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Multiquip manual LS400/LS500 PUMP - BATTERY ASSY

Models: LS500 LS400

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LS400/LS500 PUMP — BATTERY ASSY.

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

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Multiquip manual LS400/LS500 PUMP - BATTERY ASSY

Contents

OPERATION AND PARTS MANUAL THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMESMODELS LS400/LS500 SERIESLS400/LS500 PUMPProposition- PROPOSITION65 Warning 65 WARNING Diesel engine exhaust and some ofPage LS400/LS500 PUMP -TABLE OF CONTENTS MAYCO LS400/LS500COMPONENT DRAWINGS 8-10PARTS ORDERING PROCEDURES When ordering parts, please supplyOrdering parts has never been easier Choose from three easy optionsLS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERLS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSGENERAL SAFETY LS400/LS500 PUMP - RULES FOR SAFE OPERATIONTRANSPORTING LS400/LS500 PUMP - RULES FOR SAFE OPERATIONTowing MAINTENANCE SAFETY BATTERYDANGER - AMPUTATION RISK EMERGENCIESPage LS400/LS500 PUMP - SPECIFICATIONS TABLE 2. ENGINE SPECIFICATIONSTABLE 1. PUMP SPECIFICATIONS No. of CylindersLS400/LS500 PUMP - DIMENSIONS DIMENSIONSFigure 1. Dimensions TABLE 3. DIMENSIONSLS400/LS500 PUMP - IMPORTANT HAND SIGNALS Figure 2. Operation Hand SignalsLS400/LS500 PUMP - GENERAL INFORMATION CONCRETE MIX DESIGNLS400/LS500 PUMP - GENERAL INFORMATION REGIONAL DIFFERENCESFigure 4. Pumping Cycle LS400/LS500 PUMP - HOW IT WORKSFigure 3. Pumping Cycle LS400/LS500 PUMP - PUMP COMPONENTS Figure 5. Major Pump ComponentsLS400/LS500 PUMP - PUMP COMPONENTS LS400/LS500 PUMP - DIGITAL CONTROL PANEL COMPONENTS Figure 6. Pump Digital Control Panel ComponentsLS400/LS500 PUMP - DIGITAL READOUT SCREEN PRIMARY SCREEN ScreenSECONDARY SCREENS Screen ScreenFigure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components LS400/LS500 PUMP - ENGINE COMPONENTSINITIAL SERVICING LS400/LS500 PUMP - INSPECTION FUEL CHECKBEFORE STARTING Figure 8. Fuel Cap GaugeLS400/LS500 PUMP - INSPECTION ENGINE OIL CHECKFigure 10. Engine Oil Dipstick HYDRAULIC OIL CHECKFigure 14. Filling the Lubrication Box Figure 13. Hydraulic Oil Filler HoleLS400/LS500 PUMP - INSPECTION WARNING - REAR STABILIZER SAFETY LS400/LS500 PUMP - SET-UPLOCATION OF PUMP REAR STABILIZER JACKSLS400/LS500 PUMP - START-UP PROCEDURE STARTING PROCEDURE4. Place the Direction Control Switch to the FORWARD position Figure Figure 22. Direction Control Switch FORWARDWARNING - SAFETY GLASSES Figure 26. Pumping Control Switch LOCALFigure 27. Volume Control LS400/LS500 PUMP - OPERATIONFigure 30. Accumulator Pressure Gauge Figure 32. Hopper Remixer Blades RotationCAUTION - HOSE/LINE BLOCKAGE Figure 31. Hopper Remixer Control LeverREMOTE CONTROL OPTIONAL Radio Remote ControlFigure 36. Antenna Installation Figure 35. Installing Remote Control ModuleCable Remote Control Figure 38. Cable Remote ControlLS400/LS500 PUMP - OPERATION WARNING -TRANSPORTING PUMPLS400/LS500 PUMP - PUMPING INFORMATION REMIXTURESDOWNHILL PUMPING VERTICAL PUMPINGLS400/LS500 PUMP - PUMPING INFORMATION SNAP-JOINT COUPLINGSNEW PUMPS THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETECLEARING THE SYSTEM AFTER