Manuals / Multiquip / Household Appliance / Water Pump

Multiquip LS500, LS400 manual

Models: LS500 LS400

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NOTES

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

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Contents

SERIES OPERATION AND PARTS MANUALTHIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES MODELS LS400/LS500Diesel engine exhaust and some of LS400/LS500 PUMPProposition- PROPOSITION65 Warning 65 WARNINGPage 8-10 LS400/LS500 PUMP -TABLE OF CONTENTSMAYCO LS400/LS500 COMPONENT DRAWINGSChoose from three easy options PARTS ORDERING PROCEDURESWhen ordering parts, please supply Ordering parts has never been easierDANGER LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS SAFETY MESSAGE ALERT SYMBOLSCAUTION - OVER-SPEED CONDITIONS LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - ACCIDENTAL STARTINGLS400/LS500 PUMP - RULES FOR SAFE OPERATION GENERAL SAFETYTowing LS400/LS500 PUMP - RULES FOR SAFE OPERATIONTRANSPORTING EMERGENCIES MAINTENANCE SAFETYBATTERY DANGER - AMPUTATION RISKPage No. of Cylinders LS400/LS500 PUMP - SPECIFICATIONSTABLE 2. ENGINE SPECIFICATIONS TABLE 1. PUMP SPECIFICATIONSTABLE 3. DIMENSIONS LS400/LS500 PUMP - DIMENSIONSDIMENSIONS Figure 1. DimensionsFigure 2. Operation Hand Signals LS400/LS500 PUMP - IMPORTANT HAND SIGNALSCONCRETE MIX DESIGN LS400/LS500 PUMP - GENERAL INFORMATIONREGIONAL DIFFERENCES LS400/LS500 PUMP - GENERAL INFORMATIONFigure 3. Pumping Cycle LS400/LS500 PUMP - HOW IT WORKSFigure 4. 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 COMPONENTSScreen LS400/LS500 PUMP - DIGITAL READOUT SCREENPRIMARY SCREEN Screen SECONDARY SCREENS ScreenINITIAL SERVICING LS400/LS500 PUMP - ENGINE COMPONENTSFigure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components Figure 8. Fuel Cap Gauge LS400/LS500 PUMP - INSPECTIONFUEL CHECK BEFORE STARTINGHYDRAULIC OIL CHECK LS400/LS500 PUMP - INSPECTIONENGINE OIL CHECK Figure 10. Engine Oil DipstickLS400/LS500 PUMP - INSPECTION Figure 13. Hydraulic Oil Filler HoleFigure 14. Filling the Lubrication Box REAR STABILIZER JACKS WARNING - REAR STABILIZER SAFETYLS400/LS500 PUMP - SET-UP LOCATION OF PUMPFigure 22. Direction Control Switch FORWARD LS400/LS500 PUMP - START-UP PROCEDURESTARTING PROCEDURE 4. Place the Direction Control Switch to the FORWARD position FigureLS400/LS500 PUMP - OPERATION WARNING - SAFETY GLASSESFigure 26. Pumping Control Switch LOCAL Figure 27. Volume ControlFigure 31. Hopper Remixer Control Lever Figure 30. Accumulator Pressure GaugeFigure 32. Hopper Remixer Blades Rotation CAUTION - HOSE/LINE BLOCKAGEFigure 35. Installing Remote Control Module REMOTE CONTROL OPTIONALRadio Remote Control Figure 36. Antenna InstallationWARNING -TRANSPORTING PUMP Cable Remote ControlFigure 38. Cable Remote Control LS400/LS500 PUMP - OPERATIONVERTICAL PUMPING LS400/LS500 PUMP - PUMPING INFORMATIONREMIXTURES DOWNHILL PUMPINGTHE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETE LS400/LS500 PUMP - PUMPING INFORMATIONSNAP-JOINT COUPLINGS NEW PUMPSWARNING - BLOCKAGES CLEARING THE SYSTEM AFTER MIX SET UPWARNING - HOSE/LINE PRESSURE CLEARING CONCRETE BLOCKAGEWARNING - SHUTTLE TUBES “REVERSE” PUMPING PROCEDURESHUTTLE TUBE INSPECTION PROCEDURE CLEARING SHUTTLETUBE BLOCKAGEDANGER - AMPUTATION RISK LS400/LS500 PUMP - MAINTENANCE PUMPCLEANING THE PUMP AND DELIVERY SYSTEM WARNING - HYDRAULIC OIL LS400/LS500 PUMP - MAINTENANCE PUMPWARNING - ACID CLEANING HYDRAULIC OIL SYSTEM MAINTENANCEFigure 39. Battery Electrolyte Levels LS400/LS500 PUMP - MAINTENANCE PUMPBATTERY MAINTENANCE CAUTION - BATTERY MAINTENANCE SAFETYCYLINDER LUBRICATION BOX CAUTION - SAFETY GUIDELINESCLEANINGTHE LUBRICATION BOX Figure 40. Cleaning the Lubrication Box3. When the output volume at the end of the delivery line WEAR PLATE AND CUTTING RINGreplace the rubber energizer ring LS400/LS500 PUMP - MAINTENANCE PUMPDANGER - AMPUTATION RISK LS400/LS500 PUMP - MAINTENANCE PUMPThe size and type of aggregate The type of concrete being pumped CAUTION - HYDRAULIC OILTEMPERATURE Wear Plate and Ring Replacement ProcedureWear Plate Installation Wear Ring installationEXTENDED STORAGE INSTRUCTIONS Figure 42. Cylinder Stroke Control Switch JOGFigure 43. Manual Cylinder Jogging Switch WHEEL BEARINGSHydraulic Brakes LS400/LS500 PUMP - MAINTENANCE TRAILERManually Adjusting the Brakes Trailer BrakesFigure 48. Wheel Hub Components Wheel Hub Adjustment LS400/LS500 PUMP - MAINTENANCE TRAILERAdjustable Channel Figure 47. Adjustable Channel With Pintle Eye CouplerWARNING - Trailer Impact Danger - Raising the TrailerDANGER - Trailer Inspection Torsion SuspensionTrailer Towing Guidelines LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESTRAILER SAFETY INFORMATION Common Causes for Loss of TrailerWARNING - Transporting Personnel LS400/LS500 PUMP -TRAILER SAFETY GUIDELINESCAUTION - Local Towing Regulations Driving ConditionsLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES Reporting Safety DefectsInoperable Brakes, Lights or Mirrors Trailer Towing TipsFigure 51. VIN Tag Location LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESTrailer VIN Tag Figure 50. Vehicle VIN TagTow Vehicle Electrical ConnectorSafety Chains Trailer Lighting and Braking ConnectorWARNING - Hitch Ball Load Rating Figure 52. Ball Hitch Coupler Adjustable TongueCoupler Types Ball Hitch CouplerLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES WARNING - Defective Hitch BallWARNING - Uncoupled Hitch Ball Figure 53. Ball Hitch Coupling MechanismFigure 55. Breakaway Brake System Breakaway Cable Surge Brake System Attaching Safety ChainWARNING - Safety Chains Rigging Breakaway Brake SystemUncoupling the Ball Hitch LS400/LS500 PUMP - TRAILER SAFETY GUIDELINESConnecting Trailer Lights TIRE SAFETYWARNING - Tire Pressure WARNING - Lug Nut LooseningDetermining Load Limit of Trailer WARNING - Improper Lug Nut TorqueFigure 57. Standard Tire Sidewall Information StepDetermining Load Limit of Tow Vehicle Step Tire FundamentalsTable 6. Speed Rating Uniform Tire Quality Grading Standards UTQGSLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES Replacing Worn or Damaged Tires Tire Safety TipsFigure 58. UTQGS Tire Information Tire RepairLug Nut Torque Requirements WARNING - Flying ObjectsWheel Rims Wheels, Bearings and Lug NutsLS400/LS500 PUMP -TRAILER SAFETY GUIDELINES Figure 60. Trailer to Tow Vehicle Wiring DiagramWARNING - Trailer Lights DANGER - AMPUTATION RISK LS400/LS500 PUMP - TROUBLESHOOTING PUMPTABLE 9. PUMP TROUBLESHOOTING WARNING - HYDRAULIC SYSTEM HAZARDTABLE 9. PUMP TROUBLESHOOTING