visually Check for Oil Leaks X

Month-ly6-Mont-hsOperational

kly

Hours

2 hrs

DANGER - AMPUTATION RISK

CLEANING THE PUMP AND DELIVERY SYSTEM

Cleaning the pump is a very important operation as it

During routine maintenance or removing material blockage, you will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at

EXTREME RISK

of injury or

AMPUTATION

if the engine is running or if pressure is in the hydraulic system.

Prior to performing any maintenance on the pump,

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

follow described lock out-tag out procedures. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The

2. Pump concrete until the opening of the concrete cylinder

pressure reading on the accumulator pressure gauge

MUST

read

3. Stop the pump.

4. Carefully disconnect the first hose joint at the shuttle

ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump.

procedure, ensure that there is no blockage in the hose and line or in the shuttle tube. If a blockage exists, clear it.

intake in the hopper is visible.

tube discharge elbow.

PAGE 36 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — MAINTENANCE (PUMP)

5. Add water to the hopper. Pump and flush clean the entire hopper, shuttle tube and discharge elbow with water.

6. Scoop out 12 inches of concrete from the inboard end of the delivery hose. “Cork screw” a 6" x 6" x 8" sponge into the end of the first hose section. Reconnect the hose to the discharge elbow.

7. 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 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.

WARNING - ACID CLEANING

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 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. When changing the hydraulic oil or topping off the reservoir, use only the following type. (Reservoir capacity - 50 gal.)

under 50°F

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.

Hydraulic oil: Shell Oil Tellius 68 or

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

Mobil DFE 26 Texaco Rand HDC

Texaco Multitak 20 Lubriplate ED-2

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 37

LS400/LS500 PUMP — MAINTENANCE (PUMP)

BATTERY MAINTENANCE

CAUTION - BATTERY MAINTENANCE SAFETY

Wear 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:



safety glasses

Be careful not to let the battery electrolyte come in contact with your body or clothing.

Always wear 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.

eye protection

face mask

and

rubber gloves

, since

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. #6 (09/19/11)

LS400/LS500 PUMP — MAINTENANCE (PUMP)

CYLINDER LUBRICATION BOX

ACCUMULATOR CIRCUIT

WARNING - FREEZING CONDITIONS

When using the pump during freezing conditions, completely drain the water box and cover the hopper after pumping. Frozen liquid will restrict the piston travel and cause

severe damage

to the pump.

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

CAUTION - SAFETY GUIDELINES

charge the accumulator. Contact your Mayco

Before checking lubrication level, follow lock out-tag out procedures. Stop the engine and remove the engine starter key.

service department or your local Hydac representative for proper charging procedure.

1. The lubrication level should be checked everyday prior

The accumulator circuit has two functions in the hydraulic system.

to pumping and maintained at a height of 5 inches or

■

about ½ the concrete cylinder height. We recommend using a 30-weight motor oil.

2. As the rubber piston cups naturally wear, fine cement

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.

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

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

of the box.

DANGER - ACCUMULATOR CHARGING

dry nitrogen

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).

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.

4. When the box is clean replace drain plug, add new lubrication and install the top cover.

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

pressure gauge

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

Figure 40. Cleaning the Lubrication Box

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 39

or bladder replacement.

accumulator

(Figure 30) should read 1750 PSI.

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

2. Concrete slurry squirting into the air from the hopper (Volcano effect)

3. When the output volume at the end of the delivery line decreases in pressure

4. Unusual frequent material packs in the Shuttle tube

6+877/(78%(

,16,'(+233(5

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.

58%%(5

(1(5*,=(5

&877,1*

5,1*

:($5

3/$7(

*22'6($/ /($.,1*

Figure A. Wear Plate and Cutting Ring

PAGE 40 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — MAINTENANCE (PUMP)

CHANGING THE CONCRETE CYLINDER PISTON CUPS

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

■

The fluid level and cleanliness of the lubrication box.

■

The size and type of aggregate.

■

The type of concrete being pumped.

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

DANGER - AMPUTATION RISK

During routine maintenance or removing material blockage, you will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at

EXTREME RISK

engine is running or if pressure is in the hydraulic system.

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.

MUST

of injury or

read

AMPUTATION

if the

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

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

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

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

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

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

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

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.

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

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

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

LS400/LS500 PUMP — MAINTENANCE (PUMP)

CHANGING THE WEAR PLATE AND RING

Due to the swinging motion of the Nun-plate and the abrasive nature of concrete, it is normal for the cutting ring to wear on the side that shears through the concrete inside the hopper. If the wear ring and wear plate do not fully seat against each other the concrete slurry will pump into the hopper. This condition can be easily observed by the sudden change of the level of concrete inside the hopper during each stroke.

Wear Plate and Ring Replacement Procedure

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

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

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

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

5. Remove the four 1/2” 1-¼” bolts that hold the shuttle tube to the nun-plate and remove shuttle tube.

Using two small pry bars remove the rubber energizer ring, steel insert ring and wear ring.

Wear Plate Installation

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 Ring installation

1. Install the wear ring into the nun plate.

2. Install the steel insert ring inside of the rubber energizer ring.

3. Install the energizer ring assembly into the nun-plate.

After installing the above mentioned components the machine can be reassembled by reversing steps 1 through 5 of the Wear Plate and Ring Replacement Procedure.

HEAT EXCHANGER COOLING FAN

This section is intended to make sure the fan is working properly. Under normal conditions the fan should be running any time the engine is turned on.

CAUTION - HYDRAULIC OIL TEMPERATURE

If the hydraulic oil temperature exceeds 170 degrees

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.

