MODELS LS400/LS500
OPERATION AND PARTS MANUAL
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES
SERIES
LS400/LS500 PUMPProposition- PROPOSITION65 Warning 65 WARNING
Diesel engine exhaust and some of
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COMPONENT DRAWINGS
LS400/LS500 PUMP -TABLE OF CONTENTS
MAYCO LS400/LS500
8-10
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PARTS ORDERING PROCEDURES
When ordering parts, please supply
Choose from three easy options
SAFETY MESSAGE ALERT SYMBOLS
LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
DANGER
CAUTION - ACCIDENTAL STARTING
LS400/LS500 PUMP - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - OVER-SPEED CONDITIONS
GENERAL SAFETY
LS400/LS500 PUMP - RULES FOR SAFE OPERATION
LS400/LS500 PUMP - RULES FOR SAFE OPERATION
TRANSPORTING
Towing
DANGER - AMPUTATION RISK
MAINTENANCE SAFETY
BATTERY
EMERGENCIES
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TABLE 1. PUMP SPECIFICATIONS
LS400/LS500 PUMP - SPECIFICATIONS
TABLE 2. ENGINE SPECIFICATIONS
No. of Cylinders
Figure 1. Dimensions
LS400/LS500 PUMP - DIMENSIONS
DIMENSIONS
TABLE 3. DIMENSIONS
LS400/LS500 PUMP - IMPORTANT HAND SIGNALS
Figure 2. Operation Hand Signals
LS400/LS500 PUMP - GENERAL INFORMATION
CONCRETE MIX DESIGN
LS400/LS500 PUMP - GENERAL INFORMATION
REGIONAL DIFFERENCES
LS400/LS500 PUMP - HOW IT WORKS
Figure 4. Pumping Cycle
Figure 3. Pumping Cycle
LS400/LS500 PUMP - PUMP COMPONENTS
Figure 5. Major Pump Components
LS400/LS500 PUMP - PUMP COMPONENTS
LS400/LS500 PUMP - DIGITAL CONTROL PANEL COMPONENTS
Figure 6. Pump Digital Control Panel Components
SECONDARY SCREENS Screen
LS400/LS500 PUMP - DIGITAL READOUT SCREEN
PRIMARY SCREEN Screen
Screen
LS400/LS500 PUMP - ENGINE COMPONENTS
Figure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components
INITIAL SERVICING
BEFORE STARTING
LS400/LS500 PUMP - INSPECTION
FUEL CHECK
Figure 8. Fuel Cap Gauge
Figure 10. Engine Oil Dipstick
LS400/LS500 PUMP - INSPECTION
ENGINE OIL CHECK
HYDRAULIC OIL CHECK
Figure 13. Hydraulic Oil Filler Hole
Figure 14. Filling the Lubrication Box
LS400/LS500 PUMP - INSPECTION
LOCATION OF PUMP
WARNING - REAR STABILIZER SAFETY
LS400/LS500 PUMP - SET-UP
REAR STABILIZER JACKS
4. Place the Direction Control Switch to the FORWARD position Figure
LS400/LS500 PUMP - START-UP PROCEDURE
STARTING PROCEDURE
Figure 22. Direction Control Switch FORWARD
Figure 27. Volume Control
WARNING - SAFETY GLASSES
Figure 26. Pumping Control Switch LOCAL
LS400/LS500 PUMP - OPERATION
CAUTION - HOSE/LINE BLOCKAGE
Figure 30. Accumulator Pressure Gauge
Figure 32. Hopper Remixer Blades Rotation
Figure 31. Hopper Remixer Control Lever
Figure 36. Antenna Installation
REMOTE CONTROL OPTIONAL
Radio Remote Control
Figure 35. Installing Remote Control Module
LS400/LS500 PUMP - OPERATION
Cable Remote Control
Figure 38. Cable Remote Control
WARNING -TRANSPORTING PUMP
DOWNHILL PUMPING
LS400/LS500 PUMP - PUMPING INFORMATION
REMIXTURES
VERTICAL PUMPING
NEW PUMPS
LS400/LS500 PUMP - PUMPING INFORMATION
SNAP-JOINT COUPLINGS
THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETE
CLEARING CONCRETE BLOCKAGE
CLEARING THE SYSTEM AFTER MIX SET UP
WARNING - HOSE/LINE PRESSURE
WARNING - BLOCKAGES
CLEARING SHUTTLETUBE BLOCKAGE
“REVERSE” PUMPING PROCEDURE
SHUTTLE TUBE INSPECTION PROCEDURE
