OPERATION AND PARTS MANUAL SERIES MODELS LS400/LS500 CONCRETE PUMPS (DEUTZ F4L2011, BF4L2011 DIESEL ENGINES) Revision #6 (09/19/11) To find the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Proposition 65 Warning LS400/LS500 PUMP — PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP —TABLE OF CONTENTS MAYCO LS400/LS500 COMPONENT DRA WINGS DRAWINGS CONCRETE PUMPS Name Plate and Decals ..................................... 86-89 Frame Assy. ....................................................... 90-91 Axle Assy. ........................................................... 92-93 Brake Line Assy. ................................................ 94-95 Brake Lights Assy. .............................................. 96-97 Trailer Hitch Assy. ..............................
www.multiquip.com PARTS ORDERING PROCEDURES Ordering parts has never been easier! Choose from three easy options: Order via Internet (Dealers Only): Best Deal! Effective: January 1st, 2006 If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip. com. Order parts on-line using Multiquip’s SmartEquip website! N View Parts Diagrams N Order Parts N Print Specification Information To obtain an MQ Account, contact your District Sales Manager for more information.
LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS! Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others. This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the Multiquip Mayco LS400/LS500 Concrete pump.
LS400/LS500 PUMP — SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury. CAUTION - ACCIDENTAL STARTING ALWAYS place the Engine ON/OFF switch in the OFF position. NEVER perform maintenance on the unit with the ignition key in the ON position. CAUTION - OVER-SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings.
LS400/LS500 PUMP — RULES FOR SAFE OPERATION DANGER - READ OPERATION AND PARTS Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only. The following safety guidelines should always be used when operating the LS400/LS500 concrete pump: GENERAL SAFETY ■ DO NOT operate or service this equipment before reading this entire manual.
LS400/LS500 PUMP — RULES FOR SAFE OPERATION ■ NEVER run engine without air filter. Severe engine damage may occur. ■ ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using pump. ■ ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children. ■ DO NOT operate this equipment unless the hopper grate, guards and safety devices are attached and in place.
LS400/LS500 PUMP — RULES FOR SAFE OPERATION MAINTENANCE SAFETY DANGER - AMPUTATION RISK During routine maintenance or removing material blockage, you will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at EXTREME RISK of injury or AMPUTATION if the engine is running or if pressure is in the hydraulic system. Prior to performing any maintenance on the pump, follow described lock out-tag out procedures.
NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — SPECIFICATIONS TABLE 1. PUMP SPECIFICATIONS Model LS-400 LS-500 Pumping Rate Up to 40 cu. yds. per hour* Up to 50 cu. yds. per hour* Pumping Method Reciprocating Piston Maximum Aggregate Size 1-1/2 in. minus (38mm) Ver tical Pumping Height Up to Excess of 250 ft. (76m) Piston Face Pressure 1150 psi Horizontal Pumping Distance 1000 ft. (305m)* Cylinder Lubrication Box Capacity 2 Gallons (7.
LS400/LS500 PUMP — DIMENSIONS TABLE 3. DIMENSIONS REF. DIMENSIONS A 43 in. (109.2 cm.) B 172 in. (437 cm.) C 24 in. (61 cm.) D 70 in. (177.8 cm.) E 68 in. (172.2 cm.) Figure 1. Dimensions MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — IMPORTANT HAND SIGNALS Figure 2 displays the basic hand signals commonly used in concrete pumping operations. Figure 2. Operation Hand Signals PAGE 14 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — GENERAL INFORMATION CONCRETE MIX DESIGN Mix design is most important to achieve maximum pumpability. Pumpability is affected by, among other factors, the type and gradation of aggregate used. Natural aggregates make a more workable mix and pump more readily than crushed aggregates. A blend of natural and crushed aggregates will produce a workable mix. The type and gradation of aggregates is equally important for workability as the size and percentage of coarse aggregates in the mix.
LS400/LS500 PUMP — GENERAL INFORMATION REGIONAL DIFFERENCES Concrete is made by mixing locally available rock and sand with cement and water. For this reason there are great differences in the pumpability of concrete from one region of the country to another. It is impossible to define a specific mix for each region that the concrete pump be will working in. Therefore, the mixes listed in Appendix - Concrete Mix Information will provide a basic guideline for establishing the proper mix design for your area.
LS400/LS500 PUMP — HOW IT WORKS The following is a brief explanation of how the concrete cylinders, hydraulic cylinders, shuttle tube, valves and hopper work in sequence to pump concrete. The hydraulic pressure is generated by a variable volume, pressure compensated, axial piston pump that is driven by a diesel engine. The rod sides of the drive cylinders are hydraulically connected together creating a “slave circuit,” which allows hydraulic oil to transfer from one piston to the other.
LS400/LS500 PUMP — PUMP COMPONENTS Figure 5. Major Pump Components PAGE 18 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — PUMP COMPONENTS Figure 5 illustrates the location of the major components for the LS400/LS500 Concrete Pump. The function of each component is described below: 1. Tow Hitch Coupler – Requires a 2-inch ball hitch or a 3-inch pintle. Capable of towing 6,000 lbs. 2. Documentation Box – Contains engine and pump operation, parts and maintenance information. 3. Manifold Access Door– Release latch and lift door to access the Hydraulic Manifold Block. 4.
LS400/LS500 PUMP — DIGITAL CONTROL PANEL COMPONENTS 5 3 1 4 12 E 12 SCROLL 50 75 GENCY ST O ER M P RESET 1000 0 500 1500 20 00 0 SET 11 VOLUME OFF ON START INCREASE DECREASE 2 ACCUMULATOR PRESSURE 13 IGNITION 7 12 50 75 1000 0 FLOW DIRECTION FORWARD CONTROL 500 1500 8 CENTER OFF CYLINDER STROKE 20 00 0 REMOTE LOCAL REVERSE JOG AUTOMATIC JOG “B” JOG “A” PUMPING PRESSURE REMOTE 9 10 6 Figure 6. Pump Digital Control Panel Components 1. 2. 3. 4. 5. 6. 7.
LS400/LS500 PUMP — DIGITAL READOUT SCREEN PRIMARY SCREEN Screen 1 Indicates the various modes of the switch settings. Monitors engine RPM - Idle speed 900, High speed 2550. Battery charge indicator - Normal charge 13+ volts. Indicates electrical malfunction - Refer to Troubleshooting section. INDICATES STATUS OF PUMP ( ON OR OFF) INDICATES BATTERY CHARGE 1 LS 400 OFF 0000 ENG RPM BATTERY 12.
LS400/LS500 PUMP — ENGINE COMPONENTS Figure 7. Deutz F4L2011F/BF4L2011 Diesel Engine Components INITIAL SERVICING The engine (Figure 7) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing. 1. Fuel Filter – Service the fuel filter as recommended in the maintenance section of this manual. 2. Oil Filter – Prevents dirt and other debris from entering the engine.