Fahrenheit, shut down the pump. DO NOT continue to operate the pump. Failure to shut down the pump will result in severe damage to the pump.

PAGE 42 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — MAINTENANCE (PUMP)

WHEEL BEARINGS

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. 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.

3. Back off the adjusting nut 1/6 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.

to 1/4 turn or to the nearest

PRESSURE TEST

1. To determine the pressure of the Hydraulic System, set

Cylinder Stroke Control Switch

the

JOG position.

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.

Figure 43. Manual Cylinder Jogging Switch

(Figure 42) to the

EXTENDED STORAGE INSTRUCTIONS

The following preventative maintenance is recommended for extended periods of storage.

1. Check brake system for proper fluid level in master cylinder and bleed all lines.

2. Lubricate all links and pivots to prevent any rusting.

3. Remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC formula 5-56) under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and brake lining.

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.

13. The Pumping Pressure Gauge (Figure 44) should read approximately 4400 ± 50 PSI.

Figure 44. Pumping Pressure Gauge

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 43

LS400/LS500 PUMP — MAINTENANCE (TRAILER)

The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance.

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

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

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.

vehicle. The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle, but no less than once per year. This inspection includes an assessment of the condition and proper operation of the wheel cylinders, brake shoes, brake drums and hubs.

Manually Adjusting the Brakes

Most axles are fitted with a brake mechanism that will adjust the brakes during a hard stop. However, some braking systems are not automatically adjusted by hard stopping. These brakes require manual adjustment. The following steps apply to adjust most manually adjustable brakes.

1. Jack up the trailer and secure it on adequate capacity jack stands.

2. Be sure the wheel and brake drum rotate freely.

3. Remove the adjusting-hole cover from the adjusting slot on the bottom of the brake backing plate.

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.

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.

PAGE 44 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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.

HYDRAULIC

BRAKE FLUID

RESERVOIR

Figure 46. Trailer Actuator

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

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!

necessary adjustment or repairs.



Replace bearings that have flat spots on rollers, broken roller cages, rust or pitting. Always replace bearings

Adjustable Channel

Your trailer may be equipped with an adjustable channel

and cups in sets. The inner and outer bearings are to be replaced at the same time.

(Figure 47) that allows the coupler to be raised or lowered to



a desired height. Periodically check the channel bolts for damage or loosening.

Replace seals that have nicks, tears or wear.



Lubricate the bearings with a high quality EP-2 automotive wheel bearing grease.

BEARING

OIL

SEAL

CONE

BEARING

CUP

WHEEL

HUB

COTTER

Figure 47. Adjustable Channel

With Pintle Eye Coupler

Wheel Hub Adjustment

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

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).

inspect the bearings for wear and damage.

LUG NUT

SPINDLE

WASHER

CASTLE

NUT

Figure 48. Wheel Hub Components

DUST

CAP

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

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.

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

MOUNTING

BRACKET

SPINDLE

TORSION

ARM

TORSION

BAR

NYLOC NUT

GRADE C

AXLE TUBE

5/8”-18

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.

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

welds repaired by your dealer.

perform the repair. If not, have the

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.

Danger - Worn or Defective Suspension

Worn or broken suspension parts can cause loss of control, damage to equipment and severe bodily injury even

death!

Check suspension regularly.

PAGE 46 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

■

TRAILER SAFETY INFORMATION

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.

Common Causes for Loss of Trailer

■

Driving too fast for the conditions (maximum speed when towing a trailer is 55 m.p.h.).

■

Overloading the trailer or loading the trailer unevenly

■

Trailer improperly coupled to the hitch

■

No braking on trailer

■

Not maintaining proper tire pressure

■

Not keeping lug nuts tight

■

Not properly maintaining the trailer structure.

■

Ensure machine is towed level to tow vehicle.

Trailer Towing Guidelines

■

Recheck the load tiedowns to make sure the load will not shift during towing.

■

Before towing, check coupling, safety chain, safety brake, tires, wheels and lights.

■

Check the lug nuts or bolts for tightness.

■

Check coupler tightness after towing 50 miles.

■

Use your mirrors to verify that you have room to change lanes or pull into traffic.

ALWAYS use lower gears for climbing and descending grades.

■

DO NOT ride the brakes while descending grades, they may get so hot that they stop working. Then you will potentially have a runaway tow vehicle and trailer.

■

To conserve fuel, don’t use full throttle to climb a hill. Instead, build speed on the approach.

■

Slow down for bumps in the road. Take your foot off the brake when crossing the bump.

■

DO NOT brake while in a curve unless absolutely necessary. Instead, slow down before you enter the curve and power through the curve. This way, the towing vehicle remains in charge.

■

DO NOT apply the brakes to correct extreme trailer swaying. Continued pulling of the trailer, and even slight acceleration, will provide a stabilizing force.

■

Anticipate the trailer “swaying.” Swaying is the trailer reaction to the air pressure wave caused by passing trucks and buses. Continued pulling of the trailer provides a stabilizing force to correct swaying. DO NOT apply the brakes to correct trailer swaying.

■

Use lower gear when driving down steep or long grades. Use the engine and transmission as a brake. Do not ride the brakes, as they can overheat and become ineffective.

■

Be aware of your trailer height, especially when approaching roofed areas and around trees.

■

Make regular stops, about once each hour. Confirm that:

A. Coupler is secure to the hitch and is locked.

■

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.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 47

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.

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

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

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

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

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 se-

DANGER - Hitch/Tow Vehicle Load Rating

lected and matched to the Gross Vehicle Weight Rating (GVWR) of your trailer, you can cause an accident that could lead to death or serious injury.

