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Multiquip manual Operation And Parts Manual, MODELS LS400/LS500, Series, Concrete Pumps

Models: LS500 LS400

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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 ALLTIMES.

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Multiquip LS500, LS400 manual Operation And Parts Manual, This Manual Must Accompany The Equipment At Alltimes, Series

Contents

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES OPERATION AND PARTS MANUALMODELS LS400/LS500 SERIESDiesel engine exhaust and some of LS400/LS500 PUMPProposition- PROPOSITION65 Warning 65 WARNINGPage MAYCO LS400/LS500 LS400/LS500 PUMP -TABLE OF CONTENTSCOMPONENT DRAWINGS 8-10When ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Choose from three easy optionsHAZARD SYMBOLS LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERWARNING - ROTATING PARTS LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSLS400/LS500 PUMP - RULES FOR SAFE OPERATION GENERAL SAFETYTRANSPORTING LS400/LS500 PUMP - RULES FOR SAFE OPERATIONTowing BATTERY MAINTENANCE SAFETYDANGER - AMPUTATION RISK EMERGENCIESPage TABLE 2. ENGINE SPECIFICATIONS LS400/LS500 PUMP - SPECIFICATIONSTABLE 1. PUMP SPECIFICATIONS No. of CylindersDIMENSIONS LS400/LS500 PUMP - DIMENSIONSFigure 1. Dimensions TABLE 3. DIMENSIONSFigure 2. Operation Hand Signals LS400/LS500 PUMP - IMPORTANT HAND SIGNALSCONCRETE MIX DESIGN LS400/LS500 PUMP - GENERAL INFORMATIONREGIONAL DIFFERENCES LS400/LS500 PUMP - GENERAL INFORMATIONFigure 4. Pumping Cycle LS400/LS500 PUMP - HOW IT WORKSFigure 3. Pumping Cycle Figure 5. Major Pump Components LS400/LS500 PUMP - PUMP COMPONENTSLS400/LS500 PUMP - PUMP COMPONENTS Figure 6. Pump Digital Control Panel Components LS400/LS500 PUMP - DIGITAL CONTROL PANEL COMPONENTSPRIMARY SCREEN Screen LS400/LS500 PUMP - DIGITAL READOUT SCREENSECONDARY SCREENS Screen ScreenFigure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components LS400/LS500 PUMP - ENGINE COMPONENTSINITIAL SERVICING FUEL CHECK LS400/LS500 PUMP - INSPECTIONBEFORE STARTING Figure 8. Fuel Cap GaugeENGINE OIL CHECK LS400/LS500 PUMP - INSPECTIONFigure 10. Engine Oil Dipstick HYDRAULIC OIL CHECKFigure 14. Filling the Lubrication Box Figure 13. Hydraulic Oil Filler HoleLS400/LS500 PUMP - INSPECTION LS400/LS500 PUMP - SET-UP WARNING - REAR STABILIZER SAFETYLOCATION OF PUMP REAR STABILIZER JACKSSTARTING PROCEDURE LS400/LS500 PUMP - START-UP PROCEDURE4. Place the Direction Control Switch to the FORWARD position Figure Figure 22. Direction Control Switch FORWARDFigure 26. Pumping Control Switch LOCAL WARNING - SAFETY GLASSESFigure 27. Volume Control LS400/LS500 PUMP - OPERATIONFigure 32. Hopper Remixer Blades Rotation Figure 30. Accumulator Pressure GaugeCAUTION - HOSE/LINE BLOCKAGE Figure 31. Hopper Remixer Control LeverRadio Remote Control REMOTE CONTROL OPTIONALFigure 36. Antenna Installation Figure 35. Installing Remote Control ModuleFigure 38. Cable Remote Control Cable Remote ControlLS400/LS500 PUMP - OPERATION WARNING -TRANSPORTING PUMPREMIXTURES LS400/LS500 PUMP - PUMPING INFORMATIONDOWNHILL PUMPING VERTICAL PUMPINGSNAP-JOINT COUPLINGS LS400/LS500 PUMP - PUMPING INFORMATIONNEW PUMPS THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETEWARNING - HOSE/LINE PRESSURE CLEARING THE SYSTEM AFTER MIX SET UPCLEARING