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