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