CONCRETE BLOCKAGE WARNING - BLOCKAGESSHUTTLE TUBE INSPECTION PROCEDURE “REVERSE” PUMPING PROCEDURECLEARING SHUTTLETUBE BLOCKAGE WARNING - SHUTTLE TUBESCLEANING THE PUMP AND DELIVERY SYSTEM LS400/LS500 PUMP - MAINTENANCE PUMPDANGER - AMPUTATION RISK WARNING - ACID CLEANING LS400/LS500 PUMP - MAINTENANCE PUMPHYDRAULIC OIL SYSTEM MAINTENANCE WARNING - HYDRAULIC OILBATTERY MAINTENANCE LS400/LS500 PUMP - MAINTENANCE PUMPCAUTION - BATTERY MAINTENANCE SAFETY Figure 39. Battery Electrolyte LevelsCLEANINGTHE LUBRICATION BOX CAUTION - SAFETY GUIDELINESFigure 40. Cleaning the Lubrication Box CYLINDER LUBRICATION BOXreplace the rubber energizer ring WEAR PLATE AND CUTTING RINGLS400/LS500 PUMP - MAINTENANCE PUMP 3. When the output volume at the end of the delivery lineThe size and type of aggregate The type of concrete being pumped LS400/LS500 PUMP - MAINTENANCE PUMPDANGER - AMPUTATION RISK Wear Plate Installation Wear Plate and Ring Replacement ProcedureWear Ring installation CAUTION - HYDRAULIC OILTEMPERATUREFigure 43. Manual Cylinder Jogging Switch Figure 42. Cylinder Stroke Control Switch JOGWHEEL BEARINGS EXTENDED STORAGE INSTRUCTIONSManually Adjusting the Brakes LS400/LS500 PUMP - MAINTENANCE TRAILERTrailer Brakes Hydraulic BrakesAdjustable Channel LS400/LS500 PUMP - MAINTENANCE TRAILERFigure 47. Adjustable Channel With Pintle Eye Coupler Figure 48. Wheel Hub Components Wheel Hub AdjustmentDANGER - Trailer Inspection Danger - Raising the TrailerTorsion Suspension WARNING - Trailer ImpactTRAILER SAFETY INFORMATION LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESCommon Causes for Loss of Trailer Trailer Towing GuidelinesCAUTION - Local Towing Regulations LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESDriving Conditions WARNING - Transporting PersonnelInoperable Brakes, Lights or Mirrors Reporting Safety DefectsTrailer Towing Tips LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESTrailer VIN Tag LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESFigure 50. Vehicle VIN Tag Figure 51. VIN Tag LocationSafety Chains Electrical ConnectorTrailer Lighting and Braking Connector Tow VehicleCoupler Types Figure 52. Ball Hitch Coupler Adjustable TongueBall Hitch Coupler WARNING - Hitch Ball Load RatingWARNING - Uncoupled Hitch Ball WARNING - Defective Hitch BallFigure 53. Ball Hitch Coupling Mechanism LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESWARNING - Safety Chains Rigging Attaching Safety ChainBreakaway Brake System Figure 55. Breakaway Brake System Breakaway Cable Surge Brake SystemConnecting Trailer Lights LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESTIRE SAFETY Uncoupling the Ball HitchDetermining Load Limit of Trailer WARNING - Lug Nut LooseningWARNING - Improper Lug Nut Torque WARNING - Tire PressureDetermining Load Limit of Tow Vehicle Step StepTire Fundamentals Figure 57. Standard Tire Sidewall InformationLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES Uniform Tire Quality Grading Standards UTQGSTable 6. Speed Rating Figure 58. UTQGS Tire Information Tire Safety TipsTire Repair Replacing Worn or Damaged TiresWheel Rims WARNING - Flying ObjectsWheels, Bearings and Lug Nuts Lug Nut Torque RequirementsWARNING - Trailer Lights Figure 60. Trailer to Tow Vehicle Wiring DiagramLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES TABLE 9. PUMP TROUBLESHOOTING LS400/LS500 