Models LS400/LS500
Diesel engine exhaust and some
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LS400/LS500 Pump -TABLE of Contents
Ordering parts has never been easier
Parts Ordering Procedures
LS400/LS500 Pump Safety Message Alert Symbols
Is running or hot
You can be injured if you do not follow directions
Always wear approved respiratory protection
LS400/LS500 Pump Safety Message Alert Symbols
LS400/LS500 Pump Rules for Safe Operation
General Safety
LS400/LS500 Pump Rules for Safe Operation
Transporting
Towing
Battery
Maintenance Safety
Emergencies
Always know the location of the nearest and first aid kit
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Pump Specifications
LS400/LS500 Pump Specifications
Dimensions
Dimensions
Operation Hand Signals
LS400/LS500 Pump Important Hand Signals
Concrete MIX Design
LS400/LS500 Pump General Information
Regional Differences
LS400/LS500 Pump General Information
Pumping Cycle
LS400/LS500 Pump HOW IT Works
LS400/LS500 Pump Pump Components
LS400/LS500 Pump Pump Components
LS400/LS500 Pump Digital Control Panel Components
Switch controls the pumping function. The leftmost
Operation
Counterclockwise to the Stop position
Primary Screen
LS400/LS500 Pump Digital Readout Screen
Initial Servicing
LS400/LS500 Pump Engine Components
Fuel Check
Before Starting
Check fastening nuts and bolts for tightness
Engine OIL Check
LS400/LS500 Pump Inspection
Remove the engine oil dipstick from its holder Figure
Hydraulic OIL Check
Hydraulic Oil Filler Hole
Location of Pump
LS400/LS500 Pump SET-UP
Rear Stabilizer Jacks
Hydraulic Rear Stabilizer Jacks Optional
Starting Procedure
LS400/LS500 Pump START-UP Procedure
Hose Lubrication
LS400/LS500 Pump Operation
Pumping
Priming the Pump with Slurry Mixture
Accumulator Pressure Gauge
Radio Remote Control
Remote Control Optional
LS400/LS500 Pump Operation
Cable Remote Control
Downhill Pumping
Remixtures
Vertical Pumping
Hose Pulsation
SNAP-JOINT Couplings
LS400/LS500 Pump Pumping Information
NEW Pumps
Effects of Heat and Excessive Time on Concrete
Clearing Concrete Blockage
Clearing the System After MIX SET UP
Reverse Pumping Procedure
Shuttle Tube Inspection Procedure
Clearing Shuttletube Blockage
Cleaning the Pump and Delivery System
LS400/LS500 Pump Maintenance Pump
Hydraulic OIL System Maintenance
LS400/LS500 Pump Maintenance Pump
Brake System
Battery Maintenance
Cleaningthe Lubrication BOX
Cylinder Lubrication BOX
Accumulator Circuit
LS400/LS500 Pump Maintenance Pump
Off
Size and type of aggregate Type of concrete being pumped
Wear Plate Installation
Wear Plate and Ring Replacement Procedure
Wear Ring installation
Changingthe Wear Plate and Ring
Wheel Bearings
Extended Storage Instructions
Pressure Test
Manually Adjusting the Brakes
Trailer Brakes
Hydraulic Brakes
Adjustable Channel
LS400/LS500 Pump Maintenance Trailer
Tube
Torsion Suspension
Always use lower gears for climbing and descending grades
LS400/LS500 Pump -TRAILER Safety Guidelines
Common Causes for Loss of Trailer
Trailer Towing Guidelines