If you already have a tow vehicle, know your vehicle tow rating and make certain the 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

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.

to or greater than that of the trailer.

The trailer VIN tag contains the critical safety information for the use of your trailer. Again, be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer.

PAGE 48 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

Reporting Safety Defects

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying us.

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.)

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.

It takes longer to get up to speed, you need more room to turn and pass, and more distance to stop when towing a trailer. You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer.

Because of the significant differences in all aspects of 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.

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.

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. #6 (09/19/11) — 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.

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.

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.

SAFETY WARNING LABELS ON YOUR TRAILER

PSIC: The tire pressure (Pounds per Square Inch)

measured when Cold.

VIN: The Vehicle Identification Number.

EMPTY WEIGHT: Some information that comes with the

trailer (such as the Manufacturer’s Statement of Origin) is not a reliable source for “empty” or “net” weight. The shipping documents list average or standard weights and your trailer may be equipped with options.

To determine the “empty” or “net” weight of your trailer, weigh it on an axle scale. To find the weight of the trailer using an axle scale, you must know the axle weights of your tow vehicle without the trailer coupled. Some of the trailer weight will be transferred from the trailer to the tow vehicle axles, and an axle scale weighs all axles, including the tow vehicle axles.

Figure 50. Vehicle VIN Tag

The trailer VIN Tag contains the following critical safety information for the use of your trailer. GAWR: The maximum gross weight that an axle can support. It is the lowest of axle, wheel, or tire rating. Usually, the tire or wheel rating is lower than the axle rating, and determines GAWR.

GVWR: The maximum allowable gross weight of the 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.

Figure 51. VIN Tag Location

PAGE 50 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

Tow Vehicle

The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow. The hitch capacity must also be matched to the tow vehicle capacity. Your vehicle dealer can provide and install the proper hitch on your tow vehicle.

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.

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.

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

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

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.

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.

Jackstand

A device on the trailer that is used to raise and lower the coupler. The jack is sometimes called the “landing gear” or

Heavy Duty Flasher

the “tongue jack”.

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.

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. #6 (09/19/11) — PAGE 51

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

Coupler Types

The trailer is shipped from the factory with a 2-inch ball coupler.

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.

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.

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

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.

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.

PAGE 52 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

2-INCH

TRAILER

COUPLER

2-INCH

BALL

TOW

VEHICLE

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.

Before coupling trailer, inspect the hitch ball for wear, corrosion and cracks.

Replace worn or damaged hitch ball.

WARNING - Uncoupled Hitch Ball

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.



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.

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.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 53



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.

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

Attaching Safety Chain

TOW

VEHICLE

TRAILER

TONGUE

IMPORTANT!

SAFETY CHAIN

MASTER LINK

Figure 54. Safety Chain Arrangement

for a Bumper Pull Trailer (Ball Hitch)



Visually inspect the safety chains and hooks for wear or damage. Replace worn or damaged safety chains and hooks before towing.



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

enough slack to permit turning and to hold tongue up, if the trailer comes loose.

CROSS BOTH

SAFETY CHAINS

hitch and coupler with

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

Hydraulic Actuator

Breakaway Lever

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. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

Connecting Trailer Lights

TIRE SAFETY

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).

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

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.

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

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.

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.



Disconnect the breakaway brake switch cable. Promptly replace the pullpin in the switchbox.

The proper tightness (torque) for lug nuts is listed in the lug nut tightening section of this manual. Use a torque wrench



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

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. will slowly extend the jack and transfer the weight of the trailer tongue to the jack.

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. #6 (09/19/11) — 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.

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.

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.

WARNING - Improper Lug Nut Torque

Improper lug nut torque can cause a wheel parting from the trailer, leading to death or serious injury.

Be sure lug nuts are tight before each tow.

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.

The weight of cargo should never exceed XXX kg. Or XXX lbs

TIRE

FRONT

REAR

SPARE

TIRE AND LOADING INFORMATION

SIZE COLD TIRE PRESSURE

SEE OWNER’S

MANUAL FOR

ADDITIONAL

INFORMATION

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.

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. #6 (09/19/11)

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.

Determining Load Limit of Tow Vehicle

Step 1.

Locate the statement, “The combined weight of occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard.

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 equals 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.).

Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards and inspecting tires for cuts, slashes and other irregularities are the most important things you can do to avoid tire failure, such as tread separation or blowout and flat tires. These actions, along with other care and maintenance activities, can also:



Improve vehicle handling



Help protect you and others from avoidable breakdowns and accidents.



Improve fuel economy



Increase the tire life

Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure.

Tire Fundamentals

Federal law requires tire manufacturers to place 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. #6 (09/19/11) — 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.

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,

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.

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.

M+S: The “M+S” or “M/S” indicates that the tire

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.

Maximum Load Rating: This number indicates the maximum load in kilograms and pounds that can be carried by the tire.

Maximum Permissible Inflation Pressure: This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions.

Uniform Tire Quality Grading Standards (UTQGS)

has some mud and snow capability. Most radial tires have these markings; hence, they have some mud and snow capability.

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

Speed Rating: The speed rating denotes the speed at which

400 should last twice as long as a tire graded 200.

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.

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”.

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Qhpm99

Rhpm601

Shpm211

Thpm811

Uhpm421

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Vhpm941

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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. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

WEAR PATTERN SOLUTION

CAUSE

Center Wear

Over Inflation

Adjust pressure to particular load per tire manufacturer.

Edge Wear Under Inflation

Make sure load does not exceed axle rating. Align wheels.

Side Wear

Adjust pressure to particular load per tire manufacturer.

Loss of chamber or overloading.

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.