WARNING - SHUTTLE TUBES
LS400/LS500 PUMP - MAINTENANCE PUMP
CLEANING THE PUMP AND DELIVERY SYSTEM
DANGER - AMPUTATION RISK
HYDRAULIC OIL SYSTEM MAINTENANCE
LS400/LS500 PUMP - MAINTENANCE PUMP
WARNING - ACID CLEANING
WARNING - HYDRAULIC OIL
CAUTION - BATTERY MAINTENANCE SAFETY
LS400/LS500 PUMP - MAINTENANCE PUMP
BATTERY MAINTENANCE
Figure 39. Battery Electrolyte Levels
Figure 40. Cleaning the Lubrication Box
CAUTION - SAFETY GUIDELINES
CLEANINGTHE LUBRICATION BOX
CYLINDER LUBRICATION BOX
LS400/LS500 PUMP - MAINTENANCE PUMP
WEAR PLATE AND CUTTING RING
replace the rubber energizer ring
3. When the output volume at the end of the delivery line
LS400/LS500 PUMP - MAINTENANCE PUMP
The size and type of aggregate The type of concrete being pumped
DANGER - AMPUTATION RISK
Wear Ring installation
Wear Plate and Ring Replacement Procedure
Wear Plate Installation
CAUTION - HYDRAULIC OILTEMPERATURE
WHEEL BEARINGS
Figure 42. Cylinder Stroke Control Switch JOG
Figure 43. Manual Cylinder Jogging Switch
EXTENDED STORAGE INSTRUCTIONS
Trailer Brakes
LS400/LS500 PUMP - MAINTENANCE TRAILER
Manually Adjusting the Brakes
Hydraulic Brakes
Figure 47. Adjustable Channel With Pintle Eye Coupler
LS400/LS500 PUMP - MAINTENANCE TRAILER
Adjustable Channel
Figure 48. Wheel Hub Components Wheel Hub Adjustment
Torsion Suspension
Danger - Raising the Trailer
DANGER - Trailer Inspection
WARNING - Trailer Impact
Common Causes for Loss of Trailer
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
TRAILER SAFETY INFORMATION
Trailer Towing Guidelines
Driving Conditions
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
CAUTION - Local Towing Regulations
WARNING - Transporting Personnel
Trailer Towing Tips
Reporting Safety Defects
Inoperable Brakes, Lights or Mirrors
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
Figure 50. Vehicle VIN Tag
LS400/LS500 PUMP - TRAILER SAFETY GUIDELINES
Trailer VIN Tag
Figure 51. VIN Tag Location
Trailer Lighting and Braking Connector
Electrical Connector
Safety Chains
Tow Vehicle
Ball Hitch Coupler
Figure 52. Ball Hitch Coupler Adjustable Tongue
Coupler Types
WARNING - Hitch Ball Load Rating
Figure 53. Ball Hitch Coupling Mechanism
WARNING - Defective Hitch Ball
WARNING - Uncoupled Hitch Ball
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
Breakaway Brake System
Attaching Safety Chain
WARNING - Safety Chains Rigging
Figure 55. Breakaway Brake System Breakaway Cable Surge Brake System
TIRE SAFETY
LS400/LS500 PUMP - TRAILER SAFETY GUIDELINES
Connecting Trailer Lights
Uncoupling the Ball Hitch
WARNING - Improper Lug Nut Torque
WARNING - Lug Nut Loosening
Determining Load Limit of Trailer
WARNING - Tire Pressure
Tire Fundamentals
Step
Determining Load Limit of Tow Vehicle Step
Figure 57. Standard Tire Sidewall Information
Uniform Tire Quality Grading Standards UTQGS
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
Table 6. Speed Rating
Tire Repair
Tire Safety Tips
Figure 58. UTQGS Tire Information
Replacing Worn or Damaged Tires
Wheels, Bearings and Lug Nuts
WARNING - Flying Objects
Wheel Rims
Lug Nut Torque Requirements
Figure 60. Trailer to Tow Vehicle Wiring Diagram
WARNING - Trailer Lights
LS400/LS500 PUMP -TRAILER SAFETY GUIDELINES
WARNING - HYDRAULIC SYSTEM HAZARD
LS400/LS500 PUMP - TROUBLESHOOTING PUMP
TABLE 9. PUMP TROUBLESHOOTING
