Models LS400/LS500 | Multiquip instruction

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 manual Models LS400/LS500

Contents

Models LS400/LS500 Diesel engine exhaust and some Page LS400/LS500 Pump -TABLE of Contents Ordering parts has never been easier Parts Ordering Procedures Is running or hot LS400/LS500 Pump Safety Message Alert SymbolsYou can be injured if you do not follow directions Always wear approved respiratory protection LS400/LS500 Pump Safety Message Alert Symbols LS400/LS500 Pump Rules for Safe Operation General Safety Transporting LS400/LS500 Pump Rules for Safe OperationTowing Battery Maintenance SafetyEmergencies Always know the location of the nearest and first aid kitPage Pump Specifications LS400/LS500 Pump Specifications Dimensions Dimensions Operation Hand Signals LS400/LS500 Pump Important Hand Signals Concrete MIX Design LS400/LS500 Pump General Information Regional Differences LS400/LS500 Pump General Information Pumping Cycle LS400/LS500 Pump HOW IT Works LS400/LS500 Pump Pump Components LS400/LS500 Pump Pump Components LS400/LS500 Pump Digital Control Panel Components Switch controls the pumping function. The leftmostOperation Counterclockwise to the Stop position Primary Screen LS400/LS500 Pump Digital Readout Screen Initial Servicing LS400/LS500 Pump Engine Components Before Starting Fuel CheckCheck fastening nuts and bolts for tightness Engine OIL Check LS400/LS500 Pump InspectionRemove the engine oil dipstick from its holder Figure Hydraulic OIL Check Hydraulic Oil Filler Hole Location of Pump LS400/LS500 Pump SET-UPRear Stabilizer Jacks Hydraulic Rear Stabilizer Jacks Optional Starting Procedure LS400/LS500 Pump START-UP Procedure Hose Lubrication LS400/LS500 Pump OperationPumping Priming the Pump with Slurry Mixture Accumulator Pressure Gauge Radio Remote Control Remote Control Optional LS400/LS500 Pump Operation Cable Remote Control Downhill Pumping RemixturesVertical Pumping Hose Pulsation SNAP-JOINT Couplings LS400/LS500 Pump Pumping InformationNEW Pumps Effects of Heat and Excessive Time on Concrete Clearing Concrete Blockage Clearing the System After MIX SET UP Shuttle Tube Inspection Procedure Reverse Pumping ProcedureClearing Shuttletube Blockage Cleaning the Pump and Delivery System LS400/LS500 Pump Maintenance Pump Hydraulic OIL System Maintenance LS400/LS500 Pump Maintenance Pump Brake System Battery Maintenance Cylinder Lubrication BOX Cleaningthe Lubrication BOXAccumulator Circuit LS400/LS500 Pump Maintenance Pump Off Size and type of aggregate Type of concrete being pumped Wear Plate Installation Wear Plate and Ring Replacement ProcedureWear Ring installation Changingthe Wear Plate and Ring Extended Storage Instructions Wheel BearingsPressure Test Trailer Brakes Manually Adjusting the BrakesHydraulic Brakes Adjustable Channel LS400/LS500 Pump Maintenance Trailer Tube Torsion Suspension Always use lower gears for climbing and descending grades LS400/LS500 Pump -TRAILER Safety GuidelinesCommon Causes for Loss of Trailer Trailer Towing Guidelines Coupling to the Tow Vehicle Driving Conditions Inoperable Brakes, Lights or Mirrors Reporting Safety DefectsTrailer Towing Tips Trailer VIN Tag LS400/LS500 Pump Trailer Safety Guidelines Safety Chains Electrical ConnectorTrailer Lighting and Braking Connector Tow Vehicle Ball Hitch Coupler Coupler Types Ball Hitch Coupling Mechanism  Attach the safety chains so that they Attaching Safety ChainBreakaway Brake System Connecting Trailer Lights LS400/LS500 Pump Trailer Safety GuidelinesUncoupling the Ball Hitch Unsafe Tires, Lug Nuts or Wheels Tire and Loading Information Placard Determining Load Limit of Trailer Determining Load Limit of Tow Vehicle Step StepTire Fundamentals P indicates the tire is for passenger vehicles Uniform Tire Quality Grading Standards Utqgs Tire Repair Tire Safety TipsReplacing Worn or Damaged Tires Load Range Wheels, Bearings and Lug Nuts Wheel RimsLug Nut Torque Requirements Start all wheel lug nuts by hand Lights and Signals Trailer to Tow Vehicle Wiring Diagram Zero prior to performing any maintenance on the pump LS400/LS500 Pump Troubleshooting Pump LS400/LS500 Pump Troubleshooting Pump PSI Engine Troubleshooting LS400/LS500 Pump -TROUBLESHOOTING Engine Brake System Troubleshooting LS400/LS500 Pump -TROUBLESHOOTING Trailer Brake System Electrical Troubleshooting LS400/LS500 Pump Troubleshooting ElectricalRefer to for the location of components for troubleshooting Malfunction Probable Cause Solution LS400/LS500 Pump Troubleshooting