PUMP - TROUBLESHOOTING PUMPWARNING - HYDRAULIC SYSTEM HAZARD DANGER - AMPUTATION RISKTABLE 9. PUMP TROUBLESHOOTING CONTINUED LS400/LS500 PUMP - TROUBLESHOOTING PUMPTABLE 9. PUMP TROUBLESHOOTING CONTINUED LS400/LS500 PUMP - TROUBLESHOOTING PUMPDecrease volume control on main Engine overloaded when pumpingTABLE 10. ENGINE TROUBLESHOOTING LS400/LS500 PUMP -TROUBLESHOOTING ENGINESYMPTOM POSSIBLE PROBLEMTABLE 11. BRAKE SYSTEM TROUBLESHOOTING LS400/LS500 PUMP -TROUBLESHOOTING TRAILER BRAKE SYSTEMSYMPTOM POSSIBLE PROBLEMTABLE 12. ELECTRICAL TROUBLESHOOTING LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALSOLUTION PROBABLE CAUSETABLE 12. ELECTRICAL TROUBLESHOOTING continued LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALSOLUTION PROBABLE CAUSELS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL Figure 61. Location of Components for Electrical TroubleshootingPROXIMITY SWITCH “B” ALTERNATOR V-BELT PROXIMITY SWITCH “A” MAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOIDMANIFO LD LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXF C D LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXE H G A I L K J CONNECTIONS TO J3 AND J4 CONNECTORS ON LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXDIGITAL CONTROL BOX LS400 AND LS500 C A H DF G LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXFigure 65. Optional Hopper Vibrator Wiring Diagram LS400/LS500 PUMP - WIRING DIAGRAM HOPPER VIBRATORFigure 66. Hydraulic System Diagram LS400/LS500 PUMP - HYDRAULIC SYSTEM DIAGRAMMANIFOLD Figure 67. Manifold Block Ports LS400/LS500 PUMP - MANIFOLD BLOCK PORTSMANIFOLD BLOCK PORTS Washed Sand-#200 wash APPENDIX - CONCRETE MIX INFORMATIONA.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE APPENDIX - CONCRETE MIX INFORMATIONFigure 68-C. SlumpTest Full-Overflow APPENDIX - SLUMPTEST PROCEDUREFigure 68-A. SlumpTest 1/3 Full Figure 68-B. SlumpTest 2/3 FullFigure 69. Recommended Shotcrete System APPENDIX - RECOMMENDED SHOTCRETE SYSTEMRECOMMENDED SHOTCRETE SYSTEM APPENDIX - RECOMMENDED SHOTCRETE SYSTEMNO. PART NO PART NAMERECOMMENDED SHOTCRETE ACCESSORIES APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIESFigure 70. Shotcrete System Accessories HAS PASSED THROUGH THE ENTIRE HOSE LENGTHAPPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES REMARKSPART NAME EM26107LS400/LS500 PUMP - EXPLANATION OF CODE IN REMARKS COLUMN SAMPLE PARTS LISTQTY. Column NO. ColumnLS400/LS500 LS400/LS500 PUMP - SUGGESTED SPARE PARTSCONCRETE PUMP 1 UnitUSE THIS DECAL OPTION WHEN 3 HYDRAULIC STABILIZER JACKS ARE INSTALLED LS400/LS500 PUMP - NAMEPLATE AND DECALS10 800-30-MAYCO 1 PLACE DECAL ON LS400 MODELS ONLY 2 PLACE DECAL ON LS500 MODELS ONLYPART NAME LS400/LS500 PUMP - NAMEPLATE AND DECALSREMARKS OPTION HYD. JACKSLS400/LS500 PUMP - NAMEPLATE AND DECALS PART NAME LS400/LS500 PUMP - NAMEPLATE AND DECALSREMARKS USED ON LS400 MODELSFRAME ASSY LS400/LS500 PUMP - FRAME ASSYPART NAME LS400/LS500 PUMP - FRAME ASSYREMARKS CHAIN, TRAILER HITCH, 3/8 X 40, GRADEAXLE ASSY. RIGHT/LEFT LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFTPART NAME LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFTREMARKS EM98116BRAKE LINE ASSY LS400/LS500 PUMP - BRAKE LINE ASSYPART NAME LS400/LS500 PUMP - BRAKE LINE ASSY34566 KIT, MAIN BRAKE LINEBRAKE LIGHT ASSY LS400/LS500 PUMP - BRAKE LIGHT ASSYPART NAME LS400/LS500 PUMP - BRAKE LIGHT