DANGER - AMPUTATION RISK
LS400/LS500 PUMP - TROUBLESHOOTING PUMP
TABLE 9. PUMP TROUBLESHOOTING CONTINUED
Decrease volume control on main
LS400/LS500 PUMP - TROUBLESHOOTING PUMP
TABLE 9. PUMP TROUBLESHOOTING CONTINUED
Engine overloaded when pumping
SYMPTOM
LS400/LS500 PUMP -TROUBLESHOOTING ENGINE
TABLE 10. ENGINE TROUBLESHOOTING
POSSIBLE PROBLEM
SYMPTOM
LS400/LS500 PUMP -TROUBLESHOOTING TRAILER BRAKE SYSTEM
TABLE 11. BRAKE SYSTEM TROUBLESHOOTING
POSSIBLE PROBLEM
SOLUTION
LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL
TABLE 12. ELECTRICAL TROUBLESHOOTING
PROBABLE CAUSE
SOLUTION
LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL
TABLE 12. ELECTRICAL TROUBLESHOOTING continued
PROBABLE CAUSE
PROXIMITY SWITCH “B” ALTERNATOR V-BELT PROXIMITY SWITCH “A”
Figure 61. Location of Components for Electrical Troubleshooting
LS400/LS500 PUMP - TROUBLESHOOTING ELECTRICAL
MAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOID
LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX
MANIFO LD
LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX
F C D
E H G A I L K J
LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX
CONNECTIONS TO J3 AND J4 CONNECTORS ON
DIGITAL CONTROL BOX LS400 AND LS500
LS400/LS500 PUMP - WIRING DIAGRAM CONTROL BOX
C A H DF G
LS400/LS500 PUMP - WIRING DIAGRAM HOPPER VIBRATOR
Figure 65. Optional Hopper Vibrator Wiring Diagram
LS400/LS500 PUMP - HYDRAULIC SYSTEM DIAGRAM
Figure 66. Hydraulic System Diagram
MANIFOLD
LS400/LS500 PUMP - MANIFOLD BLOCK PORTS
Figure 67. Manifold Block Ports
MANIFOLD BLOCK PORTS
APPENDIX - CONCRETE MIX INFORMATION
Washed Sand-#200 wash
APPENDIX - CONCRETE MIX INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
Figure 68-A. SlumpTest 1/3 Full
APPENDIX - SLUMPTEST PROCEDURE
Figure 68-C. SlumpTest Full-Overflow
Figure 68-B. SlumpTest 2/3 Full
APPENDIX - RECOMMENDED SHOTCRETE SYSTEM
Figure 69. Recommended Shotcrete System
NO. PART NO
APPENDIX - RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
PART NAME
Figure 70. Shotcrete System Accessories
APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
HAS PASSED THROUGH THE ENTIRE HOSE LENGTH
PART NAME
REMARKS
APPENDIX - RECOMMENDED SHOTCRETE ACCESSORIES
EM26107
QTY. Column
SAMPLE PARTS LIST
LS400/LS500 PUMP - EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
CONCRETE PUMP
LS400/LS500 PUMP - SUGGESTED SPARE PARTS
LS400/LS500
1 Unit
10 800-30-MAYCO
LS400/LS500 PUMP - NAMEPLATE AND DECALS
USE THIS DECAL OPTION WHEN 3 HYDRAULIC STABILIZER JACKS ARE INSTALLED
1 PLACE DECAL ON LS400 MODELS ONLY 2 PLACE DECAL ON LS500 MODELS ONLY
REMARKS
LS400/LS500 PUMP - NAMEPLATE AND DECALS
PART NAME
OPTION HYD. JACKS
LS400/LS500 PUMP - NAMEPLATE AND DECALS
REMARKS
LS400/LS500 PUMP - NAMEPLATE AND DECALS
PART NAME
USED ON LS400 MODELS
LS400/LS500 PUMP - FRAME ASSY
FRAME ASSY
REMARKS
LS400/LS500 PUMP - FRAME ASSY
PART NAME
CHAIN, TRAILER HITCH, 3/8 X 40, GRADE
LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFT
AXLE ASSY. RIGHT/LEFT
REMARKS
LS400/LS500 PUMP - AXLE ASSY. RIGHT/LEFT
PART NAME
EM98116
LS400/LS500 PUMP - BRAKE LINE ASSY
BRAKE LINE ASSY
34566
LS400/LS500 PUMP - BRAKE LINE ASSY
PART NAME
KIT, MAIN BRAKE LINE
LS400/LS500 PUMP - BRAKE LIGHT ASSY
BRAKE LIGHT ASSY
HARNESS ASSY. W/RECEPTACLES
LS400/LS500 PUMP - BRAKE LIGHT ASSY
PART NAME
REMARKS