MIX SET UP WARNING - HOSE/LINE PRESSURECLEARING CONCRETE BLOCKAGE WARNING - BLOCKAGES“REVERSE” PUMPING PROCEDURE SHUTTLE TUBE INSPECTION PROCEDURECLEARING SHUTTLETUBE BLOCKAGE WARNING - SHUTTLE TUBESCLEANING THE PUMP AND DELIVERY SYSTEM LS400/LS500 PUMP - MAINTENANCE PUMPDANGER - AMPUTATION RISK LS400/LS500 PUMP - MAINTENANCE PUMP WARNING - ACID CLEANINGHYDRAULIC OIL SYSTEM MAINTENANCE WARNING - HYDRAULIC OILLS400/LS500 PUMP - MAINTENANCE PUMP BATTERY MAINTENANCECAUTION - BATTERY MAINTENANCE SAFETY Figure 39. Battery Electrolyte LevelsCAUTION - SAFETY GUIDELINES CLEANINGTHE LUBRICATION BOXFigure 40. Cleaning the Lubrication Box CYLINDER LUBRICATION BOXWEAR PLATE AND CUTTING RING replace the rubber energizer 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 and Ring Replacement Procedure Wear Plate InstallationWear Ring installation CAUTION - HYDRAULIC OILTEMPERATUREFigure 42. Cylinder Stroke Control Switch JOG Figure 43. Manual Cylinder Jogging SwitchWHEEL BEARINGS EXTENDED STORAGE INSTRUCTIONSLS400/LS500 PUMP - MAINTENANCE TRAILER Manually Adjusting the BrakesTrailer Brakes Hydraulic BrakesLS400/LS500 PUMP - MAINTENANCE TRAILER Adjustable ChannelFigure 47. Adjustable Channel With Pintle Eye Coupler Figure 48. Wheel Hub Components Wheel Hub AdjustmentDanger - Raising the Trailer DANGER - Trailer InspectionTorsion Suspension WARNING - Trailer ImpactLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES TRAILER SAFETY INFORMATIONCommon Causes for Loss of Trailer Trailer Towing GuidelinesLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES CAUTION - Local Towing RegulationsDriving Conditions WARNING - Transporting PersonnelReporting Safety Defects Inoperable Brakes, Lights or MirrorsTrailer Towing Tips LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESLS400/LS500 PUMP - TRAILER SAFETY GUIDELINES Trailer VIN TagFigure 50. Vehicle VIN Tag Figure 51. VIN Tag LocationElectrical Connector Safety ChainsTrailer Lighting and Braking Connector Tow VehicleFigure 52. Ball Hitch Coupler Adjustable Tongue Coupler TypesBall Hitch Coupler WARNING - Hitch Ball Load RatingWARNING - Defective Hitch Ball WARNING - Uncoupled Hitch BallFigure 53. Ball Hitch Coupling Mechanism LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESAttaching Safety Chain WARNING - Safety Chains RiggingBreakaway Brake System Figure 55. Breakaway Brake System Breakaway Cable Surge Brake SystemLS400/LS500 PUMP - TRAILER SAFETY GUIDELINES Connecting Trailer LightsTIRE SAFETY Uncoupling the Ball HitchWARNING - Lug Nut Loosening Determining Load Limit of TrailerWARNING - Improper Lug Nut Torque WARNING - Tire PressureStep Determining Load Limit of Tow Vehicle StepTire Fundamentals Figure 57. Standard Tire Sidewall InformationLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES Uniform Tire Quality Grading Standards UTQGSTable 6. Speed Rating Tire Safety Tips Figure 58. UTQGS Tire InformationTire Repair Replacing Worn or Damaged TiresWARNING - Flying Objects Wheel RimsWheels, Bearings and Lug Nuts Lug Nut Torque RequirementsWARNING - Trailer Lights Figure 60. Trailer to Tow Vehicle Wiring DiagramLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES LS400/LS500 PUMP - TROUBLESHOOTING PUMP TABLE 9. PUMP