TABLE 7 TIRE WEAR TROUBLESHOOTING

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

rim to be properly inspected before being plugged and patched.

Figure 58. UTQGS Tire Information

Replacing Worn or Damaged Tires

Replace the tire before towing the trailer if the tire treads

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 informa-

tion indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehicle).

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.

. Tires must be removed from the

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.



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. #6 (09/19/11) — PAGE 59

LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES

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WARNING - Flying Objects

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel

ALWAYS

removing or installing force fitted parts DO NOT attempt to repair or modify a

wear safety glasses when

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:

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.

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.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.

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.

PAGE 60 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

Figure 59. Wheel Lug Nuts Tightening Sequence

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.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 61

WARNING - Trailer Lights

Improper operating taillights, stoplights and turn signals can cause collisions.

Check all lights before each tow.

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

During routine maintenance or removing material blockage, you will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at

EXTREME RISK

of injury or

AMPUTATION

if the

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. engine is running or if pressure is in the hydraulic system.

MUST

read ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump.

WARNING - HYDRAULIC SYSTEM HAZARD

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PAGE 62 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TROUBLESHOOTING (PUMP)

TABLE 9. PUMP TROUBLESHOOTING (CONTINUED)

Problem Possible Problem To Troubleshoot

Shuttle Cylinder does not stroke

Shuttle Cylinder slow to complete stroke

Incorrect Accumulator System Pressure

Contaminated Relief Valve

Swing Solenoid not energizing

Swing Valve not functioning properly

Improper Flow Control setting Fully open Flow Control Valve

Incorrect Engine RPM setting

Incorrect Main Hydraulic System Operating Pressure

Contaminated Swing Relief Cartridge

Low Accumulator System Pressure

Hopper Discharge Nipple Seal improperly lubricated

Check the system pressure reading. Verify it is approx. 1750 PSI

Check the manifold for a contaminated Relief Valve

Check for burned out solenoid and 12V signal voltage

Manually cycle the pump using the manual cylinder jogging switch

Verify the engine’s high RPM speed is set to 2550

Check the pump pressure gauge. Verify it is approx. 4400 PSI

Check the manifold for contaminated Swing Relief Cartridge

Check the accumulator pressure reading. Verify it is approx. 1750 PSI

Check the Hopper Discharge Nipple Seal for seizing and lack of lubricant

Pump Engine will idle but not increase to full operating speed

Battery voltage falls below 12VDC on digital display, causing engine not to start

Misaligned hopper creating excessive friction on the outlet nipple bearing sleeve

Lack of lubrication Grease Nun Plate Bushing

Throttle Control Block Solenoid not energizing

Blown out fuse Check the fuse

Dead battery Check the charge on the battery

Wiring connection inside Control Box

Realign hopper ensuring S-tube is rotating in the center of the hopper outlet.

Check for burned out solenoid and 12V signal voltage

Check the wiring connections and verify power is reaching ignition switch

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 63

LS400/LS500 PUMP — TROUBLESHOOTING (PUMP)

TABLE 9. PUMP TROUBLESHOOTING (CONTINUED)

Problem Possible Problem To Troubleshoot

Main Hydraulic Pump Noisy

Engine bogs down

Machine does not deliver volume and pressure

Insufﬁcient oil

Air in system

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 overloaded when pumping

Low engine speed Check engine RPM

Volume control set to low Adjust control to full open setting

Main hydraulic pressure too low

Cooling fan

Check oil level and for closed suction strainer

Check for aeration reservoir

Vacuum leak in suction line

Decrease volume control on main pump

Material hose pack

Check for proper pressure or for contaminated relief cartridge

Check fan electrical connection or for burnt fan motor.

Fan rotating in wrong direction

Hydraulic ﬂuid gets hot

Accumulator gauge reads below 1750 PSI

Concrete slurry in lubrication box

Material cylinder piston cups squeel Low on lubrication Check oil level

Cylinders not completely extended (short stroke)

Contaminated cooler ﬁns Clean cooler ﬁns

Return ﬁlter element closed Replace ﬁlter

Main relief cartridge contaminated or 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

Defective unloader cartridge electrical coil

Unloader cartridge coil not energizing Check for 12 Volt signal voltage

Defective gear pump Replace pump

Worn or defective urethane cups or worn material cylinder

Excessive amount of hydraulic on cylinder rod side

Hydraulic cylinder piston head seal leaking

Replace or set to proper pressure

Replace

Inspect cylinder. Check values for contamination or faulty spring

Replace seals

PAGE 64 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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.

GNITOOHSELBUORTENIGNE.01ELBAT

MOTPMYSMELBORPELBISSOPNOITULOS

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ytpmeknatleuF.retlifleufecalpeR

deggolcretlifleuF.retlifleufecalpeR

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dekcolbretlifriA .retlifriaecalperronaelC

secnaraelcevlavtcerrocnI .noitacificepsenignerepsevlavtsujdA

rotcejnitanoitcnuflaM.launamenigneeeS

nevyletauqedasiknattahterusnE

amenigneeeS

.noitcaevitcerrocroflaun

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

GNITOOHSELBUORTMETSYSEKARB.11ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

gniraebleehwdetaehrevO .esaerghtiwkcapdnagniraebleehwecalpeR

diulfekarbwoL .metsysekarbdeelbdnalliF

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esioneohsekarB .yrassecenfiecalperroseohstsujdA.smurdtcepsnI

rednilycleehwgnikaeL .metsysekarbdeelbdnarednilycleehwecalperdnakcehC

leveldiulfekarbwoL .metsysekarbdeelbdnadiulfekarbdevorppatodhtiwlliF

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dehcnipgniebenilekarB .enilekarbecalpeR

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gnirpselbactsniagastserrosehcuotdaebrotacidnilitnuelbacnopu

.gardtneverpdnasekarbemarfehtesaelerylluflliwsihT.pots

PAGE 66 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)

Refer to Figure 61 for the location of components for troubleshooting.