CONTINUED LS400/LS500 PUMP - TROUBLESHOOTING PUMPEngine overloaded when pumping LS400/LS500 PUMP - TROUBLESHOOTING PUMPTABLE 9. PUMP TROUBLESHOOTING CONTINUED Decrease volume control on mainPOSSIBLE PROBLEM LS400/LS500 PUMP -TROUBLESHOOTING ENGINETABLE 10. ENGINE TROUBLESHOOTING SYMPTOMPOSSIBLE PROBLEM LS400/LS500 PUMP -TROUBLESHOOTING TRAILER BRAKE SYSTEMTABLE 11. BRAKE SYSTEM TROUBLESHOOTING SYMPTOMPROBABLE CAUSE LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALTABLE 12. ELECTRICAL TROUBLESHOOTING SOLUTIONPROBABLE CAUSE LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICALTABLE 12. ELECTRICAL TROUBLESHOOTING continued SOLUTIONMAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOID Figure 61. Location of Components for Electrical TroubleshootingLS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL PROXIMITY SWITCH “B” ALTERNATOR V-BELT PROXIMITY SWITCH “A”MANIFO LD LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXE H G A I L K J LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXF C D DIGITAL CONTROL BOX LS400 AND LS500 LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXCONNECTIONS TO J3 AND J4 CONNECTORS ON C A H DF G LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOXFigure 65. Optional Hopper Vibrator Wiring Diagram LS400/LS500 PUMP - WIRING DIAGRAM HOPPER VIBRATORMANIFOLD LS400/LS500 PUMP - HYDRAULIC SYSTEM DIAGRAMFigure 66. Hydraulic System Diagram MANIFOLD BLOCK PORTS LS400/LS500 PUMP - MANIFOLD BLOCK PORTSFigure 67. Manifold Block Ports Washed Sand-#200 wash APPENDIX - CONCRETE MIX INFORMATIONA.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE APPENDIX - CONCRETE MIX INFORMATIONFigure 68-B. SlumpTest 2/3 Full APPENDIX - SLUMPTEST PROCEDUREFigure 68-C. SlumpTest Full-Overflow Figure 68-A. SlumpTest 1/3 FullFigure 69. Recommended Shotcrete System APPENDIX - RECOMMENDED SHOTCRETE SYSTEMPART NAME APPENDIX - RECOMMENDED SHOTCRETE SYSTEMRECOMMENDED SHOTCRETE SYSTEM NO. PART NOHAS PASSED THROUGH THE ENTIRE HOSE LENGTH APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIESRECOMMENDED SHOTCRETE ACCESSORIES Figure 70. Shotcrete System AccessoriesEM26107 REMARKSAPPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES PART NAMENO. Column SAMPLE PARTS LISTLS400/LS500 PUMP - EXPLANATION OF CODE IN REMARKS COLUMN QTY. Column1 Unit LS400/LS500 PUMP - SUGGESTED SPARE PARTSLS400/LS500 CONCRETE PUMP1 PLACE DECAL ON LS400 MODELS ONLY 2 PLACE DECAL ON LS500 MODELS ONLY LS400/LS500 PUMP - NAMEPLATE AND DECALSUSE THIS DECAL OPTION WHEN 3 HYDRAULIC STABILIZER JACKS ARE INSTALLED 10 800-30-MAYCOOPTION HYD. JACKS LS400/LS500 PUMP - NAMEPLATE AND DECALSPART NAME REMARKSLS400/LS500 PUMP - NAMEPLATE AND DECALS USED ON LS400 MODELS LS400/LS500 PUMP - NAMEPLATE AND DECALSPART NAME REMARKSFRAME ASSY LS400/LS500 PUMP - FRAME ASSYCHAIN, TRAILER HITCH, 3/8 X 40, GRADE LS400/LS500 PUMP - FRAME ASSYPART NAME REMARKSAXLE ASSY. RIGHT/LEFT LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFTEM98116 LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFTPART NAME REMARKSBRAKE LINE ASSY LS400/LS500 PUMP - BRAKE LINE ASSYKIT, MAIN BRAKE LINE LS400/LS500 PUMP - BRAKE LINE ASSYPART NAME 34566BRAKE LIGHT ASSY LS400/LS500 PUMP - BRAKE LIGHT ASSYREMARKS LS400/LS500 PUMP - BRAKE LIGHT ASSYPART NAME HARNESS