ASSYHARNESS ASSY. W/RECEPTACLES REMARKSTRAILER HITCH ASSY LS400/LS500 PUMP -TRAILER HITCH ASSYPART NAME LS400/LS500 PUMP -TRAILER HITCH ASSYEM29228 LS400/LS500 PUMP - BATTERY ASSY BATTERY ASSY LS400/LS500 PUMP - BATTERY ASSYBATTERY BOX W/ BELT BATTERY 12V 125AHOPPER ASSY LS400/LS500 PUMP - HOPPER ASSYPART NAME LS400/LS500 PUMP - HOPPER ASSYREMARKS INCLUDES ITEMS W/%HOPPER ATTACHMENT ASSY LS400/LS500 PUMP - HOPPER ATTACHMENT ASSYPART NAME LS400/LS500 PUMP - HOPPER ATTACHMENT ASSYREMARKS HOPPER INTERIOR ASSY LS400/LS500 PUMP - HOPPER INTERIOR ASSYPART NAME LS400/LS500 PUMP - HOPPER INTERIOR ASSYREMARKS BOLT, COUNTER SUNK 5/8-11 x 3 INSHUTTLE CYLINDER ASSY LS400/LS500 PUMP - SHUTTLE CYLINDER ASSYPART NAME LS400/LS500 PUMP - SHUTTLE CYLINDER ASSYREMARKS INCLUDES ITEMS WLUBRICATION PISTONS ASSY LS400/LS500 PUMP - LUBRICATION PISTONS ASSYPART NAME LS400/LS500 PUMP - LUBRICATION PISTONS ASSYREMARKS BOLT, 3/8 NC X 1.3/4 IN. G5LS400/LS500 PUMP - LUBRICATION PISTONS ASSY PART NAME LS400/LS500 PUMP - LUBRICATION PISTONS ASSYEM514920 FUEL TANK ASSY LS400/LS500 PUMP - FUELTANK ASSYPART NAME LS400/LS500 PUMP - FUELTANK ASSYREMARKS WASHER, LOCK 5/16 INHEAT EXCHANGER ASSY LS400/LS500 PUMP - HEAT EXCHANGER ASSYPART NAME LS400/LS500 PUMP - HEAT EXCHANGER ASSYREMARKS HEAT EXCHANGER ASSYACCUMULATOR ASSY LS400/LS500 PUMP - ACCUMULATOR ASSYPART NAME LS400/LS500 PUMP - ACCUMULATOR ASSYACCUMULATOR ASSY ACCUMULATOR TEST/CHARGE KITREMIXER CONTROL ASSY LS400/LS500 PUMP - REMIXER CONTROL ASSYPART NAME LS400/LS500 PUMP - REMIXER CONTROL ASSYREMARKS POSITION LS400/LS500 PUMP - LUBRICATION PANELLOCATION LENGTH OF LINESPART NAME LS400/LS500 PUMP - LUBRICATION PANELENGINE COVER ASSY LS400/LS500 PUMP - ENGINE COVER ASSYPART NAME LS400/LS500 PUMP - ENGINE COVER ASSYREMARKS EM517737HYDRAULIC TANK ASSY LS400/LS500 PUMP - HYDRAULICTANK ASSYPART NAME LS400/LS500 PUMP - HYDRAULICTANK ASSYREMARKS STRAIGHT MALE ADAPTORLS-40TD/LS-50TD ENGINE ASSY LS400/LS500 PUMP - ENGINE ASSYPART NAME LS400/LS500 PUMP - ENGINE ASSYREMARKS THROTTLE ASSY LS400/LS500 PUMP -THROTTLE ASSYPART NAME LS400/LS500 PUMP -THROTTLE ASSYREMARKS LOCK WASHER 1/4 INWATER SEPARATOR ASSY LS400/LS500 PUMP -WATER SEPARATOR ASSYPART NAME LS400/LS500 PUMP -WATER SEPARATOR ASSYREMARKS REPLACESHYDRAULIC PUMP ASSY LS400/LS500 PUMP - HYD. PUMP ASSYPART NAME LS400/LS500 PUMP - HYD. PUMP ASSYREMARKS MOTORIZED FLOW CONTROL MANIFOLD ASSYFRONT OF LS400/LS500 PUMP - MANIFOLD ASSYMACHINE MANIFOLD ASSYPART NAME LS400/LS500 PUMP - MANIFOLD ASSYREMARKS MANIFOLD ASSYCONTROL BOX ASSY LS400/LS500 PUMP - CONTROL BOX ASSYPART NAME LS400/LS500 PUMP - CONTROL BOX ASSYREMARKS CONTROL BOX HARNESSES ASSY LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSYPART NAME LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSYPOLY FLEX TUBE 1/2 IN. BLACK REMOTE CONTROL CABLE ASSY LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSYPART NAME LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSYREMARKS ADAPTER, CORD GRIP 1/2 INLS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL PART NAME LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONALSPECIAL EXPEDITING SERVICE TERMS AND CONDITIONS OF SALE - PARTSPAYMENT TERMS FREIGHT POLICYMECHANICAL DRIVE MODELS MAYCO PUMPWARRANTYHYDRAULIC DRIVE MODELS PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERE’S HOW TO GET HELPService Department Warranty Department