NOITCNUFLAM

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(

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DETROHSANIAM

NEPOBNIAM

DETROHSBNIAM

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NEPOGNIWS

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.dnuorg

DETROHSGNIWS

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MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 67

dluohstI.ecnatsiserliocdioneloserusaeM

.dionelostnrubecalpeR.smho6daer

dluohstI.ecnatsiserliocdioneloserusaeM

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LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)

)deunitnoc(GNITOOHSELBUORTLACIRTCELE.21ELBAT

NOITCNUFLAM

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(

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DIONELOSELTTORHT

DETROHS

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DIONELOSLEUF

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DIONELOSREDAOLNU

DETROHS

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EGAKAERBTLEB-V

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.dionelosdetrohsecalpeR.smho6daer

PAGE 68 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL)

O N

IGNITION

REMOTE

C EN

TER

STA

R T

MAIN “A”

SOLENOID

MAIN “B”

SOLENOID

SWING

SOLENOID

UNLOADER

SOLENOID

PROXIMITY

SC R OL

R ES

S E

DEC

I NCRE

A S E

I O N

E V E

R S E

ATI

O N

REM

OTE

E NT

E O

A R

LIN

I G

“A”

J OG

“

B”

R E

M O

T E

SWITCH “B”

ALTERNATOR

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. #6 (09/19/11) — PAGE 69

12 AWG RED (+12VDC)

DIGITAL READOUT

E-STOP

34 56 78

E-STOP

EMERGENCY

STOP

SWITCH

LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)

GND

1 2 3

MODULE

15/54

+12VDC IN

+12VDC OUT

34 56 78

+12VDC OUTPUT

50A

4 5

J2J3

FUEL SOLONOID

YELLOW

WHITE

10 AWG RED

12 AWG RED

CONTROL

BOX REAR

VIEW

8765 4321

INSIDE

CONTROL

J1 MALE

BOX

INTERFACE

CONNECTOR

(YELLOW)

P1 P1

YELLOW WHITE

YELLOW

WHITE

YELLOW

8765 4321

OUTSIDE

CONTROL

1 2 3 4 5 6 7 8

OUTSIDE

INSIDE

CONTROL

BOX

FUSE

HOLDER

30 AMP

FUSE

BOX

12 AWG RED

10 AWG BLK

14 AWG PINK/BLK (STARTER SOLENOID)

16 AWG GREEN

16 AWG YELLOW

16 AWG ORANGE

14 AWG RED

14 AWG BLACK (GND.)

SOLENOID

10 AWG RED

STARTER

BATTERY

ALTERNATOR

FUEL SOLENOID

(SHUT-DOWN)

OIL PRESSURE

SWITCH

BRN

+12VDC POWER OUT

RED

FUEL SOLENOID

(SHUT-DOWN)

CONTROLLER

BLACK

POTTED

IGNITION

SWITCH

+12VDC POWER IN

ENGINE CRANK

LOW BATTERY

TACH INPUT

LOW OIL INPUT

SWING A

CYL A

CYL B

THROTTLE

GROUND

BOX

BLK

RED

GRN

WHT/BLK

BLK

GND

CIRCUIT ACTIVE = +12VDC

CIRCUIT OFF = GND

ENGINE SPEED

SOLENOID

MAIN A

SWING A

J2 MALE

INTERFACE

CONNECTOR

(WHITE)

1 2 3 4 5 6 7

INSIDE

CONTROL

BOX

OUTSIDE

CONTROL

BOX

4 3

2 1

8 7 6 5

14 AWG RED

14 AWG BRN

14 AWG RED

14 AWG GRAY

14 AWG RED

14 AWG YEL

14 AWG RED

14 AWG WHITE

MAIN B

DEUTZ 10-PIN

ENGINE

CONNECTOR

THROTTLE

BLOCK

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. #6 (09/19/11)

LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)

IGN

ITION

REMOTE

C E

NTE R

OFF

START

S C R

O L L

R E S E

S E T

I N C R

E A S

I O N

E V E R

S E

A I C

E N

Y L

N D

“A”

R O

K E

O G “B

”

R E M

O T

Figure 62. Connections to Digital Control Box - J1 and J2 Connectors ( 2 of 2)

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 71

IGNITION

SWITCH

CONTROL

BOX REAR

VIEW

J1 J2 J3 J4 J5

15/54

LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)

50A

YELLOW WHITE YELLOW WHITE YELLOW

YELLOW

WHITE

8765 4321

INSIDE

CONTROL

P3 P3

BOX

J3 MALE

INTERFACE

CONNECTOR

(YELLOW)

1 2 3 4 5 6 7 8

INSIDE

CONTROL

BOX

ENG SOL POWER 35A 1 SEC

OVER TEMP

PROX A

NOT USED

ORANGE

BLUE

12VDC

BLUE

PROX B

PROX C

PROX D

POWER

GROUND

AUTO LUBE

FLOW A 12VDC

FLOW B 12VDC

BROKEN FAN BELT

UNLOADER

P4 P4

1 2 3 4 5 6 7 8

INSIDE

CONTROL

BOX

J4 MALE

INTERFACE

CONNECTOR

(WHITE)

8765 4321

OUTSIDE CONTROL

OUTSIDE

CONTROL

BOX

CONTROLLER

OUTSIDE

CONTROL

BOX

NOT USED

SIGNAL

NOT USED

+12 VDC

GND.