TROUBLESHOOTINGWARNING - HYDRAULIC SYSTEM HAZARD DANGER - AMPUTATION RISKLS400/LS500 PUMP - TROUBLESHOOTING PUMP TABLE 9. PUMP TROUBLESHOOTING CONTINUEDLS400/LS500 PUMP - TROUBLESHOOTING PUMP TABLE 9. PUMP TROUBLESHOOTING CONTINUEDDecrease volume control on main Engine overloaded when pumpingLS400/LS500 PUMP -TROUBLESHOOTING ENGINE TABLE 10. ENGINE TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMLS400/LS500 PUMP -TROUBLESHOOTING TRAILER BRAKE SYSTEM TABLE 11. BRAKE SYSTEM TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMLS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL TABLE 12. ELECTRICAL TROUBLESHOOTINGSOLUTION PROBABLE CAUSELS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL TABLE 12. ELECTRICAL TROUBLESHOOTING continuedSOLUTION PROBABLE CAUSEFigure 61. Location of Components for Electrical Troubleshooting LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALPROXIMITY SWITCH “B” ALTERNATOR V-BELT PROXIMITY SWITCH “A” MAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOIDLS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX MANIFO LDF 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 LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX C A H DF GLS400/LS500 PUMP - WIRING DIAGRAM HOPPER VIBRATOR Figure 65. Optional Hopper Vibrator Wiring DiagramFigure 66. Hydraulic System Diagram LS400/LS500 PUMP - HYDRAULIC SYSTEM DIAGRAMMANIFOLD Figure 67. Manifold Block Ports LS400/LS500 PUMP - MANIFOLD BLOCK PORTSMANIFOLD BLOCK PORTS APPENDIX - CONCRETE MIX INFORMATION Washed Sand-#200 washAPPENDIX - CONCRETE MIX INFORMATION A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATEAPPENDIX - SLUMPTEST PROCEDURE Figure 68-C. SlumpTest Full-OverflowFigure 68-A. SlumpTest 1/3 Full Figure 68-B. SlumpTest 2/3 FullAPPENDIX - RECOMMENDED SHOTCRETE SYSTEM Figure 69. Recommended Shotcrete SystemAPPENDIX - RECOMMENDED SHOTCRETE SYSTEM RECOMMENDED SHOTCRETE SYSTEMNO. PART NO PART NAMEAPPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIESFigure 70. Shotcrete System Accessories HAS PASSED THROUGH THE ENTIRE HOSE LENGTHREMARKS APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIESPART NAME EM26107SAMPLE PARTS LIST LS400/LS500 PUMP - EXPLANATION OF CODE IN REMARKS COLUMNQTY. Column NO. ColumnLS400/LS500 PUMP - SUGGESTED SPARE PARTS LS400/LS500CONCRETE PUMP 1 UnitLS400/LS500 PUMP - NAMEPLATE AND DECALS USE THIS DECAL OPTION WHEN 3 HYDRAULIC STABILIZER JACKS ARE INSTALLED10 800-30-MAYCO 1 PLACE DECAL ON LS400 MODELS ONLY 2 PLACE DECAL ON LS500 MODELS ONLYLS400/LS500 PUMP - NAMEPLATE AND DECALS PART NAMEREMARKS OPTION HYD. JACKSLS400/LS500 PUMP - NAMEPLATE AND DECALS LS400/LS500 PUMP - NAMEPLATE AND DECALS PART NAMEREMARKS USED ON LS400 MODELSLS400/LS500 PUMP - FRAME ASSY FRAME ASSYLS400/LS500 PUMP - FRAME ASSY PART NAMEREMARKS CHAIN, TRAILER HITCH, 3/8 X 40, GRADELS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFT AXLE ASSY. RIGHT/LEFTLS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFT PART NAMEREMARKS EM98116LS400/LS500 PUMP - BRAKE LINE ASSY BRAKE LINE ASSYLS400/LS500 PUMP - BRAKE LINE ASSY PART NAME34566 KIT, MAIN BRAKE LINELS400/LS500 PUMP - BRAKE LIGHT ASSY BRAKE LIGHT ASSYLS400/LS500 PUMP - BRAKE LIGHT ASSY PART NAMEHARNESS ASSY. W/RECEPTACLES