LS400/LS500 PUMP — INSPECTION CAUTION - GENERAL SAFETY GUIDELINES FUEL CHECK 1. NEVER operate the pump in a confined area or enclosed area structure that does not provide ample free flow of air. Check the fuel gauge built into the fuel tank cap (Figure 8) to determine if the pump's engine fuel is low. Refuel as needed. WARNING - EXPLOSIVE FUEL Diesel fuel is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.
LS400/LS500 PUMP — INSPECTION ENGINE OIL CHECK 1. Remove the engine oil dipstick from its holder (Figure 10). 6. The oil listed in Table 4 is recommended to ensure better engine performance. Use class CD or higher grade motor oil. Figure 10. Engine Oil Dipstick 2. Make sure pump/engine is placed on level ground. 3. Pull the engine oil dipstick (Figure 11) from its holder. HYDRAULIC OIL CHECK 1.
LS400/LS500 PUMP — INSPECTION 2. If the hydraulic oil level is low, remove the cap just above the oil level sight glass (Figure 13) and add the correct amount of hydraulic oil to bring the hydraulic oil level to a normal safe operating level. (Use Shell oil Tellus 68 or Mobil oil DFE26). Figure 13. Hydraulic Oil Filler Hole 3. Check the oil level in the lubrication box. If low, fill with up to 3 gallons of SAE #30 motor oil (Figure 14). The oil level must be checked daily.
LS400/LS500 PUMP — SET-UP LOCATION OF PUMP 1. Place the pump in the best location on the site to pump concrete efficiently. 2. Lay down the hose in the shortest distance possible. REAR STABILIZER JACKS To reduce excessive vibration and rocking of the pump, set the rear stabilizers as follows: 1. Locate both the left and right rear stabilizer jacks (Figure 15). Figure 17.
LS400/LS500 PUMP — START-UP PROCEDURE 4. Place the Direction Control Switch to the FORWARD position (Figure 22). STARTING PROCEDURE WARNING - GENERAL SAFETY GUIDELINES DO NOT attempt to operate this concrete pump until the Safety, General Information and Inspection sections have been read and understood. REVERSE Figure 22. Direction Control Switch (FORWARD) 5. To start the engine, insert the key (Figure 23) into the ignition switch and turn the key to the ON position. e nc y S erg to p Em 1.
LS400/LS500 PUMP — OPERATION HOSE LUBRICATION Before pumping, it is necessary to lubricate the hose. This procedure prevents separation and blockages in the hose. Inspect the lines at all times to prevent problems. Before concrete is discharged into the hopper, it is suggested that 3 to 4 gallons of water be sprayed into the hopper, followed by approximately 5 gallons of a creamy cement and water slurry (1/2 bag of cement to 5 gallons of water).
LS400/LS500 PUMP — OPERATION 4. Let the pump cycle until the hydraulic oil temperature (Figure 29) is approximately 50° to 60° F. HYDRAULIC OIL TEMPERATURE Figure 32. Hopper Remixer Blades (Rotation) Figure 29. Hydraulic Oil Temperature Gauge 5. The Accumulator Pressure Gauge (Figure 30) should read approximately 1750 pounds per square inch (psi). 7. Slide the Volume Control Switch (Figure 27) to the right to increase the volume to 25-30 strokes per minute.
LS400/LS500 PUMP — OPERATION REMOTE CONTROL (OPTIONAL) 4. Reinstall the control panel and tighten the 2 screws. The LS400/LS500 Concrete Pump has a remote control feature that allows the pump to be remotely controlled. If desired, the pump can be operated via a receiver/transmitter (radio) or a hardwire method, which utilizes a 25-ft. extension cable. Contact MQ Sales Department to order remote control. 5.
LS400/LS500 PUMP — OPERATION Radio Remote Control Programming Before starting operation of the Radio Remote Control, go to Screen 9 of the Digital Readout Screen: RADIO ADDRESS 9 NO RADIO PRESS RESET TO LEARN A NEW ONE 1. Press the ON/OFF button on the radio (wireless) remote control to turn on the power. Hold down the RESET switch. The display will now show: RADIO ADDRESS 9 NOW SCANNING FOR NEW TRANSMITTER 2.
LS400/LS500 PUMP — PUMPING INFORMATION REMIXTURES Remixtures that are designed into the concrete mix by the redi-mix company or an architectural engineering company. This section lists common admixtures and a brief explanation of their functions: A. Pozzolith 300 – or the equivalent acts as a water retarder and a lubricant. On a lean mix, long pushes, stiff mixes, and vertical pushes, Pozzolith 300R helps pumpability. B. MBVR – air entraining, acts as a lubricant. C.
LS400/LS500 PUMP — PUMPING INFORMATION The use of 2 -1/2” I.D. hose in these extreme cases reduces line pressures or the addition of slight amounts of water to the mix, if permissible, will permit easier pumping. The use of certain pumping admixtures may help. If excessive pulsation exists in the hose, it is advisable to use burlap or some means of wear protection under the hose at points where the hose may wear through the outer cover; e.g. over forms, steel or sharp curbs.
LS400/LS500 PUMP — PUMPING INFORMATION Using this procedure will make it easier to pump through the clean hose. Note: Once the concrete has reached the end of the hose, do not apply any more water in this manner as this procedure is used for starting only. 6. Hose sizing is very important: We strongly recommend on harsh mixes, vertical pushes, stiff concrete, shotcrete, long pushes, that a 2 -1/2” line be used as far as possible.
LS400/LS500 PUMP — PUMPING INFORMATION CLEARING SHUTTLE TUBE BLOCKAGE The shuttle tube is plugged if volume at the discharge end of the hose stops and the hydraulic oil pressure gauge reads 4400 PSI or more. To clear a plug in the shuttle tube, great care must be taken as a dangerous condition will exist from pressure build-up inside the shuttle tube. (With the shuttle valve, the concrete can be pumped in reverse.) Use the following procedures to clear the shuttle tubes.
LS400/LS500 PUMP — MAINTENANCE (PUMP) TABLE 5. MAINTENANCE CHECK SCHEDULE Wee- Month- 6-Mont- Operational Daily Hourly kly ly hs Hours Engine Oil X X Engine Air Filter X Fuel Filter X Hydraulic Oil Level X Lubrication Box 500 hrs. X Replace Hydraulic Oil 1000 hrs. Clean Hydraulic Filters Axle Crank X X 500 hrs. 2 hrs Grease Shuttle Tube and Hopper Outlet Zerk Points 2 hrs Check System Pressure X 40 hrs. Check Hardware for Tightness X 40 hrs.
LS400/LS500 PUMP — MAINTENANCE (PUMP) 5. Add water to the hopper. Pump and flush clean the entire hopper, shuttle tube and discharge elbow with water. 6. Scoop out 12 inches of concrete from the inboard end of the delivery hose. “Cork screw” a 6" x 6" x 8" sponge into the end of the first hose section. Reconnect the hose to the discharge elbow. 7. Fill hopper with water. Pump until sponge and clean water come out the discharge end of the hose and line system. 8.
LS400/LS500 PUMP — MAINTENANCE (PUMP) BATTERY MAINTENANCE CAUTION - BATTERY MAINTENANCE SAFETY Wear safety glasses or face mask , protective clothes, and rubber gloves when working with battery. Mishandling of the battery shortens the service life of the battery and adds to maintenance cost. When handling the battery do the following: Be careful not to let the battery electrolyte come in contact with your body or clothing.
LS400/LS500 PUMP — MAINTENANCE (PUMP) CYLINDER LUBRICATION BOX ACCUMULATOR CIRCUIT WARNING - FREEZING CONDITIONS DANGER - ACCUMULATOR CHARGING When using the pump during freezing conditions, completely drain the water box and cover the hopper after pumping. Frozen liquid will restrict the piston travel and cause severe damage to the pump.
LS400/LS500 PUMP — MAINTENANCE (PUMP) WEAR PLATE AND CUTTING RING Due to the abrasive nature of concrete, it is normal for the cutting ring to wear on its sides as it shears through the concrete inside the hopper. The metal-to-metal friction and the abrasiveness of the concrete will cause extreme wear and reduce sealing capability between the cutting ring and wear plate. If the two components do not properly seat against each other, slurry will pump into the hopper rather than out the discharge line.
LS400/LS500 PUMP — MAINTENANCE (PUMP) CHANGING THE CONCRETE CYLINDER PISTON CUPS 4. The Rubber piston cups will occasionally require replacement depending on the following factors. ■ The fluid level and cleanliness of the lubrication box. 5. ■ The size and type of aggregate. ■ The type of concrete being pumped. It is time to replace the cups when increasingly large particles of sand and cement pass into the lubrication box.
LS400/LS500 PUMP — MAINTENANCE (PUMP) CHANGING THE WEAR PLATE AND RING Wear Plate Installation Due to the swinging motion of the Nun-plate and the abrasive nature of concrete, it is normal for the cutting ring to wear on the side that shears through the concrete inside the hopper. If the wear ring and wear plate do not fully seat against each other the concrete slurry will pump into the hopper.
LS400/LS500 PUMP — MAINTENANCE (PUMP) WHEEL BEARINGS PRESSURE TEST After every 6 months of operation inspect the wheel bearings. Once a year, or when required, disassemble the wheel hubs remove the old grease and repack the bearings forcing grease between rollers, cone and cage with a good grade of high speed wheel bearing greases (never use grease heavier than 265 A.S.T.M. penetration “No. 2.”). 1. Fill the wheel hub with grease to the inside diameter of the outer races and also fill the hub grease cap.
LS400/LS500 PUMP — MAINTENANCE (TRAILER) The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance. Trailer Brakes Properly functioning brake shoes and drums are essential to ensure safety. The brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.
LS400/LS500 PUMP — MAINTENANCE (TRAILER) Periodically check the actuator mounting fasteners for damage or loosening. Inspect the actuator for worn or damaged parts. As you are towing your trailer, be aware of any changes in braking quality. This could be an early warning of brake or actuator malfunction and requires immediate attention. Consult a certified brake specialist to make necessary adjustment or repairs.
LS400/LS500 PUMP — MAINTENANCE (TRAILER) Danger - Raising the Trailer NEVER crawl under the trailer unless it is on firm and level ground and resting on properly placed and secured jack stands. The possibility exists of the trailer falling thus causing equipment damage and severe bodily harm even death! Torsion Suspension The mounting bracket (Figure 49) of the torsion suspension assembly is bolted directly to the trailer frame.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES TRAILER SAFETY INFORMATION ■ ALWAYS use lower gears for climbing and descending grades. Safety precautions should be followed at all times when operating this equipment. Failure to read, understand and follow the Operating Instructions could result in injury to yourself and others. Loss of control of the trailer or tow vehicle can result in death or serious injury. ■ DO NOT ride the brakes while descending grades, they may get so hot that they stop working.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES CAUTION - Local Towing Regulations Check with your county or state safety towing regulations department before towing your trailer. Driving Conditions When towing a trailer, you will have decreased acceleration, increased stopping distance, and increased turning radius (which means you must make wider turns to keep from hitting curbs, vehicles, and anything else that is on the inside corner).
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying us. Trailer Towing Tips Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow. Acceleration, maneuverability and braking are all diminished with a trailer in tow.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Some drivers place their hands at the bottom of the steering wheel, and while the tow vehicle is in reverse, “think” of the hands as being on the top of the wheel. When the hands move to the right (counterclockwise, as you would do to turn the tow vehicle to the left when moving forward), the rear of the trailer moves to the right.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Tow Vehicle The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow. The hitch capacity must also be matched to the tow vehicle capacity. Your vehicle dealer can provide and install the proper hitch on your tow vehicle.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Coupler Types The trailer is shipped from the factory with a 2-inch ball coupler. Ball Hitch Coupler A ball hitch coupler (Figure 52) connects to a ball that is located on or under the rear bumper of tow vehicle. This system of coupling a trailer to a tow vehicle is sometimes referred to as “bumper pull.” A ball hitch trailer may be fitted with a tongue jack that can raise and lower the coupler.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES WARNING - Defective Hitch Ball A worn, cracked or corroded hitch ball can fail while towing, and may result in death or serious injury. 2-INCH TRAILER COUPLER TOW VEHICLE Before coupling trailer, inspect the hitch ball for wear, corrosion and cracks. Replace worn or damaged hitch ball. WARNING - Uncoupled Hitch Ball A loose hitchball nut can result in uncoupling, leading to death or serious injury.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Attaching Safety Chain TOW VEHICLE TRAILER TONGUE IMPORTANT! SAFETY CHAIN MASTER LINK Breakaway Brake System If the coupler or hitch fails, a properly connected and working breakaway brake system (Figure 55) will apply the hydraulic brakes on the trailer. The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailer’s axles, the trailer/tow vehicle combination will come to a controlled stop.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Connecting Trailer Lights Connect the trailer lights to the tow vehicle’s electrical system using the electric connectors at the front of the trailer (tongue). Refer to the wiring diagram shown in the trailer wiring diagram section of this manual. Before towing the trailer check for the following: Running lights (turn on tow vehicle headlights). Brake Lights (step on tow vehicle brake pedal). Backup Lights (place tow vehicle gear shift in reverse).
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Lug nuts are also prone to loosen after first being assembled. When driving a new trailer (or after wheels have been remounted), check to make sure they are tight after the first 10, 25 and 50 miles of driving and before each tow thereafter. Failure to perform this check can result in a wheel parting from the trailer and a crash, leading to death or serious injury.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Step 1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and Loading Information placard (Figure 56). This figure equals the available amount of equipment load capacity. Step 2. Determine the weight of the equipment being loaded on the tow vehicle. That weight may not safely exceed the available equipment load capacity.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES P: The “P” indicates the tire is for passenger vehicles. Next number: This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire. Next number: This two-digit number, known as the aspect ratio, gives the tire’s ratio of height to width. Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Reference Figure 58 for additional tire information for light trucks. Make sure your tire valves have valve caps. ALWAYS check tire pressure on tow vehicle and trailer before towing. Check tire pressure at least once a month. DO NOT overload tow vehicle. Check the tire information and loading placard for safe allowable tire loading conditions.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES WARNING - Flying Objects ALWAYS wear safety glasses when removing or installing force fitted parts DO NOT attempt to repair or modify a wheel. DO NOT install an inner-tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.
LS400/LS500 PUMP — TRAILER SAFETY GUIDELINES Figure 60. Trailer to Tow Vehicle Wiring Diagram Lights and Signals Before each tow, check the trailer taillights, stoplights, turn signals and any clearance lights for proper operation. Replace any broken or burned-out lamps as necessary. Check the wire harness for cuts, fraying or other damage. If it needs replacing, contact your dealer. WARNING - Trailer Lights Improper operating taillights, stoplights and turn signals can cause collisions.
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP) The hydraulic troubleshooting procedures listed below are intended for use by individuals equipped with the proper tools and equipment and are familiar with hydraulic systems and safe shop practices. Use the Pump Troubleshooting Table (Table 8) to identify possible causes for the pump’s malfunction. Contact the Multiquip Service department for the proper repair procedure.
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP) TABLE 9. PUMP TROUBLESHOOTING (CONTINUED) Problem Possible Problem To Troubleshoot Incorrect Accumulator System Check the system pressure reading. Pressure Verify it is approx.
LS400/LS500 PUMP — TROUBLESHOOTING (PUMP) TABLE 9.
LS400/LS500 PUMP — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the diagnosis based on the Engine Troubleshooting (Table 9) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant. TABLE 10.
LS400/LS500 PUMP — TROUBLESHOOTING (TRAILER BRAKE SYSTEM) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the diagnosis based on the Brake System Troubleshooting (Table 10) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant. TABLE 11.
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL) Refer to Figure 61 for the location of components for troubleshooting. TABLE 12. ELECTRICAL TROUBLESHOOTING MALFUNCTION READING ( S c re e n 1 ) PROBABLE CAUSE Burnt 12 V cycling solenoid. Measure solenoid coil resistance. It should read 6 ohms. Replace burnt solenoid. Wire connection broken. Replace broken wire. The 12-volt cycling solenoid is shor ted directly to ground. Measure solenoid coil resistance. It should read 6 ohms.
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL) TABLE 12. ELECTRICAL TROUBLESHOOTING (continued) MALFUNCTION READING (Screen 1) PROBABLE CAUSE SOLUTION Burnt 12 V cycling solenoid. Measure solenoid coil resistance. It should read 6 ohms. Replace burnt solenoid. Wire connection broken. Replace broken wire. The 12-volt cycling solenoid is shor ted directly to ground. Measure solenoid coil resistance. It should read 6 ohms. Replace shor ted solenoid. Wire connection is shor ted directly to the ground.
LS400/LS500 PUMP — TROUBLESHOOTING (ELECTRICAL) MAIN “A” SOLENOID MAIN “B” SOLENOID SWING SOLENOID UNLOADER SOLENOID PROXIMITY SWITCH “B” SCRO LL RESET SET DECR EASE VOL UME EMERGENC Y S O T P INCRE ASE FORW ARD FLO DIRE W CTIO N REVER SE AUTOM LOCAL ATIC CON TRO L OFF ALTERNATOR ON REMO JOG CENTE TE OFF R CYLIN IGNI TION DER JOG “A” STROK STAR T E JOG “B” REM OTE E F V-BELT PROXIMITY SWITCH “A” THROTTLE SOLENOID INTERNAL FUEL SOLENOID Figure 61.
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) J1 GND 1 2 3 DIGITAL READOUT MODULE J4 4 5 L TRO CON REAR X BO W VIE 6 7 +12VDC IN A A 8 9 10 J1 J2 J3 J4 J5 11 12 +12VDC OUT E-STOP 1 2 3 4 5 6 7 8 1 2 3 4 YELLOW WHITE YELLOW WHITE YELLOW J3 J2 30 AMP FUSE E-STOP +12VDC OUTPUT J1 J1 YELLOW 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 J2 J2 WHITE 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 A 2 1 2 1 INSIDE CONTROL BOX FUEL SOLONOID 1 2 P1 10 AWG RED EMERGENCY STOP SWITCH 12 AWG RED (+12VDC)
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) F C D B E H G A SCRO LL RESET SET DECR EASE VOL UME EMERGENC Y S O T P INCRE ASE FORW ARD FLO DIRE W CTIO N REVER SE AUTO LOCAL MATIC CON TRO L JOG ON TE OFFER R CYLIN “A” STA RT IGNI TION DER JOG I OFF REMO CENTE CENT STRO KE JOG “B” REM OTE E F L K J Figure 62. Connections to Digital Control Box - J1 and J2 Connectors ( 2 of 2) MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) A A L TRO CON REAR BOX EW VI YELLOW WHITE YELLOW WHITE YELLOW J1 J2 J3 J4 J5 J3 J3 YELLOW 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 J4 J4 WHITE 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 INSIDE CONTROL BOX P3 J3 MALE INTERFACE CONNECTOR (YELLOW) OUTSIDE CONTROL BOX P3 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 A INSIDE CONTROL BOX A B OUTSIDE CONTROL BOX PROXIMITY SWITCH “B” C 16 AWG WHITE NOT USED 16 AWG BLUE NOT USED SIGNAL 16 AWG BROWN G 16 AWG GREEN SIGNA
LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) B E C A SCRO LL RESET SET VOL DECR EMERGENC UME EASE Y S O T P INCRE ASE FORW ARD FLO DIRE W CTIO N REVER SE CON AUTOM OFF TRO LOCAL ATIC L ON REMO JOG CENTE TE STA OFF R RT CYLIN IGNI DER JOG “A” TION STROK E JOG “B” REM OTE E F H D F G Figure 63. Connections to Digital Control Box - J3 and J4 Connectors ( 2 of 2) MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — WIRING DIAGRAM (HOPPER VIBRATOR) Figure 65. Optional Hopper Vibrator Wiring Diagram PAGE 74 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYDRAULIC SYSTEM DIAGRAM STA-2 STA-1 A P B T A B P T MANIFOLD T3 T1 P2 A1 A2 1750 PSI B2 B1 ACC ACCUMULATOR GAUGE T2 P1 1000 PSI T P OUT RELIEF T LS 4400 PSI RELIEF 1000 PSI T P IN OPTIONAL AGITATOR AND HYDRAULIC OUTRIGGERS 7CC 14CC MAIN PRESSURE GAUGE Figure 66. Hydraulic System Diagram MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — MANIFOLD BLOCK PORTS MANIFOLD BLOCK PORTS ACC Connect to Accumulator Tank A1 Connect to Shuttle Cylinder A2 Connect to Hydraulic Cylinder B1 Connect to Shuttle Cylinder B2 Connect to Hydraulic Cylinder GA Connect to Accumulator Gauge P1 Connect to Secondary Hyd. Pump P2 Connect to Flow Control Valve T1 Connect to Hydraulic Tank T2 Connect to Heat Exchanger T3 Connect to Tank, Relief Heat Exchanger Figure 67.
APPENDIX — CONCRETE MIX INFORMATION The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to help create a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete mixes. These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock ratio can be adjusted (65% sand 35% rock) and pumpability should be excellent.
APPENDIX — CONCRETE MIX INFORMATION A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE PAGE 78 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
APPENDIX — SLUMP TEST PROCEDURE 1. To obtain a representative sample (concrete), take several samples at three or more regular intervals throughout the discharge of the mixer or truck. DO NOT take samples at the beginning or end of the discharge. 2. Dampen the inside of the cone and place it on a smooth, moist, nonabsorbent, level surface large enough to accommodate both the slumped concrete and the slump cone. Stand on the “foot pieces” throughout the test procedure to hold the cone firmly in place. 3.
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM Figure 69. Recommended Shotcrete System PAGE 80 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM RECOMMENDED SHOTCRETE SYSTEM NO. 1 2 PART NO. EM28906 EM25837 PART NAME COUPLING, 5” H-D “CF” ELBOW, 5"x4”x90° 3 4 5 EM28905 EM402552 EM28061 COUPLING, 4” H-D w/GASKET & PIN REDUCER, 4”x2.5”x53” H-D ENDS PIPE, 2.5”x120w x 10’ H-D 6 7 EM289035 EM28001DD COUPLING, 2.5” H-D w/GASKET & PIN REDUCER, 2.5”x2”x36” H-D 8 9 10 EM23815D EM28902 EM23101 REDUCER, 2.5”x2” w/AIR VIBRATOR COUPLING, 2” H-D w/GASKET & PIN AIR VIBRATOR ASSY.
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES Figure 70. Shotcrete System Accessories Use a 1-3/8" rubber nozzle tip for a wide spray pattern. Use a 1-1/4" rubber nozzle tip for a narrow spray pattern. DO NOT INSTALL THE NOZZLE AT THE END OF THE HOSE UNTIL THE FIRST MATERIAL HAS PASSED THROUGH THE ENTIRE HOSE LENGTH. Disassemble and clean the nozzle assembly thoroughly after each job. Grease all threads before reassembly.
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES NO. 1 2 3 4 5 6 7 8 9 10 11 11 11 12 * 13 * 14 * 15 * 16 * 17 * 18 * 19 * 20 21 PART NO. EM26107 EM23101 EM132 EM23407 EM23408 EM23411 EM912073 EM23409 EM923346 EM406 EM23818 EM24841 EM23845 EM23802 EM23803 EM20816 EM23804 EM23805 EM23806 EM23807 EM911076 EM23808 PART NAME QTY. REMARKS HOPPER SCREEN ......................... 1 ..........
LS400/LS500 PUMP — EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. NOTICE The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed. SAMPLE PARTS LIST NO. 1 2% 2% 3 4 PART NO. PART NAME QTY. REMARKS 12345 BOLT..............
LS400/LS500 PUMP — SUGGESTED SPARE PARTS LS400/LS500 CONCRETE PUMP 1 Unit Qty. P/N Description 1 .......... EM16462 .............. FELT HOLDER 4 .......... EM98050 .............. PISTON CUP, ORANGE 4 .......... EM16493 .............. FELT RING 1 .......... EM98033 .............. OIL PLATE 2 .......... EM14408 .............. BRONZE RING 2 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE ) 1 .......... EM98021 .............. WEAR PLATE 2 .......... EM16816-1A ........ ENERGIZER RING 1 ..........
LS400/LS500 PUMP — NAMEPLATE AND DECALS NAMEPLATE AND DECALS 1 1 3 2 LEVER OPERATING INSTRUCTIONS HOPPER REMIXER REMIX LEVER PULL UP TO OPERATE. PUSH DOWN TO REVERSE 3 PULL UP TO OPERATE NEUTRAL NEUTRAL RIGHT REAR HYDRAULIC STABILIZER LEVER PULL UP TO EXTEND PUSH DOWN TO RETRACT LEFT REAR HYDRAULIC STABILIZER LEVER PULL UP TO EXTEND PUSH DOWN TO RETRACT PUSH DOWN TO REVERSE CIP972 15 AMPUTATION DANGER! KEEP HANDS CLEAR 5 2 SHUTTLE TUBE PIVOTS RAPIDLY AND WILL CRUSH OR CUT.
LS400/LS500 PUMP — NAMEPLATE AND DECALS NAMEPLATE AND DECALS NO. PART NO. PART NAME QTY. REMARKS 1 EM970 DECAL, HOPPER REX MIXER 1 1 TBD DECAL, LEVER OPERATING INSTRUCTIONS ..... 1 .......... OPTION (HYD. JACKS) 2 EM511091 DECAL, MINIMUM OIL LEVEL 1 3 EM97072 DECAL, CAUTION - OP. INSTRUCTIONS 2 4 517639 DECAL, MQ/MAYCO LS400 LOGO ....................... 1 .......... USED ON LS400 MODELS 5 517641 DECAL, MQ/MAYCO LS500 LOGO ....................... 1 ..........
LS400/LS500 PUMP — NAMEPLATE AND DECALS PAGE 88 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — NAMEPLATE AND DECALS NAMEPLATE AND DECALS NO. PART NO. PART NAME QTY. REMARKS 1 TBD DECAL, IMPACT HAZARD 1 2 EM97070 DECAL, ACCUMULATOR PRESSURE .................. 1 .......... INCLUDED W/ITEM 4 3 EM985 DECAL, HYDRAULIC OIL ONLY 1 4 EM97070 DECAL, PUMPING PRESSURE DECAL ............... 1 .......... INCLUDED W/ITEM 2 5 DCL300 DECAL, DANGER LUBRICATION BOX 1 6 DCL301 DECAL, SHUTTLE TUBE DANGER 1 7 517640 DECAL, MQ/MAYCO LS400 LOGO ....................... 1 ..........
LS400/LS500 PUMP — FRAME ASSY. FRAME ASSY. PAGE 90 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — FRAME ASSY. FRAME ASSY. NO. PART NO. 1 514355 2 EM516581 3 EM25610 5 EM744 8 EM491686 10 EM491744 11 509562 12 0166 A 13 503112 14 3019092 15 EM969013 16 517985 17 504456 18 6109180 19 517113 20 492376 21 0166 A 23 EM969013 24 517124 EM923350 25 26 517092 27 517095 PART NAME QTY. REMARKS FRAME, MAIN 1 CHAIN, TRAILER HITCH, 3/8 X 40", GRADE 40 2 JACK STAND, FRONT 1 CLEVIS PIN 2 PIN 2 RIVET, POP AM-44 2 BOLT, 3/8" NC X 5/8" G5 2 LOCK, WASHER 3/8" ...........................................
LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT) AXLE ASSY. (RIGHT/LEFT) PAGE 92 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT) AXLE ASSY. (RIGHT/LEFT) NO. PART NO. PART NAME QTY. REMARKS 1 EM98116 AXLE, TORSION BAR ASSY. 2 2 EM092305 BRAKE ASSY COMPLETE, RIGHT ................ 1 .............. INCLUDES ITEMS W/# 2 EM092306 BRAKE ASSY COMPLETE, LEFT .................. 1 .............. INCLUDES ITEMS W/% .......................................................................................... SEE NOTE BELOW 3 363198 OIL SEAL 1 4 363196 INNER BEARING CONE 2 IN.
LS400/LS500 PUMP — BRAKE LINE ASSY. BRAKE LINE ASSY. PAGE 94 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — BRAKE LINE ASSY. BRAKE LINE ASSY. NO. PART NO. 1 34566 2 EM512877 3 EM512876 4 34565 PART NAME KIT, MAIN BRAKE LINE ADAPTOR, STRAIGHT ADAPTOR, ELBOW KIT, WHEEL BRAKE LINE QTY. 1 2 2 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — BRAKE LIGHT ASSY. BRAKE LIGHT ASSY. PAGE 96 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — BRAKE LIGHT ASSY. BRAKE LIGHT ASSY. NO. 1 2 PART NO. 29242 29207 PART NAME BRAKE LIGHT ASSY. HARNESS ASSY. W/RECEPTACLES QTY. 2 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — TRAILER HITCH ASSY. TRAILER HITCH ASSY. PAGE 98 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — TRAILER HITCH ASSY. TRAILER HITCH ASSY. NO. PART NO. PART NAME QTY. 1 EM29228 COUPLING, TRAILER 2 IN.BALL, 6000 LBS 1 2 EM19067 ACTUATOR, BRAKE 1 3 EM503111 BOLT, HEX HEAD 1/2 NC X 4-1/2 IN. 3 4 EM492600 WASHER, FLAT 1/2 IN. 3 3 5 EM492584 NUT, LOCK 1/2 IN. 6 EM507658 BOLT, HEX HEAD 5/8 NC X 4-1/2 IN. G5 2 7 EM492586 NUT, LOCK 5/8 IN. 2 8 16137 TOW RING, 3 IN. LUNETTE EYE 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — BATTERY ASSY. PAGE 100 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — BATTERY ASSY. BATTERY ASSY. NO. PART NO. 1 EM34506 2 EM16738 3 514856 4 513577 PART NAME BATTERY BOX W/ BELT BATTERY 12V 125A BATTERY CABLE POSITIVE BATTERY CABLE NEGATIVE QTY. 1 1 1 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HOPPER ASSY. HOPPER ASSY. PAGE 102 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HOPPER ASSY. HOPPER ASSY. NO. PART NO.
LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY. HOPPER ATTACHMENT ASSY. PAGE 104 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY. HOPPER ATTACHMENT ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NO. EM514204 EM514620 EM491686 EM70134-2 EM505723 EM16166 505728 EM14165 EM619 EM968446 505121 EM968446 505123 492491 6109160 492379 3019092 515395 492584 EM969013 PART NAME QTY. REMARKS SPLASH PLATE 1 HINGE PIN 1 COTTER PIN 1/8 X 1-1/2 IN. 1 PIN, SPLASH PLATE 1 COTTER PIN 5/32 X 1-1/2 IN. 1 TIE ROD 4 NUT, HEX 1 IN. NC 12 EYE BOLT 3/4 IN. 4 O-RING 3/4 IN. 4 NUT, HEX 3/4 IN.
LS400/LS500 PUMP — HOPPER INTERIOR ASSY. HOPPER INTERIOR ASSY. PAGE 106 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HOPPER INTERIOR ASSY. HOPPER INTERIOR ASSY. NO. 1 2 3 4 5 6 6A 7 8 8 9 10 11 12 13 14 15 17 18 19 20 21 25 26 27 28 29 30 31 32 PART NO. EM16145A EM284 EM16175 EM16170 EM16176 EM98022 EM16816-1A EM16816-2 EM16804 EM16804A EM104 EM923348 EM25803 EM98065 EM512212 491701 EM210 EM16811 EM25843 EM104 491719 EM923348 EM514357 EM98021 EM969023 EM265 EM923350 EM151 EM264 EM517700 PART NAME QTY. REMARKS SWING AXLE BUSHING 2 STUD 1 IN.
LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY. SHUTTLE CYLINDER ASSY. PAGE 108 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY. SHUTTLE CYLINDER ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM16145 SWING AXLE BUSHING 2 2 EM510684 GREASE FITTING 1 3 EM16169 THRUST WASHER 1 4 EM25236 SHUTTLE CRANK, SPLINED SHAFT 1 5 EM505490 GREASE FITTING 2 6 EM16814 TENSIONER 1 7 EM424 HEX NUT 1 IN. 14NF 1 7A EM924006 COTTER PIN 5/32 X 2 IN. 1 8 EM417 NUT 1 IN. 14NF 1 9 EM98106 SHUTTLE CYLINDER ASSY. ....................... 1 ............
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 110 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 EM510265 BOLT, HEX HEAD 3/8 NC X 3-1/2 IN., BLACK OXIDE G8 6 2 EM16464 FACE PLATE 2 3 EM16465 PISTON CUP SPACER 6 4 EM98050 CUP, PISTON- ORANGE 2 5 EM14408 RING, BRONZE 2 6 EM16493 RING, FELT 2 7 EM16462 FELT HOLDER 2 8 EM16461 OILER PLATE 2 9 EM14407 O- RING, OILER PLATE 2 10 EM25801 CYLINDER, CONCRETE 2 11 EM25110 RETAINER, CYLINDER 4 12 EM963610 BOLT, 3/8 NC X 1.3/4 IN. G5 ........................
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 112 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. NO. PART NO. PART NAME QTY. 34 492366 BOLT, HEX HEAD 5/16 NC X 1 IN. G5 6 35 EM492623 WASHER, LOCK 5/16 IN. 4 36 EM514216 ADJUSTMENT ROD, PROXIMITY SWITCH 2 37 EM492556 NUT, HEX 1/2 IN. 4 38 EM514207 BRACKET, ADJUSTMENT ROD 2 39 EM492597 WASHER, FLAT 5/16 IN. 6 40 EM492582 NUT, HEX HEAD 5/16 IN 2 41 EM98211 CYLINDER, MAIN 2 42 EM514920 HOSE, MAIN HYD. CYLINDER 2 43 EM514202 EXTENSION, SPACER 2 6 44 EM185 BOLT, SOCKET HEAD 3/8 NC X 3 IN.
LS400/LS500 PUMP — FUEL TANK ASSY. FUEL TANK ASSY. PAGE 114 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — FUEL TANK ASSY. FUEL TANK ASSY. NO. PART NO. 1 EM514084 2 514080 3 492362 4 EM923343 5 34507 6 EM514559 7 506208 8 EM514536 9 EM20426 10 EM514536 11 EM20763 PART NAME QTY. REMARKS COVER, DIESEL TANK 4 GASKET 4 BOLT 5/16 X 5/8 IN. 56 WASHER, LOCK 5/16 IN. .................................. 56 ......... REPLACES 492623 CAP, FUEL W\GAUGE 1 ADAPTOR 1 CLAMP 5 HOSE, FUEL RETURN 5/16 IN. A/R ADAPTER 1 HOSE, FUEL FILTER 5/16 IN.
LS400/LS500 PUMP — HEAT EXCHANGER ASSY. HEAT EXCHANGER ASSY. PAGE 116 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HEAT EXCHANGER ASSY. HEAT EXCHANGER ASSY. NO. PART NO. 1 EM98118 2 EM514175 3 EM963610 4 3019092 5 0166 A 6 0202 7 EM923023 8 2105164 9 EM25497 10 EM514607 11 EM25566 12 EM509345 13 EM514606 14 EM509401 15 EM514604 16 EM98264 PART NAME QTY. REMARKS HEAT EXCHANGER 1 COVER, HEAT EXCHANGER 1 BOLT 3/8 IN. X 1 IN. ........................... 4 .............. REPLACES 492375 O-RING 3/8 IN. ................................... 4 .............. REPLACES 492598 WASHER, LOCK 3/8 IN. ...............
LS400/LS500 PUMP — ACCUMULATOR ASSY. ACCUMULATOR ASSY. PAGE 118 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — ACCUMULATOR ASSY. ACCUMULATOR ASSY. NO. 1 2 3 4 5 6 7 8 9 10 PART NO. EM97015 EM97016 EM9603055 3019092 0166A EM509425 EM509353 EM514603 EM98009 EM98052 PART NAME ACCUMULATOR 1 GAL. BRACKET, ACCUMULATOR BOLT, HHCS 3/8 IN. DIA. WASHER, FLAT 3/8 IN. WASHER, LOCK 3/8 IN. DIA. FITTING, STRAIGHT FITTING, 90° ELBOW HOSE, ACCUMULATOR ACCUMULATOR REPAIR KIT ACCUMULATOR TEST/CHARGE KIT QTY. 1 1 2 2 2 1 1 1 1 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — REMIXER CONTROL ASSY. REMIXER CONTROL ASSY. PAGE 120 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — REMIXER CONTROL ASSY. REMIXER CONTROL ASSY. NO. 1 2 3 4 5 6 7 8 9 PART NO. EM25495 515384 506195 EM25509 EM218 EM923343 2105164 EM98015 EM98014 PART NAME QTY. REMARKS VALVE REMIXER W/ LEVER 1 ADAPTER FITTING, T 1 ADAPTER FITTING, 90° ELBOW 1 ADAPTER FITTING, STRAIGHT 2 BOLT 5/16 X 2-1/2 IN. 2 WASHER, LOCK 5/16 IN. .............................. 2 .................REPLACES 492623 NUT, HEX 5/16 IN. ......................................... 2 .................
LS400/LS500 PUMP — LUBRICATION PANEL GREASE POINTS Grease daily, two or three hots of #2 multipurpose automotive grease. Over greasing any bearing will not damage the machine. ALWAYS grease before and after pump operation. POSITION LOCATION LENGTH OF LINES A ................................................. CLEVIS GREASE POINT ................................................ 34 in. (1.1 m) B ................................................. SWING AXLE BUSHING GREASE POINT ...................... 26 in. (.
LS400/LS500 PUMP — LUBRICATION PANEL LUBRICATION PANEL ASSY. NO. 1 2 3 4 5 PART NO. EM491701 EM508812 EM510684 EM505516 EM510487 PART NAME GREASE FITTING CONNECTOR CONNECTOR HOSE, PLASTIC HOSE, STEEL QTY. 3 2 3 A/R 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — ENGINE COVER ASSY. ENGINE COVER ASSY. PAGE 124 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — ENGINE COVER ASSY. ENGINE COVER ASSY. NO. 1 2 3 4 6 7 8 PART NO. EM517737 492356 EM923057 2101402 EM517730 492541 TK6737260 PART NAME QTY. REMARKS COVER, TOP 1 BOLT 1/4" NC X 3/4" G5 16 LOCK WASHER 1/4 IN. ........................................14 ..........REPLACES 492596 WASHER 1/4 IN. ..................................................16 ..........REPLACES 492622 COVER, FRONT ENGINE 1 NUT 5/16" NC G2 2 DOCUMENT CYLINDER 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYDRAULIC TANK ASSY. HYDRAULIC TANK ASSY. PAGE 126 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYDRAULIC TANK ASSY. HYDRAULIC TANK ASSY. NO. 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 30A 31 33 34 35 36 41 45 46 47 48 49 50 51 PART NO.
LS400/LS500 PUMP — ENGINE ASSY. LS-40TD/LS-50TD ENGINE ASSY. PAGE 128 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — ENGINE ASSY. ENGINE ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 * 13 * 14 * 15 * 16 * 17 * 18 * 19 * 24 25 26 27 28 29 30 31 32 33 PART NO. EM98189 492401 6109170 6109180 EM511021 EM510725 EM511019 TBD EM510888 22001301 22002183 01881280 01319257 01880870 01881413 EM492366 EM492623 EM492597 EM492553 EM514633 492371 EM923023 EM514714 EM923343 2105164 EM510897 01174416 01174696 EM516434 PART NAME QTY. REMARKS ENGINE, DEUTZ TURBO 76 HP BF4L2011 1 BOLT1/2 IN.X 4 FT. 4 WASHER, FLAT 1/2 IN. ........
LS400/LS500 PUMP — THROTTLE ASSY. THROTTLE ASSY. PAGE 130 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — THROTTLE ASSY. THROTTLE ASSY. NO. 1 2 3 4 5 6 7 * 8 * 9 * 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PART NO. 510792 492356 EM167 EM923057 2101402 EM16465 EM98233 EM98228 EM98232 EM25429 EM25511 EM25576 EM50449 EM25504 EM50463 EM50449 EM50462 EM50449 EMCC700 492581 515812 513213 EM501102 EM491089 510229 492366 2105164 EM98168 PART NAME QTY. REMARKS SUPPORT 1 BOLT 1/4' X 3/4 IN. 3 BOLT 1/4 X 1-3/4 IN. 4 LOCK WASHER 1/4 IN. ..................................... 4 ...........
LS400/LS500 PUMP — WATER SEPARATOR ASSY. WATER SEPARATOR ASSY. PAGE 132 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — WATER SEPARATOR ASSY. WATER SEPARATOR ASSY. NO. 1 2 3 3A 4 5 6 7 8 PART NO. 514340 TBD EM16747 P53712 492364 2105164 EM514559 EM506208 EM514536 PART NAME QTY. REMARKS BRACKET, WATER SEPARATOR 1 BOLT 2 WATER SEPARATOR ASSEMBLY 1 CARTRIDGE, WATER SEPARATOR 1 BOLT 5/16 X 1 IN. 3 HEX NUT 5/16 IN. ............................................. 3 .............. REPLACES 492582 ELBOW ADAPTER 90° MALE 2 CLAMP, HOSE 2 HOSE 5/16 IN. TBD MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYD. PUMP ASSY. HYDRAULIC PUMP ASSY. PAGE 134 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYD. PUMP ASSY. HYDRAULIC PUMP ASSY. NO. 1 2 PART NO. TBD EM514719 PART NAME QTY. REMARKS O-RING 1 FLANGE, SUCTION PIPE .......................................... 2 ............ INCLUDES ITEMS W/ 3 EM492444 BOLT 1/2 X 1-1/4 IN. 4 5 6 7 8 9 10 11 12% 13 14 16 16 17 18 19 20 21 22 23 24 25 25 26 27 29 30 31 32 33 34 35 36$ 37 39 40 6109180 EM514718 EM515207 EM514623 EM514627 EM514628 EM510902 6109180 WASHER, LOCK 1/2 IN. .............................................. 6 ............
LS400/LS500 PUMP — MANIFOLD ASSY. MANIFOLD ASSY. 7 4 6 2 FRONT OF MACHINE 5 1 3 10 A1 B1 8 16 T1 9 15 13 18 19 19 12 12A 14 A2 B2 16 T3 17 23 18 14 T2 P2 14 AAC P1 20 GA 21 24 25 22 23 22 23 PAGE 136 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — MANIFOLD ASSY. MANIFOLD ASSY. NO. 1 2 3 PART NO. EM963102 6109180 EM98261 4% 5# 6# 7# 8 9& 10% 12% 12A% 13 14 15 16 17 18 19 20 21 22 23 24 25 EM98220 EMBK227 EM98223 EMBK2097 EM98221 EM98222 EM98227 EM98228 EM98229 EM25498 EM509401 EM514488 EM25459 EM98226 EM514231 EM514489 EM491372 506193 EM25462 EM509353 EM25429 TBD PART NAME QTY. REMARKS BOLT 1/2 X 1-1/4 IN. ................................................ 4 .......... REPLACES 492393 WASHER, LOCK 1/2 IN. .........................
LS400/LS500 PUMP — CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 138 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — CONTROL BOX ASSY. CONTROL BOX ASSY. NO. 1 2 3 4 5 6 7 8 8A 12 13 14 15 18 19 20 21 PART NO. 0202 EM923023 2105164 TBD EM98206 EM98206K EM517177 EM517186 EM98120 EM98119 EM98121 EM98122 EM97068 TBD TBD TBD PART NAME QTY. REMARKS CONTROL BOX ASSY ..................................... 1 ................ CONTACT FACTORY BOLT 5/16 X 1 IN. ............................................ 4 ................ REPLACES 492364 WASHER, FLAT 5/16 IN. .................................. 4 ................
LS400/LS500 PUMP — CONTROL BOX HARNESSES ASSY. CONTROL BOX HARNESSES ASSY. PAGE 140 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — CONTROL BOX HARNESSES ASSY. CONTROL BOX HARNESSES ASSY. NO. 1 2 3 4 5 6 7 PART NO. EM514635 344102000 EM514636 EM514637 EM514638 509588 16716 PART NAME WIRE HARNESS 1 FUSE, 30 AMP WIRE HARNESS 2 WIRE HARNESS 3 WIRE HARNESS 4 POLY FLEX TUBE 1/2 IN. BLACK CONDUCTIVE DIVIDER 3/8 IN. QTY. 1 1 1 1 1 AR AR REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — REMOTE CONTROL CABLE ASSY. REMOTE CONTROL CABLE ASSY. PAGE 142 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — REMOTE CONTROL CABLE ASSY. REMOTE CONTROL CABLE ASSY. NO. 1 * 2 * 2A 3 * 4 * 5 * 6 * 7 8 9 PART NO. EM16753 EM16754 EM97075 EM491897 EM16756 EM26791 EM26790 EM26793 EM97065 EM97099 PART NAME QTY. REMARKS JUNCTION BOX 1 SWITCH 1 SWITCH 1 CONNECTOR, RING 3/16 IN. 4 GUARD SWITCH - ALUMINUM 2 SEAL, GRIP CORD 1 CORD, MX P/E 25 FT. 1 ADAPTER, CORD GRIP 1/2 IN. 1 ADAPTER, CORD 100 FT. 1 COMPLETE CORD ASSY 25 FT .............. 1 ................
LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL) PAGE 144 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV.
LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL) OPTIONAL HYDRAULIC STABILIZER ASSY. NO. 1 2 3 4 4A 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO. TBD TBD TBD EM98046 EM98047 506200 517101 517102 517103 517104 512655 25509 EM516382 517107 517105 517100 517106 517153 517154 490957 PART NAME BOLT WASHER NUT VALVE REMIXER W/ 3 LEVERS HANDLE, DIRECTIONAL VALVE FITTING 45° HOSE HOSE HOSE HOSE FITTING 90° FITTING STRAIGHT HYDRAULIC STABILIZER FITTING STRAIGHT HOSE HOSE HOSE BOLT BOLT SNAP RING QTY.
TERMS AND CONDITIONS OF SALE — PARTS PAYMENT TERMS 5. Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked. 6. The following items are not returnable: Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products. a. SPECIAL EXPEDITING SERVICE Terms of payment for parts are net 30 days.
MAYCO PUMP WARRANTY MECHANICAL DRIVE MODELS HYDRAULIC DRIVE MODELS MAYCO PUMP, hereinafter referred to as “Manufacturer’, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal use and service, for a period of one year after the date of delivery to the original retail purchaser.
OPERATION AND PARTS MANUAL HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com MQ Parts Department Tel.