BLACK

POTTED

BOX

2 1

8 7

16 AWG RED 12VDC

16 AWG BLACK

ACCUMULATOR

DUMP VALVE

“UNLOADER”

16 AWG WHITE

16 AWG BLUE

16 AWG BROWN

16 AWG GREEN

16 AWG BLUE

16 AWG BROWN

BROWN

BLUE

HEAT EXCHANGER

“COOLING FAN”

FLOW CONTROL

+12 VDC

14 AWG RED

+12

V-BELT BREAK

SWITCH

NOTE:

WHEN MEASURING VOLTAGE AT CONNECTOR P4 PINS 2 AND 3.

PLACE NEGATIVE LEAD OF

VOLTMETER TO FLOW CONTROL BODY (GROUND).

GND.

14 AWG BLACK

PROXIMITY

SWITCH “B”

INDICATOR “RED”ACTIVE

BETWEEN GND. 800 mV

PROXIMITY

SWITCH “A”

BLACK

CONNECTIONS TO J3 AND J4 CONNECTORS ON

DIGITAL CONTROL BOX (LS400 AND LS500)

Figure 63. Connections to Digital Control Box - J3 and J4 Connectors ( 1 of 2)

PAGE 72 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX)

IGNITION

REMOTE

CEN

TE R

START

S C R O

L L

E S E T

S E T

N C R E

A S E

F L

I O

R E

V E R S

A I C

O N

E N

E O

R F

Y L

“A

R O

”

K E

J O G

“B

”

R E

M O

T E

Figure 63. Connections to Digital Control Box - J3 and J4 Connectors ( 2 of 2)

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 73

LS400/LS500 PUMP — WIRING DIAGRAM (HOPPER VIBRATOR)

Figure 65. Optional Hopper Vibrator Wiring Diagram

PAGE 74 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — HYDRAULIC SYSTEM DIAGRAM

ACC

ACCUMULATOR

GAUGE

STA-1

MANIFOLD

1750 PSI

STA-2

ABB

RELIEF

1000 PSI

OPTIONAL AGITATOR AND

HYDRAULIC OUTRIGGERS

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 75

1000 PSI

7CC 14CC

MAIN

PRESSURE

GAUGE

RELIEF

4400 PSI

OUT

Figure 66. Hydraulic System Diagram

LS400/LS500 PUMP — MANIFOLD BLOCK PORTS

CCAknaTrotalumuccAottcennoC

1ArednilyCelttuhSottcennoC

2ArednilyCciluardyHottcennoC

1BrednilyCelttuhSottcenn

2BrednilyCciluardyHottcennoC

AGeguaGrotalumuccAottcennoC

1PpmuP.dyHyradnoceSottcennoC

2PevlaVlortnoCwolFot

1TknaTciluardyHottcennoC

2TregnahcxEtaeHottcennoC

3TregnahcxEtaeHfeileR,knaTottcennoC

tcennoC

STROPKCOLBDLOFINAM

Figure 67. Manifold Block Ports

PAGE 76 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

APPENDIX — CONCRETE MIX INFORMATION

The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to help create a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete mixes. These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock ratio can be adjusted (65% sand 35% rock) and pumpability should be excellent.

EXAMPLE #1 (A California Test Lab. Report) JOB: Building Foundations (Water Project) Sacks per cu./yd. 6.5 designed for 2,500 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 ABS. VOL. W.C. Sand 65 1800 2.58 11.56 PEA GRAVEL 35 1000 2.60 6.22 WATER 46 gal. 1 CEMENT 6.5 sk. 611 TOTAL 27.00 ADMIXTURE: None SLUMP 4” REMARKS This mix designed for pumping NOTE: Due to the availability of well-graded sand as shown in the above sieve analysis,

this mix pumped very successfully.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 77

APPENDIX — CONCRETE MIX INFORMATION

A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE

PAGE 78 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

APPENDIX — SLUMP TEST PROCEDURE

1. To obtain a representative sample (concrete), take

5. Fill cone to overflowing 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.

6. Remove the excess concrete

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

(Removing Excess Concrete)

the sample.

BULLET POINTED

STEEL ROD

(Figure68-C). Rod this layer 25 times with rod penetrating into but not through, the second layer. Distribute rodding evenly over the entire cross section of this layer.

Figure 68-C. Slump Test

(Full-Overflow)

(Figure 68-D) from the top of the cone, using the tamping rod as a screed.

Figure 68-D. Slump Test

FULL

(OVERFLOW)

7. Lift the cone vertically (Figure 68-E) with a slow even motion. DO NOT jar the con- crete or tilt the cone during this

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

process. ( Invert the withdrawn cone, and place it next to, but not touching the slumped concrete.

Figure 68-E. Slump Test

with the rod penetrating into, but not through, the first layer. Distribute rodding evenly over the entire cross section of the layer.

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

2/3 FULL

time of 1-½ minutes. Discard the concrete. DO NOT use it in another tests.

Figure 68-B. Slump Test (2/3 Full)

(Cone Invert)

Figure 68-F. Slump Test (Measurement)

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 79

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

Figure 69. Recommended Shotcrete System

PAGE 80 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

RECOMMENDED SHOTCRETE SYSTEM

NO. PART NO. PART NAME QTY. REMARKS

1 EM28906 COUPLING, 5” H-D “CF” 2 EM25837 ELBOW, 5"x4”x90° 3 EM28905 COUPLING, 4” H-D w/GASKET & 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 90 12 EM24841 HOSE, 2”x25’ H-D w/ENDS 13 EM23808D NOZZLE ASSEMBLY, 2” H-D 14 EM23806 NOZZLE TIP, RUBBER 1-3/8” 15 EM23807 NOZZLE TIP, RUBBER 1.25”

GENERAL RECOMMENDATIONS

■

If the site will permit, use steel pipe from the pump to the pool perimeter. It will reduce line pressures which is highly recommended.