LS400/LS500 PUMP -TRAILER HITCH ASSY
TRAILER HITCH ASSY
LS400/LS500 PUMP -TRAILER HITCH ASSY
PART NAME
EM29228
LS400/LS500 PUMP - BATTERY ASSY
BATTERY BOX W/ BELT
LS400/LS500 PUMP - BATTERY ASSY
BATTERY ASSY
BATTERY 12V 125A
LS400/LS500 PUMP - HOPPER ASSY
HOPPER ASSY
REMARKS
LS400/LS500 PUMP - HOPPER ASSY
PART NAME
INCLUDES ITEMS W/%
LS400/LS500 PUMP - HOPPER ATTACHMENT ASSY
HOPPER ATTACHMENT ASSY
LS400/LS500 PUMP - HOPPER ATTACHMENT ASSY
PART NAME
REMARKS
LS400/LS500 PUMP - HOPPER INTERIOR ASSY
HOPPER INTERIOR ASSY
REMARKS
LS400/LS500 PUMP - HOPPER INTERIOR ASSY
PART NAME
BOLT, COUNTER SUNK 5/8-11 x 3 IN
LS400/LS500 PUMP - SHUTTLE CYLINDER ASSY
SHUTTLE CYLINDER ASSY
REMARKS
LS400/LS500 PUMP - SHUTTLE CYLINDER ASSY
PART NAME
INCLUDES ITEMS W
LS400/LS500 PUMP - LUBRICATION PISTONS ASSY
LUBRICATION PISTONS ASSY
REMARKS
LS400/LS500 PUMP - LUBRICATION PISTONS ASSY
PART NAME
BOLT, 3/8 NC X 1.3/4 IN. G5
LS400/LS500 PUMP - LUBRICATION PISTONS ASSY
LS400/LS500 PUMP - LUBRICATION PISTONS ASSY
PART NAME
EM514920
LS400/LS500 PUMP - FUELTANK ASSY
FUEL TANK ASSY
REMARKS
LS400/LS500 PUMP - FUELTANK ASSY
PART NAME
WASHER, LOCK 5/16 IN
LS400/LS500 PUMP - HEAT EXCHANGER ASSY
HEAT EXCHANGER ASSY
REMARKS
LS400/LS500 PUMP - HEAT EXCHANGER ASSY
PART NAME
HEAT EXCHANGER ASSY
LS400/LS500 PUMP - ACCUMULATOR ASSY
ACCUMULATOR ASSY
ACCUMULATOR ASSY
LS400/LS500 PUMP - ACCUMULATOR ASSY
PART NAME
ACCUMULATOR TEST/CHARGE KIT
LS400/LS500 PUMP - REMIXER CONTROL ASSY
REMIXER CONTROL ASSY
LS400/LS500 PUMP - REMIXER CONTROL ASSY
PART NAME
REMARKS
LOCATION
LS400/LS500 PUMP - LUBRICATION PANEL
POSITION
LENGTH OF LINES
LS400/LS500 PUMP - LUBRICATION PANEL
PART NAME
LS400/LS500 PUMP - ENGINE COVER ASSY
ENGINE COVER ASSY
REMARKS
LS400/LS500 PUMP - ENGINE COVER ASSY
PART NAME
EM517737
LS400/LS500 PUMP - HYDRAULICTANK ASSY
HYDRAULIC TANK ASSY
REMARKS
LS400/LS500 PUMP - HYDRAULICTANK ASSY
PART NAME
STRAIGHT MALE ADAPTOR
LS400/LS500 PUMP - ENGINE ASSY
LS-40TD/LS-50TD ENGINE ASSY
LS400/LS500 PUMP - ENGINE ASSY
PART NAME
REMARKS
LS400/LS500 PUMP -THROTTLE ASSY
THROTTLE ASSY
REMARKS
LS400/LS500 PUMP -THROTTLE ASSY
PART NAME
LOCK WASHER 1/4 IN
LS400/LS500 PUMP -WATER SEPARATOR ASSY
WATER SEPARATOR ASSY
REMARKS
LS400/LS500 PUMP -WATER SEPARATOR ASSY
PART NAME
REPLACES
LS400/LS500 PUMP - HYD. PUMP ASSY
HYDRAULIC PUMP ASSY
REMARKS
LS400/LS500 PUMP - HYD. PUMP ASSY
PART NAME
MOTORIZED FLOW CONTROL MANIFOLD ASSY
MACHINE
LS400/LS500 PUMP - MANIFOLD ASSY
FRONT OF
MANIFOLD ASSY
REMARKS
LS400/LS500 PUMP - MANIFOLD ASSY
PART NAME
MANIFOLD ASSY
LS400/LS500 PUMP - CONTROL BOX ASSY
CONTROL BOX ASSY
LS400/LS500 PUMP - CONTROL BOX ASSY
PART NAME
REMARKS
LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSY
CONTROL BOX HARNESSES ASSY
LS400/LS500 PUMP - CONTROL BOX HARNESSES ASSY
PART NAME
POLY FLEX TUBE 1/2 IN. BLACK
LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSY
REMOTE CONTROL CABLE ASSY
REMARKS
LS400/LS500 PUMP - REMOTE CONTROL CABLE ASSY
PART NAME
ADAPTER, CORD GRIP 1/2 IN
LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL
LS400/LS500 PUMP - HYDRAULIC STABILIZER ASSY. OPTIONAL
PART NAME
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
MAYCO PUMPWARRANTY
MECHANICAL DRIVE MODELS
HYDRAULIC DRIVE MODELS
Service Department
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Warranty Department