Coupling to the Tow Vehicle
Driving Conditions
Reporting Safety Defects
Inoperable Brakes, Lights or Mirrors
Trailer Towing Tips
Trailer VIN Tag
LS400/LS500 Pump Trailer Safety Guidelines
Safety Chains
Electrical Connector
Trailer Lighting and Braking Connector
Tow Vehicle
Ball Hitch Coupler
Coupler Types
Ball Hitch Coupling Mechanism
Attaching Safety Chain
Attach the safety chains so that they
Breakaway Brake System
Connecting Trailer Lights
LS400/LS500 Pump Trailer Safety Guidelines
Uncoupling the Ball Hitch
Unsafe Tires, Lug Nuts or Wheels
Tire and Loading Information Placard
Determining Load Limit of Trailer
Step
Determining Load Limit of Tow Vehicle Step
Tire Fundamentals
P indicates the tire is for passenger vehicles
Uniform Tire Quality Grading Standards Utqgs
Tire Repair
Tire Safety Tips
Replacing Worn or Damaged Tires
Load Range
Wheels, Bearings and Lug Nuts
Wheel Rims
Lug Nut Torque Requirements
Start all wheel lug nuts by hand
Lights and Signals
Trailer to Tow Vehicle Wiring Diagram
Zero prior to performing any maintenance on the pump
LS400/LS500 Pump Troubleshooting Pump
LS400/LS500 Pump Troubleshooting Pump
PSI
Engine Troubleshooting
LS400/LS500 Pump -TROUBLESHOOTING Engine
Brake System Troubleshooting
LS400/LS500 Pump -TROUBLESHOOTING Trailer Brake System
Electrical Troubleshooting
LS400/LS500 Pump Troubleshooting Electrical
Refer to for the location of components for troubleshooting
Malfunction
Probable Cause Solution
LS400/LS500 Pump Troubleshooting Electrical
Location of Components for Electrical Troubleshooting
Connections to Digital Control Box J1 and J2 Connectors 1
LS400/LS500 Pump Wiring Diagram Control BOX
Connections to Digital Control Box J1 and J2 Connectors 2
LS400/LS500 Pump Wiring Diagram Control BOX
Connections to Digital Control Box J3 and J4 Connectors 1
Connections to Digital Control Box J3 and J4 Connectors 2
Optional Hopper Vibrator Wiring Diagram
LS400/LS500 Pump Wiring Diagram Hopper Vibrator
Hydraulic System Diagram
LS400/LS500 Pump Hydraulic System Diagram
Manifold Block Ports
LS400/LS500 Pump Manifold Block Ports
Appendix Concrete MIX Information
Appendix Concrete MIX Information
Appendix Slumptest Procedure
Recommended Shotcrete System
Appendix Recommended Shotcrete System
Appendix Recommended Shotcrete System
13 EM23808D Nozzle ASSEMBLY, 2 H-D
Recommended Shotcrete System NO. Part no Part Name
10 EM23101 AIR Vibrator Assy
Appendix Recommended Shotcrete Accessories
Recommended Shotcrete Accessories
Has Passed Through the Entire Hose Length
Part Name QTY Remarks
Xxxxx only Not Used on
LS400/LS500 Pump Explanation of Code in Remarks Column
Unit
LS400/LS500 Pump Suggested Spare Parts
Nameplate and Decals
LS400/LS500 Pump Nameplate and Decals
DECAL, Maintenance
DECAL, Engine RPM Setting
DECAL, Hopper REX Mixer TBD
DECAL, Minimum OIL Level
LS400/LS500 Pump Nameplate and Decals
TBD DECAL, Impact Hazard
TBD DECAL, Fault Locator
Included W/ITEM
DECAL, Hydraulic OIL only
Frame Assy
LS400/LS500 Pump Frame Assy
Jack STAND, Front
FRAME, Main
Clevis PIN
PIN