ASSY. W/RECEPTACLESTRAILER HITCH ASSY LS400/LS500 PUMP -TRAILER HITCH ASSYEM29228 LS400/LS500 PUMP -TRAILER HITCH ASSYPART NAME LS400/LS500 PUMP - BATTERY ASSY BATTERY 12V 125A LS400/LS500 PUMP - BATTERY ASSYBATTERY ASSY BATTERY BOX W/ BELTHOPPER ASSY LS400/LS500 PUMP - HOPPER ASSYINCLUDES ITEMS W/% LS400/LS500 PUMP - HOPPER ASSYPART NAME REMARKSHOPPER ATTACHMENT ASSY LS400/LS500 PUMP - HOPPER ATTACHMENT ASSYREMARKS LS400/LS500 PUMP - HOPPER ATTACHMENT ASSYPART NAME HOPPER INTERIOR ASSY LS400/LS500 PUMP - HOPPER INTERIOR ASSYBOLT, COUNTER SUNK 5/8-11 x 3 IN LS400/LS500 PUMP - HOPPER INTERIOR ASSYPART NAME REMARKSSHUTTLE CYLINDER ASSY LS400/LS500 PUMP - SHUTTLE CYLINDER ASSYINCLUDES ITEMS W LS400/LS500 PUMP - SHUTTLE CYLINDER ASSYPART NAME REMARKSLUBRICATION PISTONS ASSY LS400/LS500 PUMP - LUBRICATION PISTONS ASSYBOLT, 3/8 NC X 1.3/4 IN. G5 LS400/LS500 PUMP - LUBRICATION PISTONS ASSYPART NAME REMARKSLS400/LS500 PUMP - LUBRICATION PISTONS ASSY EM514920 LS400/LS500 PUMP - LUBRICATION PISTONS ASSYPART NAME FUEL TANK ASSY LS400/LS500 PUMP - FUELTANK ASSYWASHER, LOCK 5/16 IN LS400/LS500 PUMP - FUELTANK ASSYPART NAME REMARKSHEAT EXCHANGER ASSY LS400/LS500 PUMP - HEAT EXCHANGER ASSYHEAT EXCHANGER ASSY LS400/LS500 PUMP - HEAT EXCHANGER ASSYPART NAME REMARKSACCUMULATOR ASSY LS400/LS500 PUMP - ACCUMULATOR ASSYACCUMULATOR TEST/CHARGE KIT LS400/LS500 PUMP - ACCUMULATOR ASSYPART NAME ACCUMULATOR ASSYREMIXER CONTROL ASSY LS400/LS500 PUMP - REMIXER CONTROL ASSYREMARKS LS400/LS500 PUMP - REMIXER CONTROL ASSYPART NAME LENGTH OF LINES LS400/LS500 PUMP - LUBRICATION PANELPOSITION LOCATIONPART NAME LS400/LS500 PUMP - LUBRICATION PANELENGINE COVER ASSY LS400/LS500 PUMP - ENGINE COVER ASSYEM517737 LS400/LS500 PUMP - ENGINE COVER ASSYPART NAME REMARKSHYDRAULIC TANK ASSY LS400/LS500 PUMP - HYDRAULICTANK ASSYSTRAIGHT MALE ADAPTOR LS400/LS500 PUMP - HYDRAULICTANK ASSYPART NAME REMARKSLS-40TD/LS-50TD ENGINE ASSY LS400/LS500 PUMP - ENGINE ASSYREMARKS LS400/LS500 PUMP - ENGINE ASSYPART NAME THROTTLE ASSY LS400/LS500 PUMP -THROTTLE ASSYLOCK WASHER 1/4 IN LS400/LS500 PUMP -THROTTLE ASSYPART NAME REMARKSWATER SEPARATOR ASSY LS400/LS500 PUMP -WATER SEPARATOR ASSYREPLACES LS400/LS500 PUMP -WATER SEPARATOR ASSYPART NAME REMARKSHYDRAULIC PUMP ASSY LS400/LS500 PUMP - HYD. PUMP ASSYMOTORIZED FLOW CONTROL MANIFOLD ASSY LS400/LS500 PUMP - HYD. PUMP ASSYPART NAME REMARKSMANIFOLD ASSY LS400/LS500 PUMP - MANIFOLD ASSYFRONT OF MACHINEMANIFOLD ASSY LS400/LS500 PUMP - MANIFOLD ASSYPART NAME REMARKSCONTROL BOX ASSY LS400/LS500 PUMP - CONTROL BOX ASSYREMARKS LS400/LS500 PUMP - CONTROL BOX ASSYPART NAME CONTROL BOX HARNESSES ASSY LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSYPOLY FLEX TUBE 1/2 IN. BLACK LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSYPART NAME REMOTE CONTROL CABLE ASSY LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSYADAPTER, CORD GRIP 1/2 IN LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSYPART NAME REMARKSLS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL PART NAME LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONALFREIGHT POLICY TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSHYDRAULIC DRIVE MODELS MAYCO PUMPWARRANTYMECHANICAL DRIVE MODELS Warranty Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Service Department