■

The vibrator on the reducer by the pool improves pumpability.

■

Turn both air vibrators off whenever the pump is stopped to prevent separation of mix.

■

The air vibrators are low consumption (4.2 scfm).

■

Leave the air on at the nozzle when the pump is stopped to prevent clogging of air the hoses in the air insert.

■

Use item #11 (steel elbow) at the edge of the pool to prevent collapse of the rubber hose, which can cause blockage.

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 81

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

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

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS

1 EM26107 HOPPER SCREEN ......................... 1 .......... W/AIR VIBRATOR MOUNTING

2 EM23101 AIR VIBRATOR 1 3 EM132 BOLT, 1/2-13X2 2 4 EM23407 AIR HOSE 1 5 EM23408 BUSHING 1 6 EM23411 VALVE 1 7 EM912073 NIPPLE 2 8 EM23409 COUPLING 1 9 EM923346 WASHER, 1/2 LOCK 2 10 EM406 NUT, HEX 1/2-13 2 11 EM23818 2"X25' GROOVED HOSE 11 EM24841 2"X25' RAISED HOSE 11 EM23845 2"X50' GROOVED HOSE 12 13 14 15 16 17 18 19

20 AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO

21 EM23808 NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES ITEMS W/

EM23802 VIC ADAPTER / EM23802D H.D 1

EM23803 GUN BODY 1

EM20816 “O” RING 1

EM23804 AIR INSERT 1

EM23805 NOZZLE CLAMP 1

EM23806 NOZZLE TIP, 1-3/8", SHORT 1

EM23807 NOZZLE TIP, 1-1/4", LONG 1

EM911076 STREET ELBOW 1

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 83

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. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

QTY. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁed in the “Remarks” Column.

Serial Number Break — Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use — Indicates that the part is used only with the speciﬁc model number or model number variant listed. It can also be used to show a part is NOT used on a speciﬁc model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON 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 84 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — SUGGESTED SPARE PARTS

LS400/LS500

CONCRETE PUMP

1 Unit

Qty. P/N Description

1 .......... EM16462 .............. FELT HOLDER

4 .......... EM98050 .............. PISTON CUP, ORANGE

4 .......... EM16493 .............. FELT RING

1 .......... EM98033 .............. OIL PLATE

2 .......... EM14408 .............. BRONZE RING

2 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE )

1 .......... EM98021 .............. WEAR PLATE

2 .......... EM16816-1A ........ ENERGIZER RING

1 .......... EM16816-2 ........... INSERT RING

2 .......... EM98065 .............. SLEEVE SEAL

1 .......... EM98022 .............. WEAR RING

1 .......... EM98065 .............. RUBBER RING

2 .......... EM14407 .............. O-RING

1 .......... 34507 ................... CAP, FUEL

2 .......... EM20763 .............. FILTER, FUEL (IN LINE)

1 .......... P53712 ................. CARTRIDGE, WATER SEPARATOR

3 .......... 01174416 ............. FILTER, OIL (ENGINE)

3 .......... 01174696 ............. FILTER, FUEL (ENGINE)

3 .......... 1319257 ............... INSERT, AIR FILTER

3 .......... 1880870 ............... AIR CARTRIDGE, SAFETY

1 .......... EM98163 .............. PROXIMITY SWITCH

1 .......... EM98121 .............. ELEMENT, RETURN OIL

........................................... S/N 281100 AND BELOW

1 .......... EM98275 .............. ELEMENT, RETURN OIL,

........................................... S/N 281101 AND ABOVE

LS400/LS500

CONCRETE PUMP

3 Units

Qty. P/N Description

1 .......... EM16459 .............. PIN

2 .......... EM25801 .............. CONCRETE CYLINDER

4 .......... EM16462 .............. FELT HOLDER

6 .......... EM98050 .............. PISTON CUP, ORANGE

8 .......... EM16493 .............. FELT RING

4 .......... EM98033 .............. OIL PLATE

4 .......... EM14408 .............. BRONZE RING

4 .......... EM16145A ............ BUSHING, SWING AXLE (BRONZE )

3 .......... EM98021A ............ WEAR PLATE

4 .......... EM16816-1A ........ ENERGIZER RING

2 .......... EM16816-2 ........... INSERT RING

4 .......... EM98065 .............. SLEEVE SEAL

6 .......... EM98022 .............. WEAR RING

3 .......... EM98065 .............. RUBBER RING

6 .......... EM14407 .............. O-RING

2 .......... EM16174 .............. O-RING

2 .......... EM98163 .............. SWITCH, PROXIMITY

6 .......... 510265 ................. BOLT, HEX HEAD 3/8 NC x 3-1/4 IN. G8

1 .......... 34507 ................... CAP, FUEL

6 .......... EM20763 .............. FILTER, FUEL

3 .......... P53712 ................. CARTRIDGE, WATER SEPARATOR

9 .......... 01174416 ............. FILTER, OIL (ENGINE)

9 .......... 01174696 ............. FILTER, FUEL (ENGINE)

9 .......... 1319257 ............... INSERT, AIR FILTER

9 .......... 1180870 ............... AIR CARTRIDGE, SAFETY

2 .......... EM98121 .............. ELEMENT, RETURN OIL

........................................... S/N 281100 AND BELOW

2 .......... EM98275 .............. 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. #6 (09/19/11) — PAGE 85

NAMEPLATE AND DECALS

O N

IG NI T

ION

REMOTE

CENTER

OFF

ST ART

LS400/LS500 PUMP — NAMEPLATE AND DECALS

LEVER OPERATING INSTRUCTIONS

REMIXLEVER

PULLUP TO OPERATE.PUSH DOWNTO REVERSE

RIGHTREAR HYDRAULIC STABILIZERLEVER

PULLUP TO EXTEND PUSHDOWN TO RETRACT

NEUTRAL

LEFTREAR HYDRAULIC STABILIZERLEVER

PULLUP TO EXTEND PUSHDOWN TO RETRACT

AMPUTATIONDANGER!