Axle ASSY. RIGHT/LEFT
LS400/LS500 Pump Axle ASSY. RIGHT/LEFT
Inner Bearing Cone 2
Brake Line Assy
LS400/LS500 Pump Brake Line Assy
KIT, Main Brake Line
Brake Light Assy
LS400/LS500 Pump Brake Light Assy
29207
29242
Trailer Hitch Assy
LS400/LS500 Pump -TRAILER Hitch Assy
ACTUATOR, Brake
LS400/LS500 Pump Battery Assy
LS400/LS500 Pump Battery Assy
Hopper Assy
LS400/LS500 Pump Hopper Assy
Hopper Seal
Housing
Remixer Shaft
Follower Ring
Hopper Attachment Assy
LS400/LS500 Pump Hopper Attachment Assy
Hinge PIN
Splash Plate
PIN, Splash Plate
TIE ROD
Hopper Interior Assy
LS400/LS500 Pump Hopper Interior Assy
Ring SEAL, Shuttle Axle
Swing Axle Bushing
Wear Ring HF
RING, Energizer Rubber
Shuttle Cylinder Assy
LS400/LS500 Pump Shuttle Cylinder Assy
Tensioner
Thrust Washer
HEX NUT 1 in NF
Cotter PIN 5/32 X 2
Lubrication Pistons Assy
LS400/LS500 Pump Lubrication Pistons Assy
SWITCH, Proximity W/CABLE
BAR,PROXIMITY Switch Support
Cable HOUSING, Female
SEAL, Connector Housing
LS400/LS500 Pump Lubrication Pistons Assy
BRACKET, Adjustment ROD
Adjustment ROD, Proximity Switch
BOLT, HEX Head 5/16 NC X 1 IN. G5
WASHER, Lock 5/16
Fuel Tank Assy
LS400/LS500 Pump Fueltank Assy
Gasket
COVER, Diesel Tank
CAP, Fuel W\GAUGE
Adaptor
Heat Exchanger Assy
LS400/LS500 Pump Heat Exchanger Assy
COVER, Heat Exchanger
Heat Exchanger
Hose 4000 PSI
Hose 2000 PSI
Accumulator Assy
LS400/LS500 Pump Accumulator Assy
Part Name QTY
Remixer Control Assy
LS400/LS500 Pump Remixer Control Assy
Adapter FITTING, T
Valve Remixer W/ Lever
Adapter FITTING, 90 Elbow
Adapter FITTING, Straight
LS400/LS500 Pump Lubrication Panel
Grease Points
Position Location
Lubrication Panel Assy
Connector
HOSE, Plastic
HOSE, Steel
Engine Cover Assy
LS400/LS500 Pump Engine Cover Assy
COVER, TOP
COVER, Front Engine
Document Cylinder
Hydraulic Tank Assy
LS400/LS500 Pump Hydraulictank Assy
Hydraulic TANK, LS-S
LS-40TD/LS-50TD Engine Assy
LS400/LS500 Pump Engine Assy
HOOD, AIR Cleaner
CONNECTOR, AIR Filter
CARTRIDGE, Safety AIR
Engine Assy
Throttle Assy
LS400/LS500 Pump -THROTTLE Assy
EM98233
Support
Water Separator Assy
LS400/LS500 Pump -WATER Separator Assy
BRACKET, Water Separator TBD Bolt
Hydraulic Pump Assy
LS400/LS500 Pump HYD. Pump Assy
ADAPTER, Suction Pipe
EM492444 Bolt 1/2 X 1-1/4
Manifold Assy Front Machine
LS400/LS500 Pump Manifold Assy
Pilot VALVE, Shuttle
EMBK227
Pilot VALVE, Main Cylinder
Check Valve
Control BOX Assy
LS400/LS500 Pump Control BOX Assy
Emergency Stop Switch Assy
Ignition Switch Assy
Contact BLOCKS, Emergency Switch
Flow Direction Switch Assy
Control BOX Harnesses Assy
LS400/LS500 Pump Control BOX Harnesses Assy
Wire Harness
FUSE, 30 AMP
Conductive Divider 3/8
Remote Control Cable Assy
LS400/LS500 Pump Remote Control Cable Assy
CONNECTOR, Ring 3/16
Switch
Guard Switch Aluminum
Junction BOX
LS400/LS500 Pump Hydraulic Stabilizer ASSY. Optional
LS400/LS500 Pump Hydraulic Stabilizer ASSY. Optional
Freight Policy
Terms and Conditions of Sale Parts
Mechanical Drive Models
Mayco Pumpwarranty
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