REMARKSLS400/LS500 PUMP -TRAILER HITCH ASSY TRAILER HITCH ASSYPART NAME LS400/LS500 PUMP -TRAILER HITCH ASSYEM29228 LS400/LS500 PUMP - BATTERY ASSY LS400/LS500 PUMP - BATTERY ASSY BATTERY ASSYBATTERY BOX W/ BELT BATTERY 12V 125ALS400/LS500 PUMP - HOPPER ASSY HOPPER ASSYLS400/LS500 PUMP - HOPPER ASSY PART NAMEREMARKS INCLUDES ITEMS W/%LS400/LS500 PUMP - HOPPER ATTACHMENT ASSY HOPPER ATTACHMENT ASSYPART NAME LS400/LS500 PUMP - HOPPER ATTACHMENT ASSYREMARKS LS400/LS500 PUMP - HOPPER INTERIOR ASSY HOPPER INTERIOR ASSYLS400/LS500 PUMP - HOPPER INTERIOR ASSY PART NAMEREMARKS BOLT, COUNTER SUNK 5/8-11 x 3 INLS400/LS500 PUMP - SHUTTLE CYLINDER ASSY SHUTTLE CYLINDER ASSYLS400/LS500 PUMP - SHUTTLE CYLINDER ASSY PART NAMEREMARKS INCLUDES ITEMS WLS400/LS500 PUMP - LUBRICATION PISTONS ASSY LUBRICATION PISTONS ASSYLS400/LS500 PUMP - LUBRICATION PISTONS ASSY PART NAMEREMARKS BOLT, 3/8 NC X 1.3/4 IN. G5LS400/LS500 PUMP - LUBRICATION PISTONS ASSY PART NAME LS400/LS500 PUMP - LUBRICATION PISTONS ASSYEM514920 LS400/LS500 PUMP - FUELTANK ASSY FUEL TANK ASSYLS400/LS500 PUMP - FUELTANK ASSY PART NAMEREMARKS WASHER, LOCK 5/16 INLS400/LS500 PUMP - HEAT EXCHANGER ASSY HEAT EXCHANGER ASSYLS400/LS500 PUMP - HEAT EXCHANGER ASSY PART NAMEREMARKS HEAT EXCHANGER ASSYLS400/LS500 PUMP - ACCUMULATOR ASSY ACCUMULATOR ASSYLS400/LS500 PUMP - ACCUMULATOR ASSY PART NAMEACCUMULATOR ASSY ACCUMULATOR TEST/CHARGE KITLS400/LS500 PUMP - REMIXER CONTROL ASSY REMIXER CONTROL ASSYPART NAME LS400/LS500 PUMP - REMIXER CONTROL ASSYREMARKS LS400/LS500 PUMP - LUBRICATION PANEL POSITIONLOCATION LENGTH OF LINESLS400/LS500 PUMP - LUBRICATION PANEL PART NAMELS400/LS500 PUMP - ENGINE COVER ASSY ENGINE COVER ASSYLS400/LS500 PUMP - ENGINE COVER ASSY PART NAMEREMARKS EM517737LS400/LS500 PUMP - HYDRAULICTANK ASSY HYDRAULIC TANK ASSYLS400/LS500 PUMP - HYDRAULICTANK ASSY PART NAMEREMARKS STRAIGHT MALE ADAPTORLS400/LS500 PUMP - ENGINE ASSY LS-40TD/LS-50TD ENGINE ASSYPART NAME LS400/LS500 PUMP - ENGINE ASSYREMARKS LS400/LS500 PUMP -THROTTLE ASSY THROTTLE ASSYLS400/LS500 PUMP -THROTTLE ASSY PART NAMEREMARKS LOCK WASHER 1/4 INLS400/LS500 PUMP -WATER SEPARATOR ASSY WATER SEPARATOR ASSYLS400/LS500 PUMP -WATER SEPARATOR ASSY PART NAMEREMARKS REPLACESLS400/LS500 PUMP - HYD. PUMP ASSY HYDRAULIC PUMP ASSYLS400/LS500 PUMP - HYD. PUMP ASSY PART NAMEREMARKS MOTORIZED FLOW CONTROL MANIFOLD ASSYLS400/LS500 PUMP - MANIFOLD ASSY FRONT OFMACHINE MANIFOLD ASSYLS400/LS500 PUMP - MANIFOLD ASSY PART NAMEREMARKS MANIFOLD ASSYLS400/LS500 PUMP - CONTROL BOX ASSY CONTROL BOX ASSYPART NAME LS400/LS500 PUMP - CONTROL BOX ASSYREMARKS LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSY CONTROL BOX HARNESSES ASSYPART NAME LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSYPOLY FLEX TUBE 1/2 IN. BLACK LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSY REMOTE CONTROL CABLE ASSYLS400/LS500 PUMP - REMOTE CONTROL CABLE ASSY PART NAMEREMARKS ADAPTER, CORD GRIP 1/2 INLS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL PART NAMETERMS AND CONDITIONS OF SALE - PARTS SPECIAL EXPEDITING SERVICEPAYMENT TERMS FREIGHT POLICYMECHANICAL DRIVE MODELS MAYCO PUMPWARRANTYHYDRAULIC DRIVE MODELS HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGService Department Warranty Department