Electrical Location of Components for Electrical Troubleshooting Connections to Digital Control Box J1 and J2 Connectors 1 LS400/LS500 Pump Wiring Diagram Control BOX Connections to Digital Control Box J1 and J2 Connectors 2 LS400/LS500 Pump Wiring Diagram Control BOX Connections to Digital Control Box J3 and J4 Connectors 1 Connections to Digital Control Box J3 and J4 Connectors 2 Optional Hopper Vibrator Wiring Diagram LS400/LS500 Pump Wiring Diagram Hopper Vibrator Hydraulic System Diagram LS400/LS500 Pump Hydraulic System Diagram Manifold Block Ports LS400/LS500 Pump Manifold Block Ports Appendix Concrete MIX Information Appendix Concrete MIX Information Appendix Slumptest Procedure Recommended Shotcrete System Appendix Recommended Shotcrete System Appendix Recommended Shotcrete System 13 EM23808D Nozzle ASSEMBLY, 2 H-DRecommended Shotcrete System NO. Part no Part Name 10 EM23101 AIR Vibrator Assy Recommended Shotcrete Accessories Appendix Recommended Shotcrete AccessoriesHas Passed Through the Entire Hose Length Part Name QTY Remarks Xxxxx only Not Used on LS400/LS500 Pump Explanation of Code in Remarks Column Unit LS400/LS500 Pump Suggested Spare Parts Nameplate and Decals LS400/LS500 Pump Nameplate and Decals DECAL, Maintenance DECAL, Engine RPM SettingDECAL, Hopper REX Mixer TBD DECAL, Minimum OIL Level LS400/LS500 Pump Nameplate and Decals TBD DECAL, Impact Hazard TBD DECAL, Fault LocatorIncluded W/ITEM DECAL, Hydraulic OIL only Frame Assy LS400/LS500 Pump Frame Assy Jack STAND, Front FRAME, MainClevis PIN PIN Axle ASSY. RIGHT/LEFT LS400/LS500 Pump Axle ASSY. RIGHT/LEFT Inner Bearing Cone 2 Brake Line Assy LS400/LS500 Pump Brake Line Assy KIT, Main Brake Line Brake Light Assy LS400/LS500 Pump Brake Light Assy 29207 29242 Trailer Hitch Assy LS400/LS500 Pump -TRAILER Hitch Assy ACTUATOR, Brake LS400/LS500 Pump Battery Assy LS400/LS500 Pump Battery Assy Hopper Assy LS400/LS500 Pump Hopper Assy Hopper Seal HousingRemixer Shaft Follower Ring Hopper Attachment Assy LS400/LS500 Pump Hopper Attachment Assy Hinge PIN Splash PlatePIN, Splash Plate TIE ROD Hopper Interior Assy LS400/LS500 Pump Hopper Interior Assy Ring SEAL, Shuttle Axle Swing Axle BushingWear Ring HF RING, Energizer Rubber Shuttle Cylinder Assy LS400/LS500 Pump Shuttle Cylinder Assy Tensioner Thrust WasherHEX NUT 1 in NF Cotter PIN 5/32 X 2 Lubrication Pistons Assy LS400/LS500 Pump Lubrication Pistons Assy SWITCH, Proximity W/CABLE BAR,PROXIMITY Switch SupportCable HOUSING, Female SEAL, Connector Housing LS400/LS500 Pump Lubrication Pistons Assy BRACKET, Adjustment ROD Adjustment ROD, Proximity SwitchBOLT, HEX Head 5/16 NC X 1 IN. G5 WASHER, Lock 5/16 Fuel Tank Assy LS400/LS500 Pump Fueltank Assy Gasket COVER, Diesel TankCAP, Fuel W\GAUGE Adaptor Heat Exchanger Assy LS400/LS500 Pump Heat Exchanger Assy COVER, Heat Exchanger Heat ExchangerHose 4000 PSI Hose 2000 PSI Accumulator Assy LS400/LS500 Pump Accumulator Assy Part Name QTY Remixer Control Assy LS400/LS500 Pump Remixer Control Assy Adapter FITTING, T Valve Remixer W/ LeverAdapter FITTING, 90 Elbow Adapter FITTING, Straight Grease Points LS400/LS500 Pump Lubrication PanelPosition Location Lubrication Panel Assy ConnectorHOSE, Plastic HOSE, Steel Engine Cover Assy LS400/LS500 Pump Engine Cover Assy COVER, Front Engine COVER, TOPDocument Cylinder Hydraulic Tank Assy LS400/LS500 Pump Hydraulictank Assy Hydraulic TANK, LS-S LS-40TD/LS-50TD Engine Assy LS400/LS500 Pump Engine Assy HOOD, AIR Cleaner CONNECTOR, AIR FilterCARTRIDGE, Safety AIR Engine Assy Throttle Assy LS400/LS500 Pump -THROTTLE Assy EM98233 Support Water Separator Assy LS400/LS500 Pump -WATER Separator Assy BRACKET, Water Separator TBD Bolt Hydraulic Pump Assy LS400/LS500 Pump HYD. Pump Assy ADAPTER, Suction Pipe EM492444 Bolt 1/2 X 1-1/4 Manifold Assy Front Machine LS400/LS500 Pump Manifold Assy Pilot VALVE, Shuttle EMBK227Pilot VALVE, Main Cylinder Check Valve Control BOX Assy LS400/LS500 Pump Control BOX Assy Emergency Stop Switch Assy Ignition Switch AssyContact BLOCKS, Emergency Switch Flow Direction Switch Assy Control BOX Harnesses Assy LS400/LS500 Pump Control BOX Harnesses Assy FUSE, 30 AMP Wire HarnessConductive Divider 3/8 Remote Control Cable Assy LS400/LS500 Pump Remote Control Cable Assy CONNECTOR, Ring 3/16 SwitchGuard Switch Aluminum Junction BOX LS400/LS500 Pump Hydraulic Stabilizer ASSY. Optional LS400/LS500 Pump Hydraulic Stabilizer ASSY. Optional Freight Policy Terms and Conditions of Sale Parts Mechanical Drive Models Mayco Pumpwarranty HERE’S HOW to GET Help