KEEP HANDS CLEAR

SHUTTLETUBE PIVOTS RAPIDLY AND WILL CRUSH

ORCUT. PUT ANY BODY PARTS INTO

DONOT

THEHOPPER UNTIL MACHINE IS COMPLETELY

SHUTDOWN AND THE ACCUMULATOR

PRESSUREGAUGE READS

ZERO

P/N:DCL301

HOPPER REMIXER

PULL UPTO OPERATE

NEUTRAL

PUSH DOWNTO REVERSE

CIP972

S C

R O L L

E S E

S E T

I N C R E

A S E

F L

I O N

E V E R S

T E

R F

Y L

N D

“A”

O K

J O

G “ B”

E M

O T

Engine RPM Setting

(without change)

High RPM:

Low RPM:

RPM

WARNING

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.

P/N35137

USE DIESEL FUEL ONLY

(Read Operator’s book)

CAUTION

EM98000

800-30-MAYCO

CAUTION

EM98000

NOTES:

PLACE DECAL ON LS400 MODELS ONLY.

PLACE DECAL ON LS500 MODELS ONLY.

USE THIS DECAL (OPTION) WHEN

HYDRAULIC STABILIZER JACKS ARE INSTALLED.

PAGE 86 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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. #6 (09/19/11) — PAGE 87

LS400/LS500 PUMP — NAMEPLATE AND DECALS

PAGE 88 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

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. #6 (09/19/11) — PAGE 89

FRAME ASSY.

LS400/LS500 PUMP — FRAME ASSY.

PAGE 90 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — FRAME ASSY.

FRAME ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 514355 FRAME, MAIN 1 2 EM516581 CHAIN, TRAILER HITCH, 3/8 X 40", GRADE 40 2 3 EM25610 JACK STAND, FRONT 1 5 EM744 CLEVIS PIN 2 8 EM491686 PIN 2

10 EM491744 RIVET, POP AM-44 2 11 509562 BOLT, 3/8" NC X 5/8" G5 2

12 0166 A LOCK, WASHER 3/8" ................................................ 2......... REPLACES 492624

13 503112 BOLT 3/8" X 2-3/4" 1

14 3019092 WASHER 3/8" ........................................................... 2......... REPLACES 492598

15 EM969013 NUT 3/8" ................................................................... 1......... REPLACES 492583

16 517985 FENDOR, BOLT ON 2 17 504456 BOLT 1/2" NC X 3/4" G5 12

18 6109180 WASHER, LOCK 1/2 IN. ........................................... 12 ....... REPLACES 492626

19 517113 STABILIZER STAND 2 20 492376 BOLT 3/8" NC X 1-1/4" G5 2

21 0166 A WASHER, LOCK 3/8" ................................................ 4 ........ REPLACES 492624

23 EM969013 NUT 3/8" .................................................................... 2 ........ REPLACES 492583

24 517124 BOLT 3/4" NC X 1" G5 10

25 EM923350 WASHER, LOCK 3/4 IN. ...........................................10 ....... REPLACES EM492628

26 517092 SUPPORT PLATE, RIGHT 1 27 517095 SUPPORT PLATE, LEFT 1

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 91

AXLE ASSY. (RIGHT/LEFT)

LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT)

PAGE 92 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT)

AXLE ASSY. (RIGHT/LEFT)

NO. PART NO. PART NAME QTY. REMARKS

1 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. #6 (09/19/11) — PAGE 93

BRAKE LINE ASSY.

LS400/LS500 PUMP — BRAKE LINE ASSY.

PAGE 94 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — BRAKE LINE ASSY.

BRAKE LINE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 34566 KIT, MAIN BRAKE LINE 1 2 EM512877 ADAPTOR, STRAIGHT 2 3 EM512876 ADAPTOR, ELBOW 2 4 34565 KIT, WHEEL BRAKE LINE 1

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 95

BRAKE LIGHT ASSY.

LS400/LS500 PUMP — BRAKE LIGHT ASSY.

PAGE 96 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — BRAKE LIGHT ASSY.

BRAKE LIGHT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 29242 BRAKE LIGHT ASSY. 2 2 29207 HARNESS ASSY. W/RECEPTACLES 1

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 97

TRAILER HITCH ASSY.

LS400/LS500 PUMP — TRAILER HITCH ASSY.

PAGE 98 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

LS400/LS500 PUMP — TRAILER HITCH ASSY.

TRAILER HITCH ASSY.

NO. PART NO. PART NAME QTY. REMARKS

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 5 EM492584 NUT, LOCK 1/2 6 EM507658 BOLT, HEX HEAD 5/8 NC X 4-1/2 7 EM492586 NUT, LOCK 5/8 IN. 2 8 16137 TOW RING, 3 IN. LUNETTE EYE

IN. 3

IN. G5 2

MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 99

LS400/LS500 PUMP — BATTERY ASSY.

PAGE 100 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

Multiquip LS500, LS400 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual