Lexus - LS 400 - Owners Manual - 2011 - 2011 (2)

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. #6 (09/19/11) NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 3 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. ............................................... 98-99 Battery Assy. .................................................. 100-101 Hopper Assy. .................................................. 102-103 Hopper Attachment Assy. .............................. 104-105 Hopper Interior Assy. ..................................... 106-107 Shuttle Cylinder Assy. .................................... 108-109 Lubrication Pistons Assy. ............................... 110-111 Fuel Tank Assy. .............................................. 112-115 Heat Exchanger Assy. .................................... 116-117 Accumulator Assy. .......................................... 118-119 Remixer Control Assy..................................... 120-121 Lubrication Panel Assy. .................................. 122-123 Engine Cover Assy. ........................................ 124-125 Hydraulic Tank Assy. ...................................... 126-127 Engine Assy. ................................................... 128-129 Throttle Assy. ................................................. 130-131 Water Separator Assy. ................................... 132-133 Hydraulic Pump Assy. .................................... 134-135 Manifold Assy. ................................................ 136-137 Control Box Assy. ........................................... 138-139 Control Box Harness Assy. ............................ 140-141 Remote Control Cable Assy. .......................... 142-143 Hydraulic Stabilizer Assy. (Optional) .............. 144-145 Proposition 65 Warning ............................................. 2 Table of Contents ...................................................... 4 Parts Ordering Procedures ...................................... 5 Safety Message Alert Symbols ..............................6-7 Rules for Safe Operation .....................................8-10 Specifications .......................................................... 12 Dimensions ............................................................. 13 Important Hand Signals .......................................... 14 General Information ...........................................15-16 How it Works ........................................................... 17 Pump Components ............................................18-19 Digital Control Panel Components .......................... 20 Digital Readout Screen ........................................... 21 Engine Components ............................................... 22 Inspection ...........................................................23-25 Set-Up ..................................................................... 26 Start-Up Procedure ................................................. 27 Operation ...........................................................28-31 Pumping Information ..........................................32-35 Maintenance (Pump) .........................................36-43 Maintenance (Trailer) .........................................44-46 Trailer Safety Guidelines ....................................47-61 Troubleshooting (Pump).....................................62-64 Troubleshooting (Engine) ........................................ 65 Troubleshooting (Brake System)............................. 66 Troubleshooting (Electrical) ...............................67-69 Wiring Diagram (Control Box) ............................70-73 Wiring Diagram (Optional Hopper Vibrator) ............ 74 Hydraulic System Diagram ..................................... 75 Manifold Block Ports ............................................... 76 Appendix - Concrete Mix Information ................77-78 Appendix - Slump Test Procedure........................... 79 Appendix - Recommended Shotcrete System ...... 80-81 Appendix - Recommended Shotcrete Accessories .... 82-83 Explanation Of Codes In Remarks Column ............ 84 Suggested Spare Parts ........................................... 85 Terms and Conditions of Sale - Parts ................... 146 Mayco Pump Warranty .......................................... 147 Specification and part number are subject to change without notice. PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.* Goto www.multiquip.com and click on Order Parts to log in and save! Note: Discounts Are Subject To Change Order via Fax (Dealers Only): All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877) Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.* Note: Discounts Are Subject To Change Order via Phone: Domestic (US) Dealers Call: 1-800-427-1244 Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you. International Customers should contact their local Multiquip Representatives for Parts Ordering information. When ordering parts, please supply: R R R R R R Dealer Account Number Dealer Name and Address Shipping Address (if different than billing address) Return Fax Number Applicable Model Number Quantity, Part Number and Description of Each Part R Specify Preferred Method of Shipment:  UPS/Fed Ex  DHL N Priority One  Truck N Ground N Next Day N Second/Third Day NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST. WE ACCEPT ALL MAJOR CREDIT CARDS! MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 5 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. Refer to the engine manufacturers instructions for data relative to its safe operation. Before using this pump , ensure that the operating individual has read and understands all instructions in this manual. HAZARD SYMBOLS Potential hazards associated with operation of the pump will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols. Some examples are listed below: WARNING - LETHAL EXHAUST GASES Diesel engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air. WARNING - EXPLOSIVE FUEL SAFETY MESSAGE ALERT SYMBOLS The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER, WARNING, or CAUTION. DANGER You WILL be KILLED or SERIOUSLY injured if you do not follow directions. 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. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent. WARNING - BURN HAZARDS WARNING You COULD be KILLED or SERIOUSLY injured if you do not follow directions. CAUTION Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed. You CAN be injured if you do not follow directions PAGE 6 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable. CAUTION - RESPIRATORY HAZARDS ALWAYS wear approved respiratory protection. CAUTION - SIGHT AND HEARING HAZARDS This machine is capable of producing noise levels above 85 dB. Hearing protection is required. Always wear eye protection. CAUTION - EQUIPMENT DAMAGE MESSAGES Other important messages are provided throughout this manual to help prevent damage to your concrete pump, other property, or the surrounding environment. This pump , other proper ty, or the surrounding environment could be damaged if you do not follow instructions. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 7 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. ■ This equipment should not be operated by persons under 18 years of age. ■ NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job. ■ NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine. ■ NEVER operate this equipment under the influence or drugs or alcohol. ■ ALWAYS check the machine for loosened threads or bolts before starting. ■ ALWAYS wear proper respiratory (mask), hearing and eye protection equipment when operating the pump. ■ Whenever necessary, replace nameplate, operation and safety decals when they become difficult read. ■ Manufacture does not assume responsibility for any accident due to equipment modifications. ■ NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result. ■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or pump. ■ High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with hot! components can cause serious burns. ■ The engine section of this pump requires an adequate free flow of cooling air. NEVER operate the pump in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the pump or engine and may cause injury to people. Remember the pump's engine gives off DEADLY carbon monoxide gas. ■ ALWAYS refuel in a well-ventilated area, away from sparks and open flames. ■ ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. ■ NEVER smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot! engine. ■ NEVER operate the pump in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death. ■ Topping-off to filler port is dangerous, as it tends to spill fuel. ■ ALWAYS remove the ignition key when leaving the pump unattended. ■ ALWAYS block the wheels on the unit when using on a slope. ■ ALWAYS maintain this equipment in a safe operating condition at all times. ■ ALWAYS stop the engine before servicing, adding fuel or oil. PAGE 8 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. ■ CAUTION must be exercised while servicing this equipment. Rotating and moving parts can cause injury if contacted. ■ Keep all inexperienced and unauthorized people away from the equipment at all times. ■ Before start-up, check the hopper and remove all foreign matter and debris. ■ DO NOT use worn or damaged hose couplings, inspect all hoses and couplings for wear. Replace any worn or defective hose or couplings immediately. ■ Keep hands out of the hopper when the engine is running. ■ DO NOT disconnect hose couplings or nozzle while under pressure. Relieve pressure by activating the reverse function switch located on the control panel. ■ Unauthorized equipment modifications will void all warranties. ■ Check all fasteners periodically for tightness. Also check towing tongue bolt, lock nut and wheel lug nuts for wear. ■ Test the pump's ON/OFF switch. The purpose of this test is to shut down the engine. ■ Refer to the DEUTZ Engine Owner's Manual for engine technical questions or information recommended by Multiquip for this equipment. Damage to the equipment and or injury to user may result. ■ Always use properly rated hoses and clamps — 1500 PSI and higher. TRANSPORTING ■ ALWAYS shutdown engine before transporting the pump. ■ Tighten fuel tank cap securely to prevent fuel from spilling. ■ Drain fuel when transporting pump over long distances or bad roads. Towing ■ Before towing, check the hitch and secure the safety chain to the towing vehicle. ■ When towing, an adequate safety chain must be fastened to the frame, refer to Towing Guidelines. ■ Tow only with a vehicle and hitch rated to pull a 6,000 lbs. load. ■ If unit is equipped with ball hitch coupler, use only 2" all steel ball rated for minimum of 6,000 lbs. Use 1" hardened steel pull pin, if not equipped with ball hitch. ■ This equipment shall not be towed or operated by individuals who cannot read understand the signs, decals or operating instructions. ■ When towing at night, always have rear tail lights ON. ■ DO NOT tow unit with hopper full of material. ■ DO NOT tow unit with hoses attached. ■ DO NOT tow unit in excess of 55 MPH on highways. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 9 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. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The pressure reading on the accumulator pressure gauge MUST read ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump. ■ DO NOT drop the battery. There is the possibility of risk that the battery may explode. ■ DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur. ■ ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur. ■ ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables. ■ ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases. ■ In case the battery liquid (dilute sulfuric acid) comes in contact with clothing or skin, rinse skin or clothing immediately with plenty of water. ■ In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention. ■ NEVER lubricate components or attempt service on a running pump . EMERGENCIES ■ ALWAYS allow the pump a proper amount of time to cool before servicing. ■ ALWAYS know the location of the nearest fire extinguisher. ■ Keep the pump in proper running condition. ■ Fix damage to the pump immediately and always replace broken parts. ■ Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters. ■ DO NOT use plastic containers to dispose of hazardous waste. BATTERY The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses. Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery: ■ ALWAYS know the location of the nearest and first aid kit. ■ In emergencies always know the location of the nearest phone or keep a phone on the job site. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency. PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 11 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 (7.6 Liters) Hydraulic Fluid Capacity 50 Gallons (189 Liters) Fuel Tank Capacity 40 Gallons (76 Liters) Hopper Capacity 10 cu. ft. with optional fwd/rev remixer Material Hose 3 in., 4 in., 5 in. dia. (76.2mm, 101.6 mm, 127 mm) Deutz Diesel F4 L 2 0 1 1 Engine Model Deutz Turbo Diesel BF4L2011 Weight (with fluids) 4,760 lbs. (2,159 kg) Weight (dry/shipping) 4,560 lbs. (2,068 kg) Tire Size 7.35 in. x 14 in. (187 mm x 356 mm) Options Wireless Remote Control, Hopper Screen Vibrator, Hydraulic Rear Stabilizer * Volume output will vary depending on mix design, slump, line size used and job site condititons TABLE 2. ENGINE SPECIFICATIONS Model Deutz F4L2011F Diesel Engine Deutz BF4L2011F Diesel Engine Type 4 stroke, Air-cooled Diesel No. of Cylinders 4 Bore x Stroke 4.19 in. x 5 in. (106 mm x 127 mm) Rated Output 60 HP@ 3000 rpm 79 HP@ 3000 rpm Displacement 167 cu. in. (2.73 L) Starting Electric 12VDC Lube Oil Capacity 9.5 gal. (2.5 liters) Fuel Type #2 Diesel Fuel Battery 12V DCV Group 27 PAGE 12 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 13 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. #6 (09/19/11) 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. The term “aggregates” describes all of the solid materials, from the largest rock to the smallest grain of sand, contained in the concrete mix. Concrete mixes with a consistency as dry as one-inch slump and as wet as ten-inch slump have been pumped; but for maximum efficiency from the pump, a slump ranging from two to six inches will produce a more workable mix than one that contains more or less water. The principle of concrete pumping is based on self-lubrication. As it moves through the transfer line, the concrete takes the shape of a plastic cylinder. It is forced through the transfer line on a film of mortar that is self-troweled to the service of the transfer line around its full periphery by the slug of concrete itself. A slump rating should be used with discretion; it is not always a real indication of the pumpability of the mix. The concrete may be workable in the sense that it will readily flow into place, but the same mix may not respond to pressure. Overly wet mixes tend to separate. In addition to affecting the strength and quality of the concrete, the delivery system will not tolerate separation. Overly dry mixes are similarly unsatisfactory if they lack plasticity and tend to be crumbly. To be properly pumped, the mix must be able to continuously coat the inside of the line with a lubricating seal of mortar. There are four ways in which this seal can be lost: 1. By pumping excessively wet mixes which do not have enough cohesion to hold together. 2. By pumping harsh undersanded concrete with poorly graded aggregates which can jam together when the pressure becomes too great for the insufficient amount of sand to hold the aggregates apart. 3. By getting a rock pocket, such as mixer tailings, into the pump valve. This rock pocket will have an insufficient coating of mortar and the mix will not be plastic enough to allow the valve to operate or the mix to move in the line. 4. Through excessive bleeding. If the mix is short or fines, but the sand is otherwise fairly well graded, bleeding will not normally create any problems as long as the pump continues operation. But, if the pump is shut down, bleeding can result in a loss of lubrication and blocked erratic flow. The above are bad concrete practices, regardless of how the mix is to be placed. But, these points do show that special mixes are not always needed, within limits, for pumping concrete. Good aggregate gradation is most important to pump concrete the maximum distance. The use of admixtures can have a beneficial effect on pumpability. Most of the dispersing agents will fatten, retard bleeding, and increase workability. Thus, the average concrete can be pumped for appreciably longer distances. Air entraining agents will also improve workability, although they cannot be used as a substitute for good gradation of the aggregate. Pumping will not appreciably affect the final air content of the mix. High-early cement tends to give a more readily pumpable mix with superior water retaining qualities. However, if delays are likely to occur, extra care must be exercised due to the faster setting time over regular cement. The Mayco LS400/LS500 models will pump a wide variety of concrete pump mixes. But, there are guidelines that must be followed. Use this information in conjunction with the Operation section of this manual. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 15 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. Use this information to specify your requirements to your local ready-mix batch plant, contractor and civil engineer. It may take minor adjustments to make a mix pumpable, so you should explain your needs. The elements that have to be controlled and consistently maintained by the batch plant are: 1. The sizing and mix percentage of rocks, gap graded from the largest down through the smallest sizes. 2. Sand with a sieve analysis that has the proper percentage of fines, ASTM C33 spec. 3. Sufficient cement to produce the required design strength of the concrete and provide the lubricating binder to pump the concrete through the delivery system. Use a minimum of: 500 lbs. of cement/cu yd for 2500 p.s.i. concrete after 28 days. 530 lbs. of cement/cu yd for 3000 p.s.i. concrete after 28 days. 600 lbs. of cement/cu yd for 4000 p.s.i. concrete after 28 days. 4. Admixture pump-aid if necessary. 5. The proper amount of water to make a workable slump and plasticize the mix. In addition, this Mayco Concrete Pump can be used to pump a large aggregate hard rock as follows: 1. Pea rock (1/2" minus) pump with mixes being as low as 30% rock and 70% sand. (See page 44, for comments on cleaning the pump.) 2. Shortening pea rock when used with an air compressor and nozzle. (See back pages for recommended setup.) 3. “Mud Jacking”, high pressure grouting. PAGE 16 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. The two part cycling sequence is initiated by an electrical signal generated by two proximity switches activated by the drive cylinder. The proximity switches are normally open, magnetically sensing the movement of the main drive cylinder. As the drive cylinder piston head passes the proximity switch, an electrical signal is sent to the solenoid operated pilot valve which in turn directs pilot oil to the four valves controlling the drive cylinder and the shuttle cylinder. A one-gallon accumulator assists the movement of the shuttle tube. This circuit assures that the shuttle tube will throw with the same intensity of each stroke regardless of how fast the main drive cylinders are cycling. HIGH PRESSURE OIL FROM PUMP TO TANK PROXIMITY SWITCH HYDRAULIC CYLINDERS SLAVE Figure 4. Pumping Cycle 2 OIL CONCRETE CYLINDERS A B SHUTTLE TUBE MOTION PISTON CUP SHUTTLE TUBE In the first cycle, hydraulic pressure is applied to cylinder (B), causing the hydraulic piston, which is connected to the concrete piston and piston cup, to discharge concrete into the delivery line (Figure 3). As one cylinder is discharging concrete, the hydraulic oil from the rod side (B) of the drive cylinders is being transferred through the slave circuit causing the opposite cylinder (A) to move back on the suction stroke, filling the cylinder with concrete. The shuttle tube is sequenced to pivot to each concrete cylinder as the drive cylinders stroke to push concrete. As the second cycling sequence begins (Figure 4), the shuttle tube pivots to the opposite cylinder (A). The hydraulic piston passes under the proximity switch and sends pressure to the piston, causing it to stroke and discharge concrete into the delivery line. Hydraulic oil is transferred through the slave circuit to cylinder B, causing it to start a suction stroke, refilling it with concrete. The pumping sequence then repeats for the duration of the operation. Figure 3. Pumping Cycle 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 17 LS400/LS500 PUMP — PUMP COMPONENTS Figure 5. Major Pump Components PAGE 18 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Hydraulic Manifold Block – Manifold block that controls the flow of hydraulic pressure to the components required to control the pump. 5. Hopper Discharge Sleeve – Connect hoses or steel pipes to the discharge sleeve for pouring concrete. 6. Pump End Jack Stand – Use this jack stand to level and support the rear end of the pump. NEVER deploy on un-level ground and always check for firmness of ground. 7. Shuttle Cylinder – Under pressure, the shuttle cylinder shears concrete passing from the concrete cylinder to the delivery line during the cycle phase. 8. Tires — This trailer uses two ST205-750 x15E type tires. Tire inflation pressure is the most important factor in tire life. Pressure should be checked to 50 psi cold before operation. DO NOT bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. 9. Battery – This unit uses a +12 VDC type battery. ALWAYS use gloves and eye protection when handling the battery. 10. Hydraulic Pump – This unit incorporates an axial variable displacement hydraulic piston pump. 11. Heat Exchanger – Reduces temperature of the hydraulic oil. The exchanger draws oil from the hydraulic tank through a filter and into the heat exchanger before allowing it to flow into the hydraulic system. 12. Accumulator – Stores hydraulic oil under pressure and releases it to the shuttle cylinder and provides the pressure needed to ensure enough force is provided during cycle. 13. Remixer Control Lever – Controls the forward/reverse motion of the hopper remixer paddles. 14. Hydraulic Oil Sight Glass – Use to determine the amount of hydraulic oil remaining in tank. The sight glass also contains a temperature gauge for monitoring the temperature of the hydraulic oil. 15. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if level is low. 16. Accumulator Pressure Gauge– Used to monitor accumulator pressure. Pressure should read at least 1750 psi for correct pump operation. 17. Pumping Pressure Gauge – Used to monitor pressure in the concrete cylinders and shuttle tube. 18. Control Box – Contains the electrical components required to run the pump. See Control Box Components section for component callouts. 19. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell) holds approximately 40 gallons (176 liters). DO NOT top off fuel. Wipe up any spilled fuel immediately. 20. Hydraulic Oil Filter – This in-tank return hydraulic filter with a 10 micron cleanable filter is designed to remove all particles large enough to cause wear and job break down. Under normal conditions, replace every 6 months. 21 Lubrication Box – This box is empty when shipped from the factory. Please fill with 3 gallons (11.35 liters) of SAE 30 motor oil for first time use. Also check the dual clean-out point on bottom of lubrication box for a secure tight fit. 22. Rear Running Lights – ALWAYS check and make sure both the right and left running lights are functioning correctly before towing the pump. 23. Remixer Motor – Drives the remixer paddles inside the hopper. The motor direction is controlled by the remixer control lever. 24. Hopper/Hood – Lift hood to fill. Concrete from a RediMix truck is poured into this hopper. The hopper can hold 10 cu. ft of concrete with optional forward/reverse mixer. NEVER put hands or any other parts of you body into the hopper. 25. Tow End Jack Stand – Use this jack stand to level and support the tow end of the pump. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 19 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. 8. Emergency Stop Button – Press emergency stop button to stop pump in an emergency. Turn knob counterclockwise to disengage the stop button. Ignition Switch – Insert the ignition key here to start the engine. Turn the key clockwise to the ON position, then continue turning clockwise to the START position and release. To stop the engine turn the key fully counterclockwise to the STOP position. Digital Readout Screen – Displays and monitors the various functions of the machine. Scroll Switch – Allows the operator to scroll the various readout screens. Reset Switch – Allows the operator to reset the stroke counter. Remote Cable Connector – Insert the remote control input cable into this connector. Direction Control Switch – This 2-position switch controls the direction of flow for any mix in the pump. The leftmost position sets the pumping direction to forward and the rightmost position sets the pumping direction to reverse. Pumping Control Switch – This 3-position switch controls the pumping of the pump. The rightmost position (REMOTE) is for use with the remote control unit, the leftmost position (LOCAL) is for normal pumping operation, and the centermost position (CENTER OFF) prevents pumping. 9. 10. 11. 12. 13. Cylinder Stroke Control Switch – This 2-position switch controls the pumping function. The leftmost position (AUTOMATIC) sets the pump to automatic cycling. Set the switch to this position for normal pump operation. The rightmost position (JOG) changes the pump from automatic to manual cycling. This allows the cylinders to be manually cycled using the Manual Cylinder Jogging Switch. Manual Cylinder Jogging Switch – This 2-position switch allows the operator to manually jog the cylinders to assist in clearing material line packs and is used to test pumping pressure (See Initial Start-up Procedure section of this manual for testing procedure). The leftmost position jogs Cylinder “A” and the rightmost position jogs Cylinder “B”. Stroke Volume Control Switch – Increases or decreases the number of strokes per minute of the pump. Accumulator Pressure Gauge – This gauge monitors the internal pressure of the Accumulator tank. Normal internal pressure should read approximately 1750 PSI during pumping. Main Pressure Gauge – This gauge monitors the system pressure while pumping material. The maximum pressure rating is 4400 PSI ± 50. PAGE 20 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 12.5 V LOW OIL PSI INDICATES ENGINE RPM INDICATES ELECTRIC MALFUNCTION Screen 5 Displays the ON/OFF electrical signal status of the various 12 volt solenoids (Swing A circuit, Main A circuit, Main B circuit). INDICATES SWING A CIRCUIT IS OFF INDICATES MAIN B CIRCUIT IS OFF INDICATES PROXIMITY A CIRCUIT IS OFF Screen 2 Displays the position of the VOLUME CONTROL switch by indicating whether the increase or decrease position is on or off. INDICATES UNLOADER CIRCUIT IS OFF FLOW DEC OFF 2 FLOW INC ON INDICATES VOLUME SWITCH IS IN THE + POSITION Screen 3 Displays the number of hours the engine and pump have been used and the number of faults the pump has registered. All three indicators can be reset to zero by the RESET switch on the control panel. INDICATES NO. OF HOURS ENGINE HAS BEEN USED E HRS: 00000.0 3 PMP HRS: 00000.0 FAULTS: 00000000 RESET TO CLEAR MESSAGE OR INSTRUCTION INDICATES NO. OF HOURS PUMP HAS BEEN USED INDICATES A RUNNING COUNT OF NO. OF STROKES INDICATES THROTTLE IS ON INDICATES THE NO. OF YARDS PER HOUR 6 PROX A OFF PROX B ON FUEL SOL OFF UNLOADER OFF INDICATES PROXIMITY B CIRCUIT IS ON INDICATES FUEL SOLENOID CIRCUIT IS OFF THROTTLE ON 7 STROKES: 20 STROKES/MIN 8.2 YDS/HR 10.7 INDICATES THE NUMBER OF STROKES INDICATES THE NO. OF STROKES PER MINUTE Screen 8 Displays the electrical status of the engine fuel solenoid. To test the 12-Volt solenoid status, activate with the RESET switch on the control panel. INSTRUCTION OR MESSAGE 8 TO TEST FUEL SOL PRESS RESET FUEL SOL OFF INDICATES THE FUEL SOLENOID IS OFF Screen 9 Displays the communication status of the (optional) radio remote control. To activate a new remote control connection, use the reset switch on the control panel. 4 STROKE CTR: 0000 PRESS RESET TO ZERO STROKE CTR MESSAGE OR INFORMATION INDICATES MAIN A CIRCUIT IS OFF Screen 7 Displays the number of times the main hydraulic cylinders stroke and the yards per hour output. This indicator can be reset to zero by the RESET switch on the control panel. INDICATES NO. OF FAULTS DETECTED Screen 4 Displays the number of strokes the main hydraulic cylinders have gone through. This indicator can be reset to zero by the RESET switch on the control panel. MAIN A OFF MAIN B OFF Screen 6 Displays the ON/OFF electrical signal status for the Proximity Switch A, Proximity Switch B, Engine Fuel Solenoid, and Unloader Solenoid. SECONDARY SCREENS INDICATES VOLUME SWITCH IS NOT IN THE - POSITION 5 SWING A OFF IINSTRUCTION OR MESSAGE RADIO ADDRESS 9 COMMUNICATING PRESS RESET TO LEARN A NEW ONE INDICATES THAT RADIO REMOTE IS ON MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 21 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. Service the oil filter as recommended in the maintenance section of this manual. 3. 4. 5. Crankcase Drain Plug – Remove this plug to drain engine oil from the engine crankcase. For best results drain engine oil when oil is warm. Dip Stick – Remove dipstick to determine if the engine oil level is low. If low add oil as specified in Table 4. V-Belt Cover – Remove this cover to gain access to the V-belt. When replacing V-belt, use only recommended type V-belt. 6. Alternator – Provides power to the electrical system. Replace with only manufacturers recommended replacement parts. 7. Air Filter/Cover – Prevents dirt and other debris from entering the fuel system. Release the latches on the side of the air filter cover to gain access to filter element. Operating the engine without an air filter, with a damaged air filter, or a filter in need of replacement will allow dirt to enter the engine, causing rapid engine wear. 8. 9. Oil Filler Port/Cap – Remove this cap to add engine oil to the crankcase. Fill with recommended type of oil as specified in the maintenance section of this manual. Starter/Solenoid – This engine uses a 12 VDC , 2.7kW (3.7 HP) starter motor with solenoid. PAGE 22 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent. ALWAYS wear approved eye and hearing protection before operating the pump . NEVER operate the pumps's engine with the engine hood removed. The possibility exists of hands, long hair, and clothing becoming entangled with the V-belt, causing injury and bodily harm. NEVER place hands or feet inside the hopper . ALWAYS make while the engine is running. ALWAYS shut down the engine before performing any kind of maintenance service on the pump. See Figures 5, 6, and 7 for the location of any control or component referenced in this section. Figure 8. Fuel Cap Gauge BEFORE STARTING 1. Read safety instructions at the beginning of manual. 2. If fuel is low, remove fuel filler cap and fill with #2 diesel fuel (Figure 9). 2. Clean the entire pump, removing dirt and dust, particularly the engine cooling air inlet, and heat exchanger. 3. Check the air filter for dirt and dust. If air filter is dirty, replace air filter with a new one as required. 4. Check fastening nuts and bolts for tightness. WARNING - EXPLOSIVE FUEL Handle fuel safely. Diesel fuel is highly flammable and can be dangerous if mishandled. DO NOT smoke while refueling. DO NOT attempt to refuel pump if the engine is hot or running. ALWAYS allow engine to cool before refueling. Figure 9. Adding Diesel Fuel MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 23 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. Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass (Figure 12). NORMAL OIL LEVEL HYDRAULIC OIL TEMPERATURE MINIMUM OIL LEVEL Figure 11. Engine Oil Level Figure 12. Hydraulic Oil Sight Glass 4. Verify that oil level (Figure 11) is maintained between the two notches on the dipstick. 5. If the pump's engine oil is low, fill engine crankcase with lubricating oil through filler hole, but DO NOT overfill. PAGE 24 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. The lubrication box should be serviced as described in the maintenance section. Figure 14. Filling the Lubrication Box MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 25 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. Rear Stabilizer Stand Deployment HYDRAULIC REAR STABILIZER JACKS (OPTIONAL) REAR STABILIZER JACKS If your pump comes equipped with hydraulic rear stablizers, they can be controlled as follows: 1. Push down the middle control lever (see Figure 18) to extend the right hydraulic rear stabilizer. 2. Push up the middle control lever (see Figure 18) to retract the right hydraulic rear stabilizer. Figure 15. Locating Rear Stabilizer Jacks 3. Push down the rightmost control lever (see Figure 18) to extend the left hydraulic rear stabilizer. 4. Push up the rightmost control lever (see Figure 18) to retract the left hydraulic rear stabilizer. 2. Remove the cotter pin from the handle tee bolt eye, and then pull the handle tee to release the stabilizer jack (Figure 16). 3. Position both rear stabilizers jacks on firm (not loose) level ground (Figure 17). 4. Align the hole on the stabilizer jack with the hole on the frame body and insert handle tee bolt. 5. Insert the cotter pin into handle tee bolt eye to lock the stabilizer jack. COTTER PIN HANDLE T-BOLT REAR STABILIZER STAND MIDDLE CONTROL LEVER (CONTROLS RIGHT HYDRAULIC STABILIZER) RIGHT HYDRAULIC STABILIZER JACK LEFT HYDRAULIC STABILIZER JACK RIGHTMOST CONTROL LEVER (CONTROLS LEFT HYDRAULIC STABILIZER) Figure 18. Control Levers for Hydraulic Rear Stabilizers WARNING - REAR STABILIZER SAFETY BOLT EYE Figure 16. Rear Stabilizer Jack NEVER place feet under jack while operating. ALWAYS retract rear stabilizer jacks prior to towing. ALWAYS retract rear stabilizer jacks prior to servicing to relieve load (working pressure). PAGE 26 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Locate the Emergency Stop Switch (Figure 19) on the Hydraulic Pump Control Box. Turn the Emergency Stop switch clockwise and release (open). This will allow the engine to start. FORWARD Figure 23. Ignition Switch Figure 19. Emergency Stop Switch If the Emergency Stop switch is in the CLOSED position (stop), engine will not start. To star t the engine, make sure the Emergency Stop switch is in the OPEN position (fully extended). 2. Turn the Cylinder Stroke Control Switch to the AUTOMATIC position (Figure 20). AUTOMATIC JOG Figure 20. Cylinder Stroke Control Switch (Automatic) 6. When the ignition key is in the ON position, the Digital Readout Screen (primary) will cycle through 3 displays as shown in Figure 24. 1 LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW OIL PSI 1 LS 400 OFF 0000 ENG RPM BATTERY 12.5 V LOW RPM FAULT 1 LS 400 OFF 0000 ENG RPM BATTERY 12.5 V END OF MESSAGE Figure 24. Primary Screen (Ignition Key ON) 3. Place the Pumping Control Switch to the CENTER OFF position (Figure 21) for normal pumping operation. REMOTE LOCAL 7. Turn the key to the START position and listen for the engine to start. In warm weather let engine warm up for 5 minutes. In cold weather let engine warm up for 10 minutes. CENTER OFF Figure 21. Pumping Control Switch (OFF) MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 27 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). Getting the concrete to flow through the hose at the start of the pumping cycle can be one of the most critical operations of the pour. PRIMING THE PUMP WITH SLURRY MIXTURE It is CRITICAL to the successful operation of a concrete pump that the manifold and all delivery hoses, pipes and elbows are coated with a film of lubrication BEFORE you attempt to pump concrete. Failure to properly prepare the pump and system will result in a “dry pack” of concrete, blocking the shuttle valve tube or delivery line. 1. Connect the entire delivery system to the pump. Pour 5 gallons of water and a bag of raw cement into the hopper. 2. Place the Direction Control Switch to the REVERSE position (Figure 25). This will mix the water and cement into slurry. FORWARD REVERSE PUMPING WARNING - SAFETY GLASSES Safety glasses MUST be worn at all times when operating the pump. Failure to follow safety guidelines can result in serious injury. A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job. 1. Place the Pumping Control Switch to the LOCAL position (Figure 26) for normal pumping operation. REMOTE LOCAL CENTER OFF Figure 26. Pumping Control Switch (LOCAL) 2. Slide the Volume Control Switch (Figure 27) to the right to increase the volume to approximately 10 strokes per minute. Sliding the volume control to the left will decrease pump volume. _ DECREASE VOLUME + INCREASE VOLUME Figure 27. Volume Control Figure 25. Direction Control Switch (REVERSE) 3. Mix the slurry to the consistency of a smooth batter. 4. Position the first ready-mix truck at the hopper. Check the concrete. DO NOT discharge concrete into hopper at this time. 5. Place the Direction Control Switch in the FORWARD position. This will start the flow of the slurry to the hoses. 6. Keep the slurry flowing until most of it is pumped out. However, make sure that some slurry is left on the hopper when concrete is first discharged from the ready-mix truck. A thumping sound (cylinder stroke) should be heard. The thumping sound represents the number of strokes per minute (volume) of the pump. 3. Scroll through the Digital Readout Screen with the scroll switch to go to Screen 7 (Figure 28). This screen will show the volume in strokes per minute. THROTTLE ON 7 STROKES: 100 STROKES/MIN 10.0 YDS/HR 0.0 Figure 28. Strokes Per Minute Display PAGE 28 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Slowly discharge the concrete from the ready-mix truck into the hopper and completely fill it. Keep the pump running continuously until concrete is discharging at the end of the delivery system. If the pump is stopped during this procedure, a blockage may occur. CAUTION - HOSE/LINE BLOCKAGE If hoses or lines are blocked for any reason, or if the lines are kinked when starting up or during the pumping cycle, the pump pressure could straighten out the kink or force out the blockage. This rapid surge of material could cause the lines to whip or move in a manner that could cause injury to personnel. Figure 30. Accumulator Pressure Gauge 6. Push the Hopper Remixer Control Lever DOWNWARD (Figure 31). The Hopper Remixer Control lever is located to the left of the Hydraulic Temperature gauge. Observe that the blades (Figure 32) inside the hopper are turning in a clockwise direction (FORWARD). To turn the blades in a counterclockwise direction (REVERSE), push the Hopper Remixer Control lever UPWARD (Figure 31). 8. It is important that once the slurry procedure is completed, and concrete is flowing through the hose, DO NOT stop the pour until all the slurry is pumped out and the concrete has reached the end of the hose. The only time to stop the pump during the priming procedure is if a blockage occurs. 9. If it is necessary to replace or add a section of delivery system, after the initial lubrication procedure, wet the inside area of the hose, pipe or elbow with 5 gallons of water per 25 foot length, before adding it to the system. When pumping long distance or pumping stiff mixes, you can expect a drop in volume compared to shorter lines and wetter mixes due to the change in valve efficiency or cavitation. Figure 31. Hopper Remixer Control Lever MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 29 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. On the top of the unit, to the right of the control box (Figure 36), hammer out the knock-out hole and install the remote antenna. Radio Remote Control Installation of the Radio Remote Control Assembly ANTENNA KNOCK-OUT HOLE 1. Remove the two screws on the digital control panel of the pump. See Figure 33. SCR OLL RES ET SET CONTROL BOX DEC REA SE VO LU EMERGENC Y ME S ANTENNA CONNECTOR CABLE REAR OF CONTROL BOX O T P INCR EAS E DIRFLO FOR EC W WAR TIO D N REV ERS E CO AUT OMA TIC LOC AL JOG NT OF RO CEN TER OFF JOG CYL INDE R “A” F L ON REM OTE STA RT IGN ITIO STR OKE CONTROL BOX CONNECTOR N JOG “B” RE MO TE REMOVE 2 SCREWS Figure 33. Removing Screws from Control Panel 2. Tilt and slowly pull out the control panel and place on top of box to gain access inside the box. See Figure 34. Figure 36. Antenna Installation 6. Connect the antenna cable to the connector on the rear of the control box (Figure 36). Radio Remote Control Buttons Operation The pumping operation can be performed by radio remote control (Figure 37). Before using remote control, move the Pumping Control Switch on the control box to the REMOTE position. The buttons on the remote control have the following functions. ON/OFF - Turns the power on or off. When power is on the power LED lights red. If the battery LED turns red, 9V battery needs to be replaced. Figure 34. Pulling Out Control Panel 3. Install the wireless remote module with the 2 screws and nuts provided inside the control panel. Connect the 3-wire connector from the wireless remote module to the electronic control unit. See Figure 35. E-STOP - Turns off the pump completely in an emergency. PUMP ON/OFF - Starts and stops the forward pumping. PUMP REV - momentarily pumps in reverse direction. VOLUME (+) - used to increase the pumping volume. VOLUME (-) - used to decrease the pumping volume. SCREWS AND NUTS ELECTRONIC CONTROL UNIT BATTERY LED WIRELESS REMOTE MODULE CONNECTOR Figure 35. Installing Remote Control Module E-STOP ON OFF PUMP REV PUMP ON/OFF VOLUME VOLUME POWER LED NOTE: OLDER MODELS MAY INDICATE FLOW INSTEAD OF VOLUME Figure 37. Radio Remote Control PAGE 30 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Cable Remote Control Operation Before using cable remote control, set the pumping volume with the VOLUME switch on the control box then move the Pumping Control Switch on the control box to the REMOTE position. The cable remote control (Figure 38) has the following controls. PUMP ON/OFF - Starts and stops the forward pumping. PUMP REV - starts pumping in reverse direction. WARNING - TRANSPORTING PUMP After 5 seconds, the display will show: RADIO ADDRESS 9 COMMUNICATING PRESS RESET TO LEARN A NEW ONE 3. The remote control is now ready for use. Cable Remote Control Installation of the Cable Remote Control Assembly It will be necessary at times to move your pump from one job site location to another. Before moving the pump, make sure to pump the remaining concrete out of the hopper. Moving the pump with a full hopper of concrete can cause severe damage or breakage of the axle and axle springs, excess strain and pressure on the hub and bearing assembly. Leaking manifold seals or hose coupling gaskets which leak water can cause separation and subsequent jamming at that point. Connect the cable to the front panel of the control box (See Figure 38). CABLE REMOTE CONTROL UNIT 25 FT. CABLE PUMP REV PUMP ON/OFF TO CONTROL BOX CONNECTOR Figure 38. Cable Remote Control MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 31 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. Calcium Chloride – commonly referred to as C.C., is used as an accelerator. When pumping a load with calcium chloride, it is recommended that you wash out if the waiting time between delivery trucks becomes too long. D. Super Plasticizers – acts as an accelerator. The concrete will look very wet after the super plasticizer is added, but will begin to set up very fast. Wash out immediately if you do not have a truck waiting. Super plasticizers are used mainly on commercial jobs. E. Red Label – acts as a water retarder and an accelerator. Red label will be used mainly on commercial jobs. F. Fly Ash – is used to help increase the strength of the concrete and decrease the cement content per yard. This is one of the most common admixtures used. All admixtures will be shown on the redi-mix concrete ticket. Before starting the pumping job, ask the driver of the redi-mix truck to see the concrete ticket and note the admixtures that exist and take the proper action. DOWNHILL PUMPING Downhill pumping can be a difficult procedure on some jobs. The slurry procedure would be the same as explained PrimingThe PumpWith Slurry Mixture section of this manual. It is suggested that a sponge approximately 2”x 4”x 6” in size be placed in the hose before the start of pumping. Wet the sponge before placing it in the hose to keep the slurry from running too far ahead of the concrete, which will reduce the possibility of separation. When the pump is stopped, the material can flow slowly down, due to gravity, and cause the hose to collapse. When pumping is resumed, you can expect blockage at the point of hose collapse. To prevent this from happening, the hose can be “kinked off” at the discharge end when the pump is stopped to prevent the gravity flow of the material in the hose. The use of stiffer mixes when pumping downhill will decrease gravity flow of the material in the hose and will assure a smoother operation between the cam roller bearing and cam plate. As with any job, make sure that the hose and the couplings are in good workable shape. VERTICAL PUMPING When pumping vertically up the side of a building, above 40 feet, we would recommend the installation of steel pipe securely fastened at intervals as necessary to support the pipe. Ninety degree, long radius pipe sweeps should be installed at the top and bottom of the steel line. Use a 25 ft. hose, or short section, off the pump; and for the balance of the horizontal distance to the vertical line, use steel pipe. This type of installation has been satisfactory on many jobs being pumped in excess of 100 feet high. Line pressures are always less using steel pipe as compared to hose. When pumping vertically, using all hose, it is recommended not to go higher than 50 feet with hose. The hose should be tied off at intervals of 10 feet, if possible. Special attention should be given when tieing the hose off at the top as the hose will have a tendency to stretch when filled with concrete. This will increase the possibility of a blockage at the point where the hose is tied off. To avoid this, a long radius of 90º elbow is recommended. The suggested place to tie off is on the hose, under the clamp. It is strongly recommended that steel pipe be used on all vertical pumping for safety and convenience. HOSE PULSATION A slight pulsation of the hose will always be noticeable near the pump. Excessive pulsation of the hose near the pump is normally due to higher than average line pressures caused by stiff, harsh mixes, or extremely long pumping distances. PAGE 32 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. If it is necessary to wait 1/2 hour or more for another load of concrete, to prevent setting of the mix in the system, it is advisable to consider the following factors (A through D) affecting the concrete: SNAP-JOINT COUPLINGS When using Snap-Joint couplings with gaskets to join hose, see that they are washed clean after each job. Keeping the hose ends clean (heavy duty) is very important for the best job setup. A thin coat of grease on the rubber gasket or dipping both coupling and gasket in water before coupling the hose will make for easier installation. C. The temperature of the day, 80, 90, degrees? NEW PUMPS All new pumps are ‘water pressure tested” at the factory This procedure permits a thorough inspection of entire drive system and valving under simulated full load conditions. The pump owner can do the same by making an adapter to couple to the end of the discharge cone: e.g., the use of a standard 2" pipe cap with a 3/8" drilled hole in the center, screwed on to the end of hinged cone or reducer at the pump. Fill the hopper with water after making sure that all sand and rock have been removed from manifold. Operate pump at full throttle and the 3/8" diameter hole restriction will create sufficient back pressure to make thorough inspection of all moving parts. THE EFFECTS OF HEAT AND EXCESSIVE TIME ON CONCRETE: Hot concrete, commonly referred to as a hot load, is concrete that has been in the redi-mix truck in excess of 2 to 3 hours. On a hot day, this amount of time is even less. A brief explanation of why heat and time affect concrete: Concrete starts setting by drying up through a chemical reaction. The catalyst to this reaction is heat. When pumping a hot load, it is important to remember that when you have to stop pumping for any reason, add water to the concrete in the hopper and hand mix and move concrete in the hose every 5 minutes. If the shut down time becomes too long, wash out immediately. A. How old is the concrete? B. Is there an accelerator, calcium chloride, red label, etc., in the concrete? D. How much system you have out and how stiff was the mix you were pumping? PREVENTING MIX SET-UP AFTER PUMP SHUTDOWN When the pump is stopped for any reason during a pour; e.g., moving hose, waiting for redi-mix truck, the following suggestions are offered: 1. Leave the hopper full of concrete at the time of shutdown. It is important not to let the redi-mix driver wash too much water into the hopper, as this could cause separation of the concrete in the hopper. 2. If the shutdown period exceeds 2 to 3 minutes, turn off the engine so the vibration does not separate the mix in the hopper which can cause a blockage in the manifold when the pump is started. 3. If it is necessary to wait 10 minutes or more for another load of concrete, it is wise to start the pump and pump 6 or 8 strokes every 5 minutes to prevent setting of the mix in the system. If waiting time is excessive, it would be wise to wash out the pump and hoses and start over when the new truck arrives. 4. When pumping stiff mixes and there is waiting time between redi-mix trucks, it is advisable to add some water to the last hopper of material and “hand mix” to ensure an easier start with the following load. 5. When the pumping job requires a stiffer mix, the following method is suggested for starting: Take a water hose with a nozzle on it and apply water with a fine spray to the concrete as it comes down the redi-mix chute into the pump hopper after the slurry procedure is completed and you are ready to start pumping. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 33 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. The advantages of using the 2 -1/2” line are improved pumpability, less pumping pressure and less wear on the pump. 7. Following the pump operation, proper wash out of all materials or “build-up” within the pump manifold and hoses will prevent problems when starting the next job. 8. A thorough inspection of the drive components and greasing of all bearings after each job will ensure adequate lubrication and service to the pump which is normally operating in wet, gritty conditions. Over-greasing any bearing on your Mayco pump will not damage the bearing. 4. If waiting time is excessive, it would be wise to wash out the pump and hoses and start over when the new truck arrives. This can be avoided by being observant to the pump and system, also taking into consideration the above actors (A through D) affecting the mix. CLEARING CONCRETE BLOCKAGE WARNING - BLOCKAGES If you repeatedly pull the throttle all the way out and try to force your pump to push through blockages due to separation of material in the hose or manifold, you will soon have breakdowns and costly repairs which are not covered under warranty. If a blockage occurs, find where it is and clear it before further pumping. DO NOT increase the engine speed to clear the blockage. Increasing the engine speed will only compound the problem. If a blockage occurs in a hose, walk the hose until you find the point of trouble. The hose will be soft immediately past the blockage. To clear the blockage: 1. Disconnect the hose at the first coupling past the blockage. CLEARING THE SYSTEM AFTER MIX SET UP If, for any reason, the mix should set up in the system, the following procedure is suggested: 1. Disconnect the hose from the pump and wash the pump out immediately. WARNING - HOSE/LINE PRESSURE When disconnecting hoses, use EXTREME CAUTION! The hose is under pressure! 2 Reconnect the hose and fill the hopper with water. 3. Reconnect the hose and fill the hopper with water. DO NOT try to push all the concrete out of all of the hose lines at one time. For example: If you had 200 ft. of system out, you would disconnect each hose. Clean it out by pushing water through the first hose off the pump, then continue progressing through all the hoses, until all the system is clean. WARNING - HOSE LINE PRESSURE Use extreme care! The hose line is under pressure and can cause serious injury. 2. Elevate the hose at that point with the blockage area hanging down. 3. Using a hammer, you can pound the downstream edge of the packed area until it is free to flow. Shake all of the sand and gravel out to the end of the hose. 4. Before reconnecting the hose, start the pump and run a small amount of concrete out to the end of the hose. This will assure that all of the separation is out of the hose. Damaged hoses with internal restrictions can cause blockages. PAGE 34 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. WARNING - SHUTTLE TUBES DO NOT open any of the delivery system joint clamps. E. Chip the concrete out of the reducer with the pry bar. F. Remove the reducer. From the discharge end, chip the concrete out of the shuttle tube with the pry-bar. If concrete cannot be loosened from the outlet of the shuttle tube, remove the clean-out plug on the bottom of the hopper to discharge the concrete. G. Chip the blockage out with the pry-bar. H. Flush the shuttle tube with water. I. Before resuming operation of the pump, perform the “Reverse” Pumping Procedure to relieve pressure on the shuttle tubes. “REVERSE” PUMPING PROCEDURE A. Switch the pump into REVERSE. With pump speed at a medium-slow (approx. 12 strokes per min.) try to pull the “pack” back into the hopper with 5 or 6 reverse strokes. B. Remix the concrete in the hopper. C. Switch the pump into FORWARD. If it is still plugged, repeat “Reversing” procedure three times. If concrete still does not move, proceed to the Shuttle Tube Inspection Procedure. WARNING - ACCUMULATOR PRESSURE Make sure the accumulator pressure gauge reads ZERO psi. prior to performing any maintenance or inspection. You must follow lock out-tag out procedures. SHUTTLE TUBE INSPECTION PROCEDURE A. Stop the pump. Switch off the engine. B The senior or most experienced operator must warn all others to stand at least 20 feet away from the machine and turn their heads to face away from the pump. C. The operator will position himself beside the reducing elbow at the pump outlet. Wearing safety glasses, slip the end of a pry bar (24" length of reinforcing steel rod) under the latch of the hose clamp and flip it up. D. Carefully knock the end of the hose away from the reducer. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 35 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. Check Cutting Ware Ring and Plate X Check Trailer Brakes Function X Check Brake Lights X Check Tire Conditions X Inspect Saftey Devices / Decals X Check Wheel Bearings X Check Battery X Inspect Brake Lining Visually Check for Oil Leaks X X 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. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The pressure reading on the accumulator pressure gauge MUST read ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump. CLEANING THE PUMP AND DELIVERY SYSTEM Cleaning the pump is a very important operation as it determines how the machine will pump the next time it is used. At the end of every pour, or because of long delays during a pour, the pump and delivery system must be thoroughly cleaned by removing all concrete material. 1. Following the Clearing Concrete Blockage operating procedure, ensure that there is no blockage in the hose and line or in the shuttle tube. If a blockage exists, clear it. 2. Pump concrete until the opening of the concrete cylinder intake in the hopper is visible. 3. Stop the pump. 4. Carefully disconnect the first hose joint at the shuttle tube discharge elbow. PAGE 36 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. When the pump has been used to pump small aggregate concrete (pea rock, ½" minus) or mixes with high fines content (60% or more sand) there will be a tendency for hardened concrete to build up on the inside surface of the shuttle tube. Therefore, at the end of every such pour, after the pump and system have been cleaned and the engine shut off, remove all remaining concrete. 9. When the pump has been used to pump large aggregate concrete (" to 1 (" follow the instructions in step 8 once per week. WARNING - ACID CLEANING NEVER use muriatic acid to clean the pump. Acid will dissolve the chrome finish on material cylinder bore and main hydraulic cylinder rods. Use only a 2½" diameter clean-out hook when back-pumping into redi-mix truck. Use a safety chain to secure the clean-out hook to some solid part of the mixer truck to prevent hook from jumping off of the drum. Run the pump at 6 strokes per minute maximum speed. Deutz Model F4L2011F/BFL2011F Diesel Engine This pump is equipped with either a Deutz F4L2011F or Deutz BF4L2011F turbo diesel engine. For information concerning the procedure in checking, removing, cleaning, etc. of the various engine parts or any other information on the engine not contained herein, refer to the engine manufacturer’s instruction manual. HYDRAULIC OIL SYSTEM MAINTENANCE The Mayco pump is equipped with an in-tank return hydraulic filter with a 10 micron cleanable filter. The element has been designed to remove all particles large enough to cause wear and job break down. Under normal conditions, we recommend replacement every 6 month. The most important factor to keep in mind is the effect of cold weather on the hydraulic oil. The viscosity (thickness) of the hydraulic oil will be much heavier. ALWAYS run machine until oil temperature reaches a minimum of 50°F. before pumping. Damage to the main piston pump will occur if the machine is cycled too fast before the oil temperature reaches the minimum of 50°F. Cycle the machine at 6-8 strokes per minute at approximately 1/3 throttle. In areas where the weather normally remains under 50°F., use Shell Oil Tellus 46 (or the equivalent). The above steps must be followed or severe damage to the main axial piston pump can occur. 1. When changing the hydraulic oil or topping off the reservoir, use only the following type. (Reservoir capacity - 50 gal.) Hydraulic oil: Shell Oil Tellius 68 or Mobil DFE 26 Texaco Rand HDC WARNING - HYDRAULIC OIL DO NOT mix oil brands! This may impair quality. 2. ■ Lubrication: Grease daily/Hour (Recommended after each Pour) Main hydraulic cylinders - 2 Place ■ ■ ■ Axle crank Shuttle cylinders “S” tube outlet flange Grease Type: - 1 Place - 2 Place - 3 Place Lithium Based EP Texaco Multitak 20 Lubriplate ED-2 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 37 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.  Always wear eye protection and rubber gloves, since the battery contains sulfuric acid which burns skin and eats through clothing.  Always check the battery terminals periodically to ensure that they are in good condition.  Use wire brush or sand paper to clean the battery terminals.  Always check battery for cracks or any other damage. If white pattern appears inside the battery or paste has accumulated at the bottom, replace the battery.  If the pump will not be in operation for a long period of time, store in cool dry place and check the battery charge level every month to maintain the performance of the battery.  Check the battery regularly and make sure that each electrolyte level is to the bottom of the vent well (Figure 39). If necessary add only distilled water in a well-ventilated area. BRAKE SYSTEM The brake system should be periodically checked. Look for fluid leaks worn or cracked hoses. Check the reservoir for proper fluid levels. The Atwood surge brake should be checked for damage. Make sure that all links and pivots are kept lubricated. 1. Keep all links and pivots lubricated to prevent rusting and ensure ease of operation. Using SAE 30 oil, lubricate inside the release handle and inside the actuator body. This can be reached from the underside of the actuator. Lubricate the hitch ball with conventional automotive grease or a lubricant made for hitch balls. 2. Check for any leaks in the brake system. Periodic checks should be made on all hoses to guard against cuts and worn hoses which may cause failure (leaks, rupturing under pressure, and collapsing). Replace defective hoses. CAUTION - MASTER BRAKE CYLINDER DO NOT fill the master cylinder reservoir with used brake fluid. DO NOT fill the reservoir beyond ½" from top. DO NOT overfill; brake fluid will damage paint. 3. Check the brake fluid level in the master cylinder reservoir. Keep it filled to within ½" from the top of the reservoir. 4. At the beginning of each year, inspect the brakes for excessive wear, replace the linings if necessary. Wheel bearings and seals should be inspected and packed at this time. Figure 39. Battery Electrolyte Levels PAGE 38 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Improper accumulator charging can result in an explosion causing serious injury or death! NEVER use oxygen or compressed air to charge the accumulator! Only qualified personal should perform this procedure. Use only dry nitrogen to charge the accumulator. Contact your Mayco service department or your local Hydac representative for proper charging procedure. CAUTION - SAFETY GUIDELINES Before checking lubrication level, follow lock out-tag out procedures. Stop the engine and remove the engine starter key. 1. The lubrication level should be checked everyday prior to pumping and maintained at a height of 5 inches or about ½ the concrete cylinder height. We recommend using a 30-weight motor oil. 2. As the rubber piston cups naturally wear, fine cement particles will accumulate in the box. Once the concrete paste reaches a height of about ½ inch from the bottom of the box, drain and clean the lubrication box. CLEANING THE LUBRICATION BOX 1. Remove the top cover and the drain plug (Figure 40) located at the bottom of the box and fully drain the inside of the box. 2. Once the box is drained, start the engine and stroke the cylinder (keep hands out of box) ten to fifteen times. 3. While stroking, spray water inside of the box to thoroughly clean out all contamination (Figure 40). 4. When the box is clean replace drain plug, add new lubrication and install the top cover. The accumulator circuit has two functions in the hydraulic system. ■ The accumulator circuit furnishes the hydraulic pressure to cycle the shuttle tube. ■ The accumulator circuit also furnishes the pilot pressure necessary to activate the hydraulic system. The accumulator circuit is equipped with a bladder type accumulator (Figure 41) charged with 1100 PSI of dry nitrogen. The accumulator stores one gallon of hydraulic oil, which is, under 1750 PSI of pressure. Figure 41. Accumulator When the pump cycles, a part of the stored oil is released to the shuttle cylinder. This pressure release assures the shuttle tube has enough force to shear the cylinder of concrete passing from the concrete cylinder to the concrete delivery line during the cycle phase. CHECKING ACCUMULATOR BLADDER PRESSURE The normal accumulator charge pressure should be approximately 1100 PSI. To check the accumulator pressure: 1. Start the engine and stroke the pump. The accumulator pressure gauge (Figure 30) should read 1750 PSI. Figure 40. Cleaning the Lubrication Box 2. To determine the actual accumulator PSI, stop the engine and observe the pressure gauge. As the PSI reading slowly decreases, it will reach a point where there will be a sudden drop in the PSI. The PSI reading should be taken just prior to this sudden drop. If you do not read 1100 PSI, the accumulator may require charging or bladder replacement. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 39 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. See Figure A. This condition can easily be observed: 1. The sudden change of the level of concrete inside the hopper during each pumping stroke It is important that the wear components be inspected weekly for proper sealing. Failure to inspect will eventually cause severe damage to the nun-plate and material cylinders. Visually inspect wear plate and cutting ring to ensure surfaces are sealed against each other. If a deep groove or a wide space has developed on the sealing surfaces, it is time for replacement. Due to the motion of the Shuttle tube, the cutting ring experiences a quicker rate of wear as opposed to the wear plate. The wear ring typically requires replacement two times per wear plate (2 to 1). When replacing the wear ring, also replace the rubber energizer ring. 2. Concrete slurry squirting into the air from the hopper (Volcano effect) 3. When the output volume at the end of the delivery line decreases in pressure 58%%(5 (1(5*,=(5 &877,1* 5,1* :($5 3/$7( 4. Unusual frequent material packs in the Shuttle tube 6+877/(78%( ,16,'(+233(5 *22'6($/ /($.,1* Figure A. Wear Plate and Cutting Ring PAGE 40 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Do not allow the cups to become so worn that they begin to pass lubrication into the material cylinders. If the liquid level of the lubrication box becomes to low, the rubber cups will severely deform due to excessive heat. Whenever replacement is due, both cylinder cups should be replaced. 6. Remove the three 3/8 – 16 x 3” bolts from the piston. Remove the front faceplate. 7. Install two the 3/8’ 16x3” bolts back into the piston – do not tighten. Use the two bolts as leverage to remove the rubber piston cup and rear components. Obtain two 3/8 16x7” full thread studs (these studs will be used to assist in assembly alignment) insert the two studs into the piston adapter. Coat the concrete cylinder with grease. 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. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The pressure reading on the accumulator pressure gauge MUST read ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump. CYLINDER CUP REPLACEMENT PROCEDURE 1. Remove the two hydraulic hoses connected to the remix motor. Plug the ports with fittings (not provided) to prevent hydraulic hose leakage. 2. Remove the hopper discharge nipple and loosen sleeve seal. Inspect and replace if wear is excessive. 3. Remove the two tie rod nuts and the four eyebolt nuts securing the hopper to the pump frame. Using an approved lifting device, remove the hopper using extreme care not to damage the hopper seal. Start the engine and turn on the pressure test switch. Cycle pump in reverse until hydraulic system obtains maximum pressure, then turn pump and engine off. Remove ignition key and disconnect battery. Think safety! Check the hydraulic gauges on panel and make sure accumulator pressure reads zero. One piston should be in the fully discharged position at the end of the concrete cylinder. 8. 9. Install the “O” Ring around the oiler plate. Install the plate into the concrete cylinder utilizing the studs for alignment. Felt ring must be saturated with 30 wt. oil prior to installation. 10. Install the felt holder over the oiler plate. Install felt ring into felt holder. Install the bronze ring. 11. Using silicon sealant place a small bead of sealant material on the front of the rubber piston cup and the rear of the face plate. Install over alignment studs and into concrete cylinders. 12. Insert one 3/8” 16x3” bolt into the open bolt hole, remove the alignment studs one at a time and install the remaining 3/8” 16x3” bolts. Before installing 3/8” bolt, coat the back of bolt heads with silicon sealant. Torque all three bolts equal at 55 ft. lbs. each. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 41 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. This condition can be easily observed by the sudden change of the level of concrete inside the hopper during each stroke. Wear Plate and Ring Replacement Procedure 1. 2. 1. 2. 3. 4. 5. Remove the two hydraulic hoses connected to the remix motor. Plug the ports with fittings (not provided) to prevent hydraulic hose leakage. Remove the hopper discharge nipple and loosen sleeve seal. Inspect and replace if wear is excessive. Remove the two tie rod nuts and the four eyebolt nuts securing the hopper to the pump frame. Install the two cylinder “O” rings. Using silicon sealant, coat the circumference of the concrete cylinders, the back of the wear plate and around the five bolt holes. Next, install the wear plate and the five bolts. The bolts must all be equally snugged and tightened to 100 foot pounds each. Wear Ring installation 1. Install the wear ring into the nun plate. 2. Install the steel insert ring inside of the rubber energizer ring. 3. Install the energizer ring assembly into the nun-plate. After installing the above mentioned components the machine can be reassembled by reversing steps 1 through 5 of the Wear Plate and Ring Replacement Procedure. Using an approved lifting device, remove the hopper using extreme care not to damage the hopper seal. HEAT EXCHANGER COOLING FAN Remove the four 1/2” 1-¼” bolts that hold the shuttle tube to the nun-plate and remove shuttle tube. This section is intended to make sure the fan is working properly. Under normal conditions the fan should be running any time the engine is turned on. Using two small pry bars remove the rubber energizer ring, steel insert ring and wear ring. CAUTION - HYDRAULIC OIL TEMPERATURE The energizer ring and wear ring will normally have concrete contamination holding them in position. It will be required to chip some of the concrete loose to better expose the energizer ring. 6. 7. If the hydraulic oil temperature exceeds 170 degrees Fahrenheit, shut down the pump. DO NOT continue to operate the pump. Failure to shut down the pump will result in severe damage to the pump. Clean out all concrete build up in and around the nunplate area with a wire brush. Inspect the wear components for indications of wear. The wear plate has two wear surfaces. PAGE 42 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 1. To determine the pressure of the Hydraulic System, set the Cylinder Stroke Control Switch (Figure 42) to the JOG position. 2. Reassemble the hub and mount the wheel. Then tighten the adjusting nut, at the same time turn the wheel in both directions, until there is a slight bind to be sure all the bearing surfaces are in contact. 3. Back off the adjusting nut 1/6 to 1/4 turn or to the nearest locking hole or sufficiently to allow the wheel to rotate freely within limits of .001” to .010” end play. Lock the nut at this position. 4. Install the cotter pin and dust cap, and tighten all hardware. EXTENDED STORAGE INSTRUCTIONS The following preventative maintenance is recommended for extended periods of storage. Figure 42. Cylinder Stroke Control Switch (JOG) 2. Turn and hold the Manual Cylinder Jogging Switch (Figure 43) to either JOG “A” or JOG “B” position to test the pressure of that cylinder. Figure 43. Manual Cylinder Jogging Switch 13. The Pumping Pressure Gauge (Figure 44) should read approximately 4400 ± 50 PSI. 1. Check brake system for proper fluid level in master cylinder and bleed all lines. 2. Lubricate all links and pivots to prevent any rusting. 3. Remove wheel and drum assemblies and spray a good anti-corrosion compound (CRC formula 5-56) under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and brake lining. 4. Grease all bearings and reinstall wheel and drum assemblies. 5. Make sure breakaway cable is fully released. 6. After extended storage, refer to the Maintenance Steps listed above to insure that the trailer is ready for towing. Figure 44. Pumping Pressure Gauge MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 43 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. Hydraulic Brakes If your trailer has hydraulically-operated brakes, they function the same way the hydraulic brakes do on your tow vehicle. The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle, but no less than once per year. This inspection includes an assessment of the condition and proper operation of the wheel cylinders, brake shoes, brake drums and hubs. You must check the fluid level in the master cylinder reservoir at least every three months. If you tow your trailer an average of 1,000 miles per month in a hot and dry environment, you must check the brake fluid level once a month. The brake fluid reservoir is located on the tongue of the trailer. Always fill with clean, uncontaminated DOT 4 brake fluid. Figure 45 below displays the major hydraulic/air/surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 6 as referenced in the “Manually Adjusting The Brakes” section on this page. See Table 11 Trailer Brake System Troubleshooting. Manually Adjusting the Brakes Most axles are fitted with a brake mechanism that will adjust the brakes during a hard stop. However, some braking systems are not automatically adjusted by hard stopping. These brakes require manual adjustment. The following steps apply to adjust most manually adjustable brakes. 1. Jack up the trailer and secure it on adequate capacity jack stands. 2. Be sure the wheel and brake drum rotate freely. 3. Remove the adjusting-hole cover from the adjusting slot on the bottom of the brake backing plate. 4. With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn. Note: Your trailer maybe equipped with drop spindle axles. See axle manual for your axle type. You will need a modified adjusting tool for adjusting the brakes in these axles. With drop spindle axles, a modified adjusting tool with about an 80 degree angle should be used. 5. Rotate the starwheel in the opposite direction until the wheel turns freely with a slight drag. 6. Replace the adjusting-hole cover. 7. Repeat the above procedure on all brakes. 8. Lower the trailer to the ground. Figure 45. Hydraulic Brake Components Hydraulic Brake Actuator The hydraulic brake actuator (Figure 46) is the mechanism that activates the trailer’s brake system. This actuator changes fluid power into mechanical power. Therefore, the fluid level must be checked frequently to assure that the brakes function properly. HYDRAULIC BRAKE FLUID RESERVOIR Figure 46. Trailer Actuator WARNING - Actuator Fluid Level Failure to maintain proper fluid level in the actuator may result in loss of braking action which could cause severe property damage, injury or death. PAGE 44 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Adjustable Channel Your trailer may be equipped with an adjustable channel (Figure 47) that allows the coupler to be raised or lowered to a desired height. Periodically check the channel bolts for damage or loosening. DANGER - Wheel Bearings If trailer wheels are under water for a long period of time, wheel bearings may fail. If this is the case, service wheel bearings immediately. The possibility exists of the wheels falling off, causing equipment damage and severe bodily harm even death!  Replace bearings that have flat spots on rollers, broken roller cages, rust or pitting. Always replace bearings and cups in sets. The inner and outer bearings are to be replaced at the same time.  Replace seals that have nicks, tears or wear.  Lubricate the bearings with a high quality EP-2 automotive wheel bearing grease. BEARING CONE WHEEL HUB OIL SEAL COTTER PIN BEARING CUP DUST CAP LUG NUT SPINDLE WASHER Figure 47. Adjustable Channel With Pintle Eye Coupler Wheel Bearings (Hubs) Wheel bearings (Figure 48) must be inspected and lubricated once a year or 12,000 miles to insure safe operation of your trailer. If a trailer wheel bearing is immersed in water, it must be replaced. If the pump/trailer has not been used for an extended amount of time, have the bearings inspected and packed more frequently, at least every six months and prior to use. Follow the steps below to disassemble and service the wheel bearings.  After removing the dust cap, cotter pin, spindle nut and spindle washer, remove the hub and drum to inspect the bearings for wear and damage. CASTLE NUT Figure 48. Wheel Hub Components Wheel Hub Adjustment Every time the wheel hub is removed and the bearings are reassembled, follow the steps below to check the wheel bearings for free running and adjust.  Turn the hub slowly, by hand, while tightening the spindle nut, until you can no longer turn the hub by hand.  Loosen the spindle nut just until you are able to turn it (the spindle nut) by hand. Do not turn the hub while the spindle nut is loose.  Install a new cotter pin through the spindle nut and axle.  Check the adjustments. Both the hub and the spindle nut should be able to move freely (the spindle nut motion will be limited by the cotter pin). MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 45 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. Except for periodic inspection of the bracket’s fasteners to the trailer frame, no other suspension maintenance is required on the axles. 5/8”-18 X 2” MOUNTING BOLT DANGER - Trailer Inspection When performing trailer inspection and maintenance activities, you must jack up the trailer using jacks and jack stands. When jacking and using jack stands, place them so as to clear wiring, brake lines, and suspension parts (i.e., springs, torsion bars). Place jacks and jack stands inside of the perimeter strip on the supporting structure to which the axles are attached. MOUNTING BRACKET AXLE TUBE SPINDLE TORSION ARM TORSION BAR 5/8”-18 NYLOC NUT GRADE C Figure 49. Torsion Suspension WARNING - Trailer Impact If the trailer is involved in an accident have it inspected immediately by qualified personnel. In addition, the trailer should be inspected annually for signs of wear or deformations. Danger - Worn or Defective Suspension Worn or broken suspension parts can cause loss of control, damage to equipment and severe bodily injury even death! Check suspension regularly. WARNING - Cracked or Broken Welds Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death. DO NOT repair cracked or broken welds unless you have a certified welder perform the repair. If not, have the welds repaired by your dealer. Danger - Trailer Welds Broken or damaged welds can cause injury or severe damage to your trailer and contents. Inspect all of the welds for cracks or failure at least twice a year. PAGE 46 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Then you will potentially have a runaway tow vehicle and trailer. Common Causes for Loss of Trailer ■ Slow down for bumps in the road. Take your foot off the brake when crossing the bump. ■ Driving too fast for the conditions (maximum speed when towing a trailer is 55 m.p.h.). ■ Overloading the trailer or loading the trailer unevenly ■ Trailer improperly coupled to the hitch ■ No braking on trailer ■ Not maintaining proper tire pressure ■ Not keeping lug nuts tight ■ Not properly maintaining the trailer structure. ■ Ensure machine is towed level to tow vehicle. Trailer Towing Guidelines ■ Recheck the load tiedowns to make sure the load will not shift during towing. ■ Before towing, check coupling, safety chain, safety brake, tires, wheels and lights. ■ Check the lug nuts or bolts for tightness. ■ Check coupler tightness after towing 50 miles. ■ Use your mirrors to verify that you have room to change lanes or pull into traffic. ■ Use your turn signals well in advance. Allow plenty of stopping space for your trailer and tow vehicle. ■ Allow plenty of stopping space for your trailer and tow vehicle. ■ DO NOT drive so fast that the trailer begins to sway due to speed. ■ Allow plenty of room for passing. A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without the trailer. ■ Shift your automatic transmission into a lower gear for city driving. ■ To conserve fuel, don’t use full throttle to climb a hill. Instead, build speed on the approach. ■ DO NOT brake while in a curve unless absolutely necessary. Instead, slow down before you enter the curve and power through the curve. This way, the towing vehicle remains in charge. ■ DO NOT apply the brakes to correct extreme trailer swaying. Continued pulling of the trailer, and even slight acceleration, will provide a stabilizing force. ■ Anticipate the trailer “swaying.” Swaying is the trailer reaction to the air pressure wave caused by passing trucks and buses. Continued pulling of the trailer provides a stabilizing force to correct swaying. DO NOT apply the brakes to correct trailer swaying. ■ Use lower gear when driving down steep or long grades. Use the engine and transmission as a brake. Do not ride the brakes, as they can overheat and become ineffective. ■ Be aware of your trailer height, especially when approaching roofed areas and around trees. ■ Make regular stops, about once each hour. Confirm that: A. Coupler is secure to the hitch and is locked. B. Electrical connectors are secure. C. There is appropriate slack in the safety chains. D. There is appropriate slack in the breakaway switch pullpin cable. E. Tires are not visibly low on pressure. WARNING - Drive Safely Driving too fast in severe road conditions can result in loss of control and cause death or serious injury. Decrease your speed as road, weather and lighting conditions deteriorate. ALWAYS check for local trailer-tow speed limits in your area. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 47 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). In addition, you will need a longer distance to pass, due to slower acceleration and increased length. ■ Be alert for slippery conditions. You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer, than driving a tow vehicle without a trailer. ■ Check rearview mirrors frequently to observe the trailer and traffic. ■ NEVER drive faster than what is safe. WARNING - Transporting Personnel DO NOT transport people on the trailer. The transport of people puts their lives at risk and may be illegal. Coupling to the Tow Vehicle Follow all of the safety precautions and instructions in this manual to ensure safety of persons, equipment, and satisfactory life of the trailer. Always use an adequate tow vehicle and hitch. If the vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating (GVWR) of your trailer, you can cause an accident that could lead to death or serious injury. If you already have a tow vehicle, know your vehicle tow rating and make certain the trailer’s rated capacity is less than or equal to the tow vehicle’s rated towing capacity. If you already have (or plan to buy) a trailer, make certain that the tow rating of the tow vehicle is equal to or greater than that of the trailer. WARNING - Coupler Selection/Condition Proper selection and condition of the coupler and hitch are essential to safely towing your trailer. A loss of coupling may result in death or serious injury. • Be sure the hitch load rating is equal to or greater than the load rating of the coupler • Be sure the hitch size matches the coupler size • Observe the hitch for wear, corrosion and cracks before coupling. Replace worn, corroded or cracked hitch components before coupling the trailer to the tow vehicle Be sure the hitch components are tight before coupling the trailer to the tow vehicle. WARNING - Coupler Connection An improperly coupled trailer can result in death or serious injury. DO NOT move the trailer until: • The coupler is secured and locked to hitch • The safety chains are secured to the tow vehicle • The trailer jack(s) are fully retracted DO NOT tow the trailer on the road until: • • • • • Tires and wheels are checked The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer The trailer lights are connected and checked DANGER - Hitch/Tow Vehicle Load Rating Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury. Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control, and may lead to death or serious injury. Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer. The trailer VIN tag contains the critical safety information for the use of your trailer. Again, be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer. PAGE 48 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or us. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in the Washington D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline. Inoperable Brakes, Lights or Mirrors Be sure that the brakes and all of the lights on your trailer are functioning properly before towing your trailer. Check the trailer taillights by turning on your tow vehicle headlights. Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights. Do the same thing to check the turn signal lights. (See Trailer Wiring Diagram section in this manual.) It takes longer to get up to speed, you need more room to turn and pass, and more distance to stop when towing a trailer. You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer. Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear a towed trailer. You must provide mirrors that allow you to safely observe approaching traffic. WARNING - Checking Taillights/Brakelights Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision. Before each tow: • Check that the taillights, brake lights and turn signals work. • Check that the electric brakes work by operating the brake controller inside the tow vehicle. Because of the significant differences in all aspects of maneuverability when towing a trailer, the hazards and risks of injury are also much greater than when driving without a trailer. You are responsible for keeping your vehicle and trailer in control, and for all the damage that is caused if you lose control of your vehicle and trailer. As you did when learning to drive an automobile, find an open area with little or no traffic for your first practice trailering. Of course, before you start towing the trailer, you must follow all of the instructions for inspection, testing, loading and coupling. Also, before you start towing, adjust the mirrors so you can see the trailer as well as the area to the rear of it. Drive slowly at first, 5 mph or so, and turn the wheel to get the feel of how the tow vehicle and trailer combination responds. Next, make some right and left hand turns. Watch in your side mirrors to see how the trailer follows the tow vehicle. Turning with a trailer attached requires more room. Stop the rig a few times from speeds no greater than 10 mph. If your trailer is equipped with brakes, try using different combinations of trailer/electric brake and tow vehicle brake. Note the effect that the trailer brakes have when they are the only brakes used. When properly adjusted, the trailer brakes will come on just before the tow vehicle brakes. It will take practice to learn how to back up a tow vehicle with a trailer attached. Take it slow. Before backing up, get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 49 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. Conversely, rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left while backing up. PSIC: The tire pressure (Pounds per Square Inch) measured when Cold. If you are towing a bumper hitch rig, be careful not to allow the trailer to turn too much because it will hit the rear of the tow vehicle. To straighten the rig, either pull forward or turn the steering wheel in the opposite direction. To determine the “empty” or “net” weight of your trailer, weigh it on an axle scale. To find the weight of the trailer using an axle scale, you must know the axle weights of your tow vehicle without the trailer coupled. Some of the trailer weight will be transferred from the trailer to the tow vehicle axles, and an axle scale weighs all axles, including the tow vehicle axles. Trailer VIN Tag Figure 50 below is a sample of the Vehicle Identification Number (VIN) Tag which is typically located on the left front of the trailer. See Figure 51. VIN: The Vehicle Identification Number. EMPTY WEIGHT: Some information that comes with the trailer (such as the Manufacturer’s Statement of Origin) is not a reliable source for “empty” or “net” weight. The shipping documents list average or standard weights and your trailer may be equipped with options. SAFETY WARNING LABELS ON YOUR TRAILER Figure 50. Vehicle VIN Tag The trailer VIN Tag contains the following critical safety information for the use of your trailer. GAWR: The maximum gross weight that an axle can support. It is the lowest of axle, wheel, or tire rating. Usually, the tire or wheel rating is lower than the axle rating, and determines GAWR. Figure 51. VIN Tag Location GVWR: The maximum allowable gross weight of the trailer and its contents. The gross weight of the trailer includes the weight of the trailer and all of the items within it (such as the pump, and other items). GVWR is sometimes referred to as GTWR (Gross Trailer Weight Rating), or MGTW (Maximum Gross Trailer Weight). GVWR, GTWR and MGTW are all the same rating. The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer, because some of the trailer load is to be carried by the tow vehicle, rather than by the trailer axle(s). The total weight of the cargo and trailer must not exceed the GVWR, and the load on an axle must not exceed its GAWR. PAGE 50 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Suspension System Sway bars, shock absorbers, heavy duty springs, heavy duty tires and other suspension components may be required to sufficiently tow the trailer and pump. Brake Controller For trailers equipped with electric brakes, the electric brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer. The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer. Side View Mirrors The size of the trailer that is being towed and your state law regulations determine the size of the mirrors. However, some states prohibit extended mirrors on a tow vehicle, except while a trailer is actually being towed. In this situation, detachable extended mirrors are necessary. Check with your dealer or the appropriate state agency for mirror requirements. Heavy Duty Flasher A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached to the tow vehicle flasher circuit. Electrical Connector An Electrical Connector connects the light and brake systems on the trailer to the light and brake controls on the towing vehicle. Emergency Flares and Emergency Triangle Reflectors It is wise to carry these warning devices even if you are not towing a trailer. It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the battery is running both the trailer lights and tow vehicle lights. Safety Chains If the coupler connection comes loose, the safety chains can keep the trailer attached to the tow vehicle. With properly rigged safety chains, it is possible to keep the tongue of the trailer from digging into the road pavement, even if the coupler-to-hitch connection comes apart. Trailer Lighting (and Braking) Connector A device that connects electrical power from the tow vehicle to the trailer. Electricity is used to turn on brake lights, running lights, and turn signals as required. In addition, if your trailer has a separate braking system, the electrical connector will also supply power to the brakes from the tow vehicle. Breakaway System If the trailer coupler connection comes loose, the breakaway system can actuate emergency electric or hydraulic brakes depending on the type of actuator on the trailer. The breakaway cable must be rigged to the tow vehicle with appropriate slack that will activate the system if the coupler connection comes loose. Jackstand A device on the trailer that is used to raise and lower the coupler. The jack is sometimes called the “landing gear” or the “tongue jack”. WARNING An improperly coupled trailer can result in death or serious injury. DO NOT move the trailer until: • The coupler is secured and locked to hitch; • The safety chains are secured to the tow vehicle • The trailer jack(s) are fully retracted. DO NOT tow the trailer on the road until: • • • • • Tires and wheels are checked; The trailer brakes are checked; The breakaway switch is connected to the tow vehicle; The load is secured to the trailer The trailer lights are connected and checked. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 51 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. The tongue jack is mounted to the A-frame (front, or tongue) part of the trailer. By rotating the jack handle clockwise, the jack will extend and raise the tongue of the trailer. The load rating of the coupler and the necessary ball size are listed on the trailer tongue. You must provide a hitch and ball for your tow vehicle where the load rating of the hitch and ball is equal to or greater than that of your trailer. Also, the ball size must be the same as the coupler size. If the hitch ball is too small, too large, is underrated, is loose or is worn, the trailer can come loose from the tow vehicle and may cause death or serious injury. THE TOW VEHICLE, HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating (GVWR). IT IS ESSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER. The ball size and load rating (capacity) are marked on the ball; hitch capacity is marked on the hitch. When replacing a ball, the load rating must match or exceed the GVWR of the trailer. Figure 52. Ball Hitch Coupler Adjustable Tongue Before each tow, coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation. Check the locking device that secures the coupler to the ball for proper operation. If you see or feel evidence of wear, such as flat spots, deformations, pitting or corrosion, on the ball or coupler, immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system. All bent or broken coupler parts must be replaced before towing the trailer. The coupler handle lever must be able to rotate freely and automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W motor oil. Keep the ball socket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism. Before coupling the tow vehicle to the trailer, be sure the size and rating of hitch ball match the size and rating of the coupler. Hitch balls and couplers are marked with their size and rating. WARNING - Hitch Ball Load Rating Coupler-to-hitch mismatch can result in uncoupling, leading to death or serious injury. Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler. Be sure the SIZE of the hitch ball matches the size of the ball coupler. PAGE 52 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Be sure the hitch ball is tight to the hitch before coupling the trailer.  Rock the ball to make sure it is tightened to the hitch, and visually check that the hitch ball nut is solid against the lock washer and hitch frame.  Wipe the inside and outside of the coupler. Clean and visually inspect it for cracks and deformations. Feel the inside of the coupler for worn spots and pits.  Be sure the coupler is secured tightly to the tongue of the trailer. All coupler fasteners must be visibly solid against the trailer frame.  The bottom surface of the coupler must be above the top of the hitch ball. Use the tongue jackstand to support the trailer tongue. Wood or concrete blocks may also be used. Coupling the Trailer to the Tow Vehicle (Ball Coupler)  Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease.  Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler.  Using the jackstand at the front of trailer (tongue), turn the jackstand crank handle to raise the trailer. If the ball coupler does not line up with the hitch ball, adjust the position of the tow vehicle.  Open the coupler locking mechanism. Ball couplers have a locking mechanism with an internal moving piece and an outside handle. In the open position, the coupler is able to drop fully onto the hitch ball. 2-INCH BALL Figure 53. Ball Hitch Coupling Mechanism  Lower the trailer (Figure 53) until the coupler fully engages the hitch ball.  Engage the coupler locking mechanism. In the engaged position, the locking mechanism securely holds the coupler to the hitch ball.  Insert a pin or lock through the hole in the locking mechanism.  Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged. A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle. Using the trailer jackstand, verify that you can raise the rear of the tow vehicle by 1-inch after the coupler is locked to the hitch.  Lower the trailer so that its entire tongue weight is held by the hitch.  Raise the jackstand to a height where it will not interfere with the road. Overloading can damage the tongue jack. DO NOT use the tongue jack to raise the tow vehicle more than 1 inch. If the coupler cannot be secured to the hitch ball, do not tow the trailer. Call your dealer for assistance. Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 53 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. Connect Cable to Tow Vehicle Breakaway Lever CROSS BOTH SAFETY CHAINS Figure 54. Safety Chain Arrangement for a Bumper Pull Trailer (Ball Hitch) Hydraulic Actuator  Visually inspect the safety chains and hooks for wear or damage. Replace worn or damaged safety chains and hooks before towing.  Attach the safety chains so that they: A. Cross underneath the coupler. See Figure 54. B. Loop around a frame member of the tow vehicle or holes provided in the hitch system (DO NOT attach them to an interchangeable part of the hitch assembly). C. Have enough slack to permit tight turns, but not be close to the road surface, so if the trailer un couples, the safety chains can hold the tongue up above the road. WARNING - Safety Chains Rigging Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle, leading to death or serious injury, if the trailer uncouples from the tow vehicle. • Fasten chains to frame of tow vehicle. DO NOT fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose. • Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. Figure 55. Breakaway Brake System Breakaway Cable Surge Brake System The breakaway brake system includes a brake cable connected to the tow vehicle on one end and to the emergency brake lever located on the hydraulic actuator on the other end. WARNING - Brakeaway Cable An ineffective breakaway brake system can result in a runaway trailer, leading to death or serious injury, if the coupler or ball hitch fails. Connect the breakaway cable to the tow vehicle; and NOT to the hitch, ball or support. Before towing the trailer, test the function of the breakaway brake system. If the breakaway brake system is not working, DO NOT tow the trailer. Have it serviced or repaired. DO NOT tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure. Replace the breakaway brake battery (if equipped) at intervals specified by manufacturer. PAGE 54 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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).  Turn Signals (activate tow vehicle directional signal lever). WARNING - Improper Electrical Connections Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision. Before each tow:  Check that the taillights, brake lights and turn signals work  Check that the electric brakes work by operating the brake controller inside the tow vehicle. Uncoupling the Ball Hitch Follow these steps to uncouple ball hitch from tow vehicle:  Block trailer tires to prevent the trailer from rolling, before jacking the trailer up.  Disconnect the electrical connector.  Disconnect the breakaway brake switch cable. Promptly replace the pullpin in the switchbox.  Before extending jackstand, make certain the ground surface below the jackstand foot will support the tongue load.  Rotate the jackstand handle (or crank) clockwise. This will slowly extend the jack and transfer the weight of the trailer tongue to the jack. TIRE SAFETY Unsafe Tires, Lug Nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load. Therefore, it is essential to inspect the trailer tires before each tow. If a tire has a bald spot, bulge, cuts, is showing any cords, or is cracked, replace the tire before towing. If a tire has uneven tread wear, take the trailer to a dealer service center for diagnosis. Uneven tread wear can be caused by tire imbalance, axle misalignment or incorrect inflation. Tires with too little tread will not provide adequate tracking on wet roadways and can result in loss of control, leading to death or serious injury. Improper tire pressure causes an unstable trailer and can result in a tire blowout and loss of control. Therefore, before each tow you must also check the tire pressure. Tire pressure must be checked when tires are cold. Allow 3 hours cool-down after driving as much as 1 mile at 40 m.p.h. before checking tire pressure. NOTE: Trailer tires will be inflated to higher pressures than passenger vehicle tires. Since trailer wheels and lug nuts (or bolts) are subjected to greater side loads than automobile wheels, they are more prone to loosen. Before each tow, check to make sure they are tight. The proper tightness (torque) for lug nuts is listed in the lug nut tightening section of this manual. Use a torque wrench to tighten the lug nuts. If you do not have a torque wrench, use a lug wrench (from your tow vehicle) and tighten the nuts as much as you can. Then have a service garage or trailer dealer tighten the lug nuts to the proper torque. WARNING - Lug Nut Tightening Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off, leading to death or serious injury. Tighten lug nuts before each tow. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 55 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. WARNING - Lug Nut Loosening Lug nuts are prone to loosen after initial installation, which can lead to death or serious injury. Check lug nuts for tightness on a new trailer or when wheel(s) have been remounted after the first 10, 25 and 50 miles of driving. Determining Load Limit of Trailer Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit. This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the Gross Axle Weight Rating (GAWR). This is the most a the axle can weigh. There is a vehicle placard (Figure 56) located in the same location as the certification label described above. This placard provides tire and loading information. In addition, this placard will show a statement regarding maximum cargo capacity. TIRE AND LOADING INFORMATION WARNING - Improper Lug Nut Torque The weight of cargo should never exceed XXX kg. Or XXX lbs. TIRE Improper lug nut torque can cause a wheel parting from the trailer, leading to death or serious injury. FRONT Be sure lug nuts are tight before each tow. REAR SPARE WARNING - Tire Pressure Improper tire pressure can result in a blowout and loss of control, which can lead to death or serious injury. Be sure tires are inflated to pressure indicated on side wall before towing trailer. SIZE COLD TIRE PRESSURE SEE OWNER’S MANUAL FOR ADDITIONAL INFORMATION Figure 56. Tire and Loading Information Placard If additional work items (hoses, tools, clamps etc.) are going to be added to the trailer, be sure they are distributed evenly to prevent overloading front to back and side to side. Heavy items should be placed low and as close to the axle positions as reasonable. Too many items on one side may overload a tire. Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the certification/VIN label and/or on the Tire and Loading Information placard. This value should never exceed the maximum cold inflation pressure stamped on the tire. PAGE 56 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. The trailer’s Tire Information Placard is attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards and inspecting tires for cuts, slashes and other irregularities are the most important things you can do to avoid tire failure, such as tread separation or blowout and flat tires. These actions, along with other care and maintenance activities, can also:  Improve vehicle handling  Help protect you and others from avoidable breakdowns and accidents. Determining Load Limit of Tow Vehicle  Improve fuel economy Step 1. Locate the statement, “The combined weight of occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard.  Increase the tire life Step 2. Determine the combined weight of the driver and passengers who will be riding in your vehicle. Step 3. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds. Step 4. The resulting figure equals the available amount of cargo and luggage capacity. For example, if the “XXX” amount e q u a l s 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.). Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure. Tire Fundamentals Federal law requires tire manufacturers to place standardized information on the sidewall of all tires (Figure 57). This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall. Step 5. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage capacity calculated in Step 4. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the tow vehicle’s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle. Figure 57. Standard Tire Sidewall Information MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 57 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. P: The “R” stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years. Next number: This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter. U.S. DOT Tire Identification Number: This begins with the letters “DOT” and indicates that the tire meets all federal standards. The next two numbers or letters are the plant code where it was manufactured, and the last four numbers represent the week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other numbers are marketing codes used at the manufacturer’s discretion. This information is used to contact consumers if a tire defect requires a recall. Tire Ply Composition and Materials Used: The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in the tire, which include steel, nylon, polyester, and others. Next number: This two- or three-digit number is the tire’s load index. It is a measurement of how much weight each tire can support. You may find this information in your owner’s manual. If not, contact a local tire dealer. Note: You may not find this information on all tires because it is not required by law. Maximum Load Rating: This number indicates the maximum load in kilograms and pounds that can be carried by the tire. M+S: The “M+S” or “M/S” indicates that the tire has some mud and snow capability. Most radial tires have these markings; hence, they have some mud and snow capability. Uniform Tire Quality Grading Standards (UTQGS) Speed Rating: The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. The ratings range from 99 miles per hour (mph) to 186 mph. These ratings are listed in Table 7. Note: You may not find this information on all tires because it is not required by law. Table 6. Speed Rating Letter Rating Speed Rating Q 99 mph R 106 mph S 112 mph T 118 mph U 124 mph H 130 mph V 149 mph W 168* mph Y 186* mph Maximum Permissible Inflation Pressure: This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. Treadwear Number: This number indicates the tire’s wear rate. The higher the treadwear number is, the longer it should take for the tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200. Traction Letter: This letter indicates a tire’s ability to stop on wet pavement. A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest as “AA”,”A”, “B”, and “C”. Temperature Letter: This letter indicates a tire’s resistance to heat. The temperature grade is for a tire that is inflated properly and not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can cause heat build-up and possible tire failure. From highest to lowest, a tire’s resistance to heat is graded as “A”, “B”, or “C”. PAGE 58 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Tire Repair The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected before being plugged and patched. Figure 58. UTQGS Tire Information Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT: The “LT” indicates the tire is for light trucks or trailers. ST: An “ST” is an indication the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold: This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehicle). Max. Load Single kg (lbs) at kPa (psi) Cold This information indicates the maximum load and tire pressure when the tire is used as a single. Load Range This information identifies the tire’s load-carrying capabilities and its inflation limits. Tire Safety Tips  Slow down if you have to go over a pothole or other object in the road.  DO NOT run over curbs or other foreign objects in the roadway, and try not to strike the curb when parking.  Check tire inflation pressure weekly during use to insure the maximum tire life and tread wear. Replacing Worn or Damaged Tires Replace the tire before towing the trailer if the tire treads have less than 1/16 inch depth or the telltale bands are visible. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. A bubble, cut or bulge in a side wall can result in a tire blowout. Inspect both side walls of each tire for any bubble, cut or bulge; and replace a damaged tire before towing the trailer. Table 8 below will help pinpoint the causes and solutions of tire wear problems. TABLE 7 TIRE WEAR TROUBLESHOOTING CAUSE WEAR PATTERN SOLUTION Center Wear Over Inflation Adjust pressure to particular load per tire manufacturer. Edge Wear Under Inflation Adjust pressure to particular load per tire manufacturer. Side Wear Loss of chamber or overloading. Make sure load does not exceed axle rating. Align wheels. Toe Wear Incorrect toe-in Align wheels. Cupping Out-of balance Check bearing adjustment and balance tires. Flat Spots Wheel lockup & tire skidding. Avoid sudden stops when possible and adjust brakes.  DO NOT bleed air from tires when they are hot.  Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or trauma.  Remove bits of glass and foreign objects wedged in the tread. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 59 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. Wheel Rims If the trailer has been struck, or impacted, on or near the wheels, or if the trailer has struck a curb, inspect the rims for damage (i.e. being out of round); and replace any damaged wheel. Inspect the wheels for damage every year, even if no obvious impact has occurred. Wheels, Bearings and Lug Nuts A loose, worn or damaged wheel bearing is the most common cause of brakes that grab. To check wheel bearings, jack trailer and check wheels for side-to-side looseness. If the wheels are loose, or spin with a wobble, the bearings must be serviced or replaced. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. Most trailer axles are built with sealed bearings that are not serviceable. Sealed bearings must be replaced as complete units. Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1. Start all wheel lug nuts by hand. 2. Torque all lug nuts in sequence. See Figure 59. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 9. 3. Check to see if the lug nuts are tight after the first 10, 25 and 50 miles of driving and before each tow thereafter. TABLE 8. TIRE TORQUE REQUIREMENTS Wheel Size First Pass FT-LBS Second Pass FT-LBS Third Pass FT-LBS 12" 20-25 35-40 50-65 13" 20-25 35-40 50-65 14" 20-25 50-60 90-120 15" 20-25 50-60 90-120 16" 20-25 50-60 90-120 NEVER! use an pneumatic air gun to tighten wheel lug nuts. WARNING - Lug Nut Tightening Over-tightening lug nuts will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. WARNING - Lug Nut Inspection Lug nuts are prone to loosen after initial installation, which can lead to death or serious injury. Check all wheel lug nuts periodically. Figure 59. Wheel Lug Nuts Tightening Sequence PAGE 60 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Check all lights before each tow. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 61 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. DANGER - AMPUTATION RISK WARNING - HYDRAULIC SYSTEM HAZARD 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. Stop the engine by turning off the ignition switch and remove the starter key. Place a “DO NOT OPERATE” tag over the switch and disconnect the battery. The pressure reading on the accumulator pressure gauge MUST read ZERO. ALWAYS make sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump. DO NOT open hydraulic lines or loosen hydraulic fittings while the engine is running! Hydraulic fluid under pressure can penetrate the skin, blind, cause burns or create other potentially dangerous hazards. TABLE 9. PUMP TROUBLESHOOTING Problem Possible Problem To Troubleshoot Incorrect System Operating Pressure Check the pump pressure gage. Verify it is approx. 4400 PSI Incorrect Engine RPM setting Verify the engine's high RPM speed is set to 2550 Contaminated Main Relief Valve Check the manifold for a contaminated Relief Valve Obstructed Material Cylinders check for obstructions (dried material) inside the cylinders Incorrect Directional Control Operating Pressure Verify the Directional Control operating pressure is approx. 1000 PSI Contaminated Relief Valve Check the manifold for a contaminated Relief Valve Broken Shaft Coupler Key Check the Hopper Remixer shaft coupler for a broken key Loose Shaft Retaining Set Collar Check the Shaft Retaining Set Collar for tightness Main Hydraulic Cylinder will not cycle Hopper Remix Paddles will not rotate PAGE 62 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 1750 PSI Check the manifold for a Contaminated Relief Valve contaminated Relief Valve Shuttle Cylinder does not stroke Check for burned out solenoid and Swing Solenoid not energizing 12V signal voltage Manually cycle the pump using the Swing Valve not functioning properly manual cylinder jogging switch Improper Flow Control setting Fully open Flow Control Valve Verify the engine’s high RPM speed is Incorrect Engine RPM setting set to 2550 Incorrect Main Hydraulic System Check the pump pressure gauge. Operating Pressure Verify it is approx. 4400 PSI Check the manifold for contaminated Contaminated Swing Relief Cartridge Swing Relief Cartridge Shuttle Cylinder slow to complete Check the accumulator pressure stroke Low Accumulator System Pressure reading. Verify it is approx. 1750 PSI Hopper Discharge Nipple Seal Check the Hopper Discharge Nipple improperly lubricated Seal for seizing and lack of lubricant Misaligned hopper creating excessive Realign hopper ensuring S-tube is friction on the outlet nipple bearing rotating in the center of the hopper sleeve outlet. Lack of lubrication Grease Nun Plate Bushing Pump Engine will idle but not increase Throttle Control Block Solenoid not Check for burned out solenoid and to full operating speed energizing 12V signal voltage Blown out fuse Check the fuse Battery voltage falls below 12VDC on Dead battery Check the charge on the battery digital display, causing engine not to Check the wiring connections and start Wiring connection inside Control Box verify power is reaching ignition switch MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 63 LS400/LS500 PUMP — TROUBLESHOOTING (PUMP) TABLE 9. PUMP TROUBLESHOOTING (CONTINUED) Problem Possible Problem To Troubleshoot Check oil level and for closed suction Insufficient oil strainer Check for aeration reservoir Air in system Main Hydraulic Pump Noisy Vacuum leak in suction line Excessive pump wear Repair or replace Excessive engine speed Check for correct engine RPM Low engine speed Check engine RPM Main relief cartridge set to low Adjust relief cartridge Engine bogs down Decrease volume control on main pump Engine overloaded when pumping Material hose pack Low engine speed Check engine RPM Machine does not deliver volume and Volume control set to low Adjust control to full open setting pressure Check for proper pressure or for Main hydraulic pressure too low contaminated relief cartridge Check fan electrical connection or for burnt fan motor. Cooling fan Fan rotating in wrong direction Contaminated cooler fins Clean cooler fins Hydraulic fluid gets hot Return filter element closed Replace filter Main relief cartridge contaminated or Replace or set to proper pressure set too low Hydraulic oil level too low Fill to proper level Accumulator bottle low on notrogen Check precharge pressure 1100 PSI Contaminated safety relief cartridge Replace cartridge Accumulator gauge reads below 1750 Defective unloader cartridge electrical Replace PSI coil Unloader cartridge coil not energizing Check for 12 Volt signal voltage Defective gear pump Replace pump Worn or defective urethane cups or Concrete slurry in lubrication box Replace worn material cylinder Material cylinder piston cups squeel Low on lubrication Check oil level Excessive amount of hydraulic on Inspect cylinder. Check values for cylinder rod side contamination or faulty spring Cylinders not completely extended (short stroke) Hydraulic cylinder piston head seal Replace seals leaking PAGE 64 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. ENGINE TROUBLESHOOTING SYMPTOM Engine will not star t or star t is delayed, although engine can be turned over. At low temperatures engine will not star t. Engine fires but stops soon as star ter is switched off. Engine stops by itself during normal operation. Low engine power, output and speed. Low engine power output and low speed, black exhaust smoke. POSSIBLE PROBLEM SOLUTION Speed control lever is in "STOP" position Set speed control lever to "START" position. No fuel reaching injection pump Add fuel. Check entire fuel system. Defective fuel pump Replace fuel pump. Fuel filter clogged Replace fuel filter and clean tank. Faulty fuel supply line Replace or repair fuel line. Compression too low Check piston, cylinder and valves. Adjust or repair per engine repair manual. Fuel injector not working correctly Repair or replace injector in accordance with engine repair manual. Oil pressure too low Check engine oil pressure. Low star ting temperature limit exceeded Comply with cold star ting instructions and proper oil viscosity. Fuel separates has inadequate resistance to low temperatures Check whether clear (not turbid) fuel emerges from the fuel line (detach from injection pump). If the fuel is turbid or separated, warm up the engine or drain the complete fuel supply system. Refuel with winter grade diesel fuel. Engine oil too thick Refill engine crankcase with correct type of oil for winter environment. Throttle lever in STOP position Reposition throttle lever to RUN position. Fuel filter blocked Replace fuel filter. Fuel supply blocked Check the entire fuel system. Fuel tank empty A d d f u e l. Fuel filter blocked Replace fuel filter. Fuel tank empty Replace fuel filter. Fuel filter clogged Replace fuel filter. Fuel tank venting is inadequate Ensure that tank is adequately vented. Speed control lever does not remain in selected position See engine manual for corrective action. Engine oil level too full Correct engine oil level? Air filter blocked Clean or replace air filter. Incorrect valve clearances Adjust valves per engine specification. Malfunction at injector See engine manual. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 65 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. BRAKE SYSTEM TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Overheated wheel bearing Replace wheel bearing and pack with grease. Low brake fluid Fill and bleed brake system. Siezed acutator master cylinder Replace/Rebuild master cylinder. Brake shoe noise Inspect drums. Adjust shoes or replace if necessary. Leaking wheel cylinder Check and replace wheel cylinder and bleed brake system. Low brake fluid level Fill with dot approved brake fluid and bleed brake system. Brake actuator frame damage Replace complete actuator unit. Brake line being pinched Replace brake line. Seized actuator Replace or rebuild actuator. Broken return spring Replace spring. Brakes improperly adjusted Check adjustment. Break-away cable system par tially activated Break-away cable might be pulled. Determine cause and correct. Pry up on cable until indicator bead touches or rests against cable spring stop. This will fully release the frame brakes and prevent drag. Brakes squeak, chatter or chuck. Brakes overheah, fail to operate, pull to the side, or function poorly PAGE 66 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Replace shor ted solenoid. Wire connection is shor ted directly to the ground. Correct connection. 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. Correct connection. 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. Correct connection. MAIN A OPEN MAIN A SHORTED SOLUTION MAIN B OPEN MAIN B SHORTED SWING OPEN SWING SHORTED MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 67 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. Correct connection. 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. Correct connection. 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. Correct connection. ALTERNATOR FAILURE Defective alternator. Replace alternator. V-BELT BREAKAGE Engine blower cooling fan V-belt is broken requiring replacement. Replace v-belt. THROTTLE SOLENOID OPEN THROTTLE SOLENOID SHOR TED FUEL SOLENOID OPEN FUEL SOLENOID SHOR TED UNLOADER SOLENOID OPEN UNLOADER SOLENOID SHOR TED PAGE 68 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Location of Components for Electrical Troubleshooting MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 69 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) FUSE HOLDER 5 6 7 8 12 AWG RED OUTSIDE CONTROL BOX W D SOLENOID 10 AWG RED H P1 4 3 2 1 8 7 6 5 INSIDE CONTROL BOX 12 AWG RED BATTERY 10 AWG BLK 14 AWG PINK/BLK (STARTER SOLENOID) 16 AWG GREEN 16 AWG YELLOW 16 AWG ORANGE 14 AWG RED 1 14 AWG BLACK (GND.) 2 A 15/54 58 J OIL PRESSURE SWITCH 17 30 I ALTERNATOR G A OUTSIDE CONTROL BOX 1 2 3 4 5 6 7 8 A A J1 MALE INTERFACE CONNECTOR (YELLOW) STARTER F K 50A FUEL SOLENOID (SHUT-DOWN) 19 IGNITION SWITCH CIRCUIT ACTIVE = +12VDC CIRCUIT OFF = GND +12VDC POWER IN ENGINE CRANK A LOW BATTERY TACH INPUT J2 MALE INTERFACE CONNECTOR (WHITE) P2 P2 LOW OIL INPUT SWING A CYL A CYL B THROTTLE BRN RED +12VDC POWER OUT GROUND RED GRN WHT/BLK BLK FUEL SOLENOID (SHUT-DOWN) CONTROLLER BLACK POTTED BOX C 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 BLK GND MAIN B A INSIDE CONTROL BOX 14 AWG RED B D MAIN A DEUTZ 10-PIN ENGINE CONNECTOR 14 AWG BRN E 14 AWG RED 14 AWG GRAY SWING A 14 AWG RED MA 14 AWG YEL NI FO 14 AWG RED 14 AWG WHITE LD OUTSIDE CONTROL BOX TH R BLOTT OC LE K ENGINE SPEED SOLENOID L Figure 62. Connections to Digital Control Box - J1 and J2 Connectors ( 1 of 2) PAGE 70 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 71 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 SIGNAL NOT USED 16 AWG BLUE NOT USED 16 AWG BROWN INDICATOR “RED” ACTIVE BETWEEN GND. 800 mV +12 VDC GND. A PROXIMITY SWITCH “A” F BLACK BROWN BLUE ENG SOL POWER 35A 1 SEC OVER TEMP PROX A NOT USED PROX B PROX C NOT USED HEAT EXCHANGER “COOLING FAN” PROX D POWER B GROUND NOT USED AUTO LUBE FLOW A 12VDC FLOW B 12VDC CONTROLLER BLACK POTTED BOX +12 VDC 14 AWG RED 1 UNLOADER C P4 ORANGE BLUE 12VDC BLUE A 15/54 30 IGNITION SWITCH 58 50A 19 H P4 4 3 A 2 B 1 8 7 6 16 AWG RED 12VDC 5 16 AWG BLACK 1 2 3 4 5 6 7 8 A 17 INSIDE CONTROL BOX D FLOW CONTROL BROKEN FAN BELT OUTSIDE CONTROL BOX J4 MALE INTERFACE CONNECTOR (WHITE) A E +12 V-BELT BREAK SWITCH 1 GND. 14 AWG BLACK 2 NOTE: WHEN MEASURING VOLTAGE AT CONNECTOR P4 PINS 2 AND 3. 1 PLACE NEGATIVE LEAD OF VOLTMETER TO FLOW CONTROL BODY (GROUND). ACCUMULATOR DUMP VALVE “UNLOADER” CONNECTIONS TO J3 AND J4 CONNECTORS ON DIGITAL CONTROL BOX (LS400 AND LS500) Figure 63. Connections to Digital Control Box - J3 and J4 Connectors ( 1 of 2) PAGE 72 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 73 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. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 75 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. Manifold Block Ports PAGE 76 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. EXAMPLE #1 (A California Test Lab. Report) JOB: Building Foundations (Water Project) Sacks per cu./yd. Gallons per sack Washed Sand-#200 wash 6.5 designed for 2,500 lbs. in 28 days 7.1 1.3 Organic matter-OK Specific gravity (SSD) Sand-2.58; Pea Gravel-2.60 Sieve analysis-percent passing Material W.C. Sand 1.5” 1” 3/4” Pea Gravel % Comb. 3/8” 100 #4 99.7 #8 79.1 #16 60.4 #30 36.5 #50 14.3 #100 4.0 #200 1.1 100 100 3.0 66 51 39 23 9 3 1.0 DESIGN FOR ONE YARD OF CONCRETE (SATURATED & SURFACE DRY): Absolute volume of aggregate in one cu. yard: Specific gravity of aggregates in one cu. yard: 17.78 cu. ft. 2.58 Weight of aggregates in one cu. yard batch: 2850 lbs. W.C. Sand PEA GRAVEL WATER 46 gal. % 65 BATCH 1800 SPEC. GRAVITY 2.58 ABS. VOL. 11.56 35 1000 1 2.60 6.22 CEMENT 6.5 sk. TOTAL ADMIXTURE: 611 None SLUMP REMARKS 4” This mix designed for pumping NOTE: Due to the availability of well-graded sand as shown in the above sieve analysis, this mix pumped very successfully. 27.00 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 77 APPENDIX — CONCRETE MIX INFORMATION A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE PAGE 78 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Fill the cone 1/3 full by volume (Figure 68-A) and rod 25 times with a 1/2” dia x 24” lg. bullet-pointed steel rod. (This is a specific requirement which will produce non-standard results unless followed exactly.) Distribute rodding evenly over the entire cross section of the sample. 5. Fill cone to overflowing (Figure68-C). Rod this layer 25 times with rod penetrating into but not through, the second layer. Distribute rodding evenly over the entire cross section of this layer. FULL (OVERFLOW) Figure 68-C. Slump Test (Full-Overflow) 6. Remove the excess concrete (Figure 68-D) from the top of the cone, using the tamping rod as a screed. Figure 68-D. Slump Test (Removing Excess Concrete) BULLET POINTED STEEL ROD 1/3 FULL 1/2 DIAMETER 24 INCHES LONG FOOT PIECE Figure 68-A. Slump Test (1/3 Full) 4. Fill cone another 1/3 (Figure 68-B) which will make the cone 2/3 full by volume. Rod this second layer 25 times with the rod penetrating into, but not through, the first layer. Distribute rodding evenly over the entire cross section of the layer. 2/3 FULL 7. Lift the cone vertically (Figure 68-E) with a slow even motion. DO NOT jar the concrete or tilt the cone during this process. ( Invert the withdrawn cone, and place it next to, but not touching the slumped concrete. Figure 68-E. Slump Test (Cone Invert) 8. Lay a straight edge (Figure 68-F) across the top of the slumped cone. Measure the amount of slump in inches from the bottom of the straight edge to the top of the slumped concrete at a point over the original center of the base . The slump operation must be complete in a maximum elapsed time of 1-½ minutes. Discard the concrete. DO NOT use it in another tests. Figure 68-B. Slump Test (2/3 Full) Figure 68-F. Slump Test (Measurement) MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 79 APPENDIX — RECOMMENDED SHOTCRETE SYSTEM Figure 69. Recommended Shotcrete System PAGE 80 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 11 EM28131D 2"x2" ELBOW 90º 12 EM24841 HOSE, 2”x25’ H-D w/ENDS 13 14 EM23808D EM23806 NOZZLE ASSEMBLY, 2” H-D NOZZLE TIP, RUBBER 1-3/8” 15 EM23807 NOZZLE TIP, RUBBER 1.25” QTY. REMARKS GENERAL RECOMMENDATIONS ■ If the site will permit, use steel pipe from the pump to the pool perimeter. It will reduce line pressures which is highly recommended. ■ The vibrator on the reducer by the pool improves pumpability. ■ Turn both air vibrators off whenever the pump is stopped to prevent separation of mix. ■ The air vibrators are low consumption (4.2 scfm). ■ Leave the air on at the nozzle when the pump is stopped to prevent clogging of air the hoses in the air insert. ■ Use item #11 (steel elbow) at the edge of the pool to prevent collapse of the rubber hose, which can cause blockage. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 81 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. DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air passages clean. PAGE 82 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .......... W/AIR VIBRATOR MOUNTING AIR VIBRATOR 1 BOLT, 1/2-13X2 2 AIR HOSE 1 BUSHING 1 VALVE 1 NIPPLE 2 COUPLING 1 WASHER, 1/2 LOCK 2 NUT, HEX 1/2-13 2 2"X25' GROOVED HOSE 2"X25' RAISED HOSE 2"X50' GROOVED HOSE VIC ADAPTER / EM23802D H.D 1 GUN BODY 1 “O” RING 1 AIR INSERT 1 NOZZLE CLAMP 1 NOZZLE TIP, 1-3/8", SHORT 1 NOZZLE TIP, 1-1/4", LONG 1 STREET ELBOW 1 AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES ITEMS W/ * MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 83 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......................1 .....INCLUDES ITEMS W/% WASHER, 1/4 IN............NOT SOLD SEPARATELY 12347 WASHER, 3/8 IN....1 .....MQ-45T ONLY 12348 HOSE ..................A/R ...MAKE LOCALLY 12349 BEARING ..............1 .....S/N 2345B AND ABOVE NO. Column QTY. Column Numbers Used — Item quantity can be indicated by a number, a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold separately. Other entries will be clarified in the “Remarks” Column. REMARKS Column Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown. Assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased. Unique Symbols — All items with same unique symbol Indicated by: “INCLUDES ITEMS W/(unique symbol)” (@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column. Serial Number Break — Used to list an effective serial number range where a particular part is used. Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine. NOTICE When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order. PART NO. Column Numbers Used — Part numbers can be indicated by a number, a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication. A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column. Indicated by: “S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX” Specific Model Number Use — Indicates that the part is used only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant. Indicated by: “XXXXX ONLY” “NOT USED ON XXXX” “Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts. “Not Sold Separately” — Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip. PAGE 84 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .......... EM16816-2 ........... INSERT RING 2 .......... EM98065 .............. SLEEVE SEAL 1 .......... EM98022 .............. WEAR RING 1 .......... EM98065 .............. RUBBER RING 2 .......... EM14407 .............. O-RING 1 .......... 34507 ................... CAP, FUEL 2 .......... EM20763 .............. FILTER, FUEL (IN LINE) 1 .......... P53712 ................. CARTRIDGE, WATER SEPARATOR 3 .......... 01174416 ............. FILTER, OIL (ENGINE) 3 .......... 01174696 ............. FILTER, FUEL (ENGINE) 3 .......... 1319257 ............... INSERT, AIR FILTER 3 .......... 1880870 ............... AIR CARTRIDGE, SAFETY 1 .......... EM98163 .............. PROXIMITY SWITCH 1 .......... EM98121 .............. ELEMENT, RETURN OIL ........................................... S/N 281100 AND BELOW 1 .......... EM98275 .............. ELEMENT, RETURN OIL, ........................................... S/N 281101 AND ABOVE LS400/LS500 CONCRETE PUMP 3 Units Qty. P/N Description 1 .......... EM16459 .............. PIN 2 .......... EM25801 .............. CONCRETE CYLINDER 4 .......... EM16462 .............. FELT HOLDER 6 .......... EM98050 .............. PISTON CUP, ORANGE 8 .......... EM16493 .............. FELT RING 4 .......... EM98033 .............. OIL PLATE 4 .......... EM14408 .............. BRONZE RING 4 .......... EM16145A ............ BUSHING, SWING AXLE (BRONZE ) 3 .......... EM98021A ............ WEAR PLATE 4 .......... EM16816-1A ........ ENERGIZER RING 2 .......... EM16816-2 ........... INSERT RING 4 .......... EM98065 .............. SLEEVE SEAL 6 .......... EM98022 .............. WEAR RING 3 .......... EM98065 .............. RUBBER RING 6 .......... EM14407 .............. O-RING 2 .......... EM16174 .............. O-RING 2 .......... EM98163 .............. SWITCH, PROXIMITY 6 .......... 510265 ................. BOLT, HEX HEAD 3/8 NC x 3-1/4 IN. G8 1 .......... 34507 ................... CAP, FUEL 6 .......... EM20763 .............. FILTER, FUEL 3 .......... P53712 ................. CARTRIDGE, WATER SEPARATOR 9 .......... 01174416 ............. FILTER, OIL (ENGINE) 9 .......... 01174696 ............. FILTER, FUEL (ENGINE) 9 .......... 1319257 ............... INSERT, AIR FILTER 9 .......... 1180870 ............... AIR CARTRIDGE, SAFETY 2 .......... EM98121 .............. ELEMENT, RETURN OIL ........................................... S/N 281100 AND BELOW 2 .......... EM98275 .............. ELEMENT, RETURN OIL ........................................... S/N 281101 AND ABOVE Part numbers on this Suggested Spare Parts List may supersede or replace the P/N shown in the text pages of this book. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 85 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. DO NOT PUT ANY BODY PARTS INTO THE HOPPER UNTIL MACHINE IS COMPLETELY SHUT DOWN AND THE ACCUMULATOR PRESSURE GAUGE READS ZERO P/N: DCL301 14 12 DIG 4 1 ITA L SCRO LL CO RESE T NT SET RO LP AN EL DECR EASE VOL UME EMERGENC Y S O T P INCRE ASE FORW ARD FLO DIRE W CTIO N REVE RSE CON TRO AUTO LOCA MATIC OFF L L ON REMO JOG CENT TE OFFER CYLIN “A” STA RT IGNI DER JOG TION STRO KE JOG “B” REM OTE 13 6 E F Engine RPM Setting (without change) 8 RPM Low RPM: RPM USE DIESEL FUEL ONLY WARNING (Read Operator’s book) To avoid injury, you MUST read and understand operator’s manual before using this machine. This machine to be operated by qualified personnel only. Ask for training as needed. 11 High RPM: 7 P/N 35137 3 CAUTION 9 NOTES: EM98000 10 800-30-MAYCO 1 PLACE DECAL ON LS400 MODELS ONLY. 2 PLACE DECAL ON LS500 MODELS ONLY. 3 USE THIS DECAL (OPTION) WHEN HYDRAULIC STABILIZER JACKS ARE INSTALLED. CAUTION 9 EM98000 PAGE 86 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .......... USED ON LS500 MODELS 6 513580 DECAL, ENGINE RPM SETTING 1 7 EM97084 DECAL, MAINTENANCE 1 8 EM995 DECAL, CAUTION DIESEL FUEL 1 9 EM98000 DECAL, CAUTION - GREASE 2 HOURS 2 10 511709 DECAL, 800-30-MAYCO 1 11 35137 DECAL, CAUTION READ MANUAL 1 12 517907 DIGITAL CONTROL PANEL LOGO 1 13 EM955 DECAL, DANGER CHARGING ACCUM. 1 14 DCL304 DECAL, DANGER IMPROPER CHARGING 1 15 DCL301 DECAL, SHUTTLE TUBE DANGER 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 87 LS400/LS500 PUMP — NAMEPLATE AND DECALS PAGE 88 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .......... USED ON LS400 MODELS 8 517642 DECAL, MQ/MAYCO LS500 LOGO ....................... 1 .......... USED ON LS500 MODELS 9 TBD DECAL, FAULT LOCATOR 1 10 EM696 DECAL, CAUTION - TOWING DECAL 1 11 DCL302 DECAL, WARNING BURN HAZARD 1 12 SERIAL PLATE ...................................................... 1 .......... CONTACT MQ PARTS DEPT. 13 TBD DECAL, TIRE LOADING 1 14 49002 DECAL, WARNING COUPLER 1 15 TBD DECAL, VIN IDENTIFICATION 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 89 LS400/LS500 PUMP — FRAME ASSY. FRAME ASSY. PAGE 90 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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" ................................................ 2......... REPLACES 492624 BOLT 3/8" X 2-3/4" 1 WASHER 3/8" ........................................................... 2......... REPLACES 492598 NUT 3/8" ................................................................... 1......... REPLACES 492583 FENDOR, BOLT ON 2 BOLT 1/2" NC X 3/4" G5 12 WASHER, LOCK 1/2 IN. ........................................... 12 ....... REPLACES 492626 STABILIZER STAND 2 BOLT 3/8" NC X 1-1/4" G5 2 WASHER, LOCK 3/8" ................................................ 4 ........ REPLACES 492624 NUT 3/8" .................................................................... 2 ........ REPLACES 492583 BOLT 3/4" NC X 1" G5 10 WASHER, LOCK 3/4 IN. ...........................................10 ....... REPLACES EM492628 SUPPORT PLATE, RIGHT 1 SUPPORT PLATE, LEFT 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 91 LS400/LS500 PUMP — AXLE ASSY. (RIGHT/LEFT) AXLE ASSY. (RIGHT/LEFT) PAGE 92 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 1 5 383911 INNER BEARING CUP 2 IN. 1 6#% 363909 WHEEL STUD 1/2 IN. - 20 UNF PRESS IN 8 7 363239 HUB AND DRUM ASSY. 2 8 363916 OUTER BEARING CONE 1 9 363420 OUTER BEARING CUP 1 10 568326 LOAD WASHER 1 IN. T5 HP 1 11 363257 SLOTTED NUT, 1 IN. UNF 2 12 363258 COTTER PIN 3/16 IN. X 1-1/2 2 13 EM514813 RIM AND TIRE 2 14 363203 WHEEL LUG NUTS 1/2 UNF 60 CON 8 15 363199 GREASE CAP 2 16 EM104 BOLT, HEX HEAD 5/8 IN. NC X 2 IN. G5 ......... 4 .............. REPLACES 503982 17 0401450160 WASHER, FLAT 5/8 IN. ................................... 8 .............. REPLACES 492602 18 EM969023 NUT, LOCK 5/8 IN. ........................................... 4 .............. REPLACES 492586 RIGHT AND LEFT SIDE AXLE ASSEMBLIES ARE IDENTICAL WITH THE EXCEPTION OF THE BRAKE ASSEMBLY. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 93 LS400/LS500 PUMP — BRAKE LINE ASSY. BRAKE LINE ASSY. PAGE 94 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 95 LS400/LS500 PUMP — BRAKE LIGHT ASSY. BRAKE LIGHT ASSY. PAGE 96 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 97 LS400/LS500 PUMP — TRAILER HITCH ASSY. TRAILER HITCH ASSY. PAGE 98 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 99 LS400/LS500 PUMP — BATTERY ASSY. PAGE 100 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 101 LS400/LS500 PUMP — HOPPER ASSY. HOPPER ASSY. PAGE 102 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) LS400/LS500 PUMP — HOPPER ASSY. HOPPER ASSY. NO. PART NO. 1 EM515980 2 EM16184 3 EM516779 4 EM200303 5 EM200301 6 EM516820 7 EM514339 8 510717 9 EM514338 10 EM514706 11 EM902153 12 EM200018 13 EM703 14 500264 16 EM511428 17 EM516780 18 EM98108 19 505989 20 6109180 21 EM25508 22 EM70860-1 23 EM50417 24 EM508830 25 492378 26 0166 A 29 EM514031 30 EM514032 31 EM514033 32 513454 33 6109180 34 492589 35 EM25483 36 EM70860 37 EM515460 39 516799 40 EM702 41 EM703 42% 516787 43 EM500264 44% 516776 45% 516775 46 EM516786 PART NAME QTY. REMARKS HOPPER ASSY 1 HOPPER SEAL 1 REMIXER SHAFT 1 FOLLOWER RING 2 GRAPHITE SEAL 6 COMPRESSION SPRING 2 HOPPER SPRING SEAT 2 BOLT 1/2 X 1-3/4 IN. 4 SUPPORT, LEFT 1 END CAP, SHAFT SUPPORT 1 BEARING 2 SET COLLAR 1 SET SCREW ............................................ 2 ................ REPLACES 492470 KEY 3/8 IN. 1 BOLT 1/2 X 3-1/2 IN. 4 HOUSING 1 MOTOR, REMIX 1 BOLT 1/2 X 1-1/4 IN. 2 WASHER, LOCK 1/2 IN. ........................... 2 ................ REPLACES 492626 ADAPTER, FITTING 2 PISTON CUP HOLDER 1 PISTON CUP 1 HANDLE 1 BOLT 3/8 X 1-3/4 IN. 4 WASHER, LOCK 3/8 IN. ........................... 4 ................ REPLACES 492624 PADDLE ARM, END 2 PADDLE ARM, MOTOR END 2 PADDLE ARM, CENTER 2 BOLT 1/2 X 3-1/4 IN. 6 WASHER, LOCK 1/2 IN. ........................... 6 ................ REPLACES 492626 HEX NUT 1/2 IN. ...................................... 6 ................ REPLACES 507661 HOSE 2 HANDLE ASSY. 1 RETAINING RING 1 SPACER 6MM 1 DOG POINT SET SCREW 3/8" 1 SET SCREW 3/8" 3 REMIX SHAFT COUPLER 1 SQUARE KEY 3/8" 1 DRIVE MEMBER COUPLER 1 MOTOR SHAFT COUPLER 1 COUPLER ASSY ...................................... 1 ................ INCLUDES ITEMS W/% MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 103 LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY. HOPPER ATTACHMENT ASSY. PAGE 104 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 4 BOLT 3/4 IN. X 3 IN. 4 HEX NUT 3/4 IN. 4 HEX BOLT 1/2 X 2-1/2 IN. 2 HEX BOLT 1/2 X 1-1/2 IN. 1 HEX NUT 1/2 IN. ................................................ 3 .............REPLACES 492556 SCREW CAP 3/8" 2 WASHER FLAT 3/8" 4 BOLT 7/16 NC X 4" G5 2 NUT LOCK 1/2" 2 NUT NYLOC 2 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 105 LS400/LS500 PUMP — HOPPER INTERIOR ASSY. HOPPER INTERIOR ASSY. PAGE 106 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. - 14 UNF 1 O-RING 1 RING SEAL, SHUTTLE AXLE 1 O-RING 1 WEAR RING HF 1 RING, ENERGIZER RUBBER 1 RING, INSERT STEEL 1 SLEEVE 5 IN. ............................................ 1 ............... JUNE 2008 AND BELOW SLEEVE 5 IN. ............................................ 1 ............... JULY 2008 AND ABOVE BOLT 5/8 X 2 IN. ........................................ 4 ............... REPLACES 503982 WASHER, LOCK 5/8 IN. 4 DISCHARGE PLATE BEARING 1 SEAL, RUBBER 1 DISCHARGE NIPPLE 1 GREASE FITTING 3 BOLT 5/8 X 2 IN. 6 SHUTTLE CYLINDER 1 NUN PLATE 1 BOLT, HEX HEAD 5/8 X 2 IN..................... 4 ............... REPLACES 503982 PIN 1 WASHER, LOCK 5/8 IN. 4 HOPPER SCREEN 1 PLATE, WEAR HF 1 NUT, HEX 5/8 IN. NC INS. ......................... 2 ............... REPLACES 492586 BOLT, COUNTER SUNK 5/8-11 x 3 IN. 2 WASHER, LOCK 3/4 IN. ............................ 2 ............... REPLACES EM492628 BOLT, HEX HEAD 3/4-10 X 2 IN. 2 BOLT, COUNTER SUNK 1/2-13 x 3 IN. 2 O-RING 2 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 107 LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY. SHUTTLE CYLINDER ASSY. PAGE 108 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 ............ INCLUDES ITEMS W/ * 9A EM98106SK SEAL KIT, SHUTTLE CYLINDER 1 EM254549 BRACKET, PIVOT 1 10 * 11 492397 BOLT 1/2 X 2-1/2 IN. 4 12 EM621 WASHER 1/2 IN. 4 13 6109180 WASHER, LOCK 1/2 IN. ............................... 4 ............ REPLACES 492626 14 492584 NUT 1/2 IN. 4 15 0820270000 CLEVIS PIN 3/4 IN. 2 * 16 COTTER PIN 2 * 0820270000 18 515249 JAM NUT 1 * 0509440000 19 FEMALE CLEVIS 2 * 3322 20 FITTING, ELBOW 2 21 EM514590 HOSE 1 22 EM514591 HOSE 1 23 517742 COVER, SHUTTLE CYLINDER 1 24 0202 BOLT ............................................................. 3 ............ REPLACES 492364 25 EM923023 WASHER, FLAT ............................................ 3 ............ REPLACES 492597 26 2105164 NUT, HEX ...................................................... 3 ............ REPLACES 492582 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 109 LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 110 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 ................................................... 8 ........ REPLACES 492375 13 0166 A WASHER LOCK 3/8 IN. .......................................................... 8 ........ REPLACES 492624 14 3019092 WASHER, FLAT 3/8 IN. ......................................................... 22 ....... REPLACES 492598 16 EM514197 LUBRICATION BOX 1 17 EM507895 PLUG 1 18 EM515796 COVER, LUBRICATION BOX 1 19 EM514610 LATCH, COVER 1 20 491754 RIVET, AM-66 2 21 492378 BOLT, 3/8 NC X 1.3/4 IN. G5 6 22 0166 A WASHER, LOCK 3/8” .............................................................. 6 ........ REPLACES 492624 23 EM274351 SEAL LUBE BOX 2 24 EM50425 FLANGE, RING 2 25 492451 BOLT 3/8 - 24 X 1 IN. HEX HEAD 8 26 EM50443 SEAL, OIL BOX 8 27 514208 BAR,PROXIMITY SWITCH SUPPORT 1 28 EM98163 SWITCH, PROXIMITY W/CABLE 2 EM98135 CABLE HOUSING, FEMALE 2 29 30 EM98134 SEAL, CONNECTOR HOUSING 6 31 EM98138 TERMINAL PIN, FEMALE 6 32 514611 GROMMMET 2 33 504505 WRAP TIE 8 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 111 LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 112 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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., BLACK OXIDE G8 45 EM25497 FITTING, 90° 4 46 EM25474 HOSE, HYDRAULIC SLAVE 1 47 EM16459 PIN, WRIST 2 48 EM505723 PIN, COTTER 4 49 EM491701 FITTING, GREASE 2 50 EM517126 LOCK WASHER 6 51 EM513352 SEAL, SQUARE 1 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 113 LS400/LS500 PUMP — FUEL TANK ASSY. FUEL TANK ASSY. PAGE 114 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. A/R FILTER, FUEL 2 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 115 LS400/LS500 PUMP — HEAT EXCHANGER ASSY. HEAT EXCHANGER ASSY. PAGE 116 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. ..................... 4 .............. REPLACES 492624 BOLT 5/16 X 1 IN. .............................. 4 .............. REPLACES 492364 WASHER, FLAT 5/16 IN. .................... 8 .............. REPLACES 492597 NUT 5/16 IN. ....................................... 4 .............. REPLACES 492582 ADAPTER 1 HOSE 4000 PSI 1 ADAPTER 1 ADAPTER 1 HOSE 2000 PSI 1 ADAPTER 1 HOSE, 2000 PSI 1 MOTOR AND FAN ASSY 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 117 LS400/LS500 PUMP — ACCUMULATOR ASSY. ACCUMULATOR ASSY. PAGE 118 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 119 LS400/LS500 PUMP — REMIXER CONTROL ASSY. REMIXER CONTROL ASSY. PAGE 120 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .................REPLACES 492553 COUPLING 1 TEST PORT 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 121 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. (.85 m) C................................................. PIVOT BRACKET GREASE POINT ................................. 41 in. (1.5 m) PAGE 122 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 123 LS400/LS500 PUMP — ENGINE COVER ASSY. ENGINE COVER ASSY. PAGE 124 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 125 LS400/LS500 PUMP — HYDRAULIC TANK ASSY. HYDRAULIC TANK ASSY. PAGE 126 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 514040 0166 A EM517295 EM251191 EM25184 492362 EM923343 EM98263 492267 16433 EM491189 EM18436 EM514605 EM514622 EM514597 EM491164 509784 517002 EM509369 491237 506094 EM98188 EM97066 EM97067 EM25523 EM509517 EM514602 EM16517 EM98112A EM98275 516814 EM16513 492376 492598 509343 TBD 516813 409401 EM16414 16516 509344 514604 514604 PART NAME QTY. REMARKS HYDRAULIC TANK, LS-S 1 LOCK, WASHER 3/8 IN. .......................................4 ........... REPLACES 492624 HANDLE 1 TANK COVER PLATE 1 RESERVOIR GASKET 1 BOLT 5/16 X 5/8 IN. 20 WASHER, LOCK 5/16 IN. .................................... 20 ..........REPLACES 492623 CAP ASSEMBLY 1 BOLT 3/16 X 5/8 IN. 6 TUBE 1 FITTING 1 90° MALE ADAPTER 2103-16-16 1 HOSE 1 FITTING 1 IN. 1 HOSE 1 ELBOW, 3/4 IN. 1 ADAPTER 1 HOSE 1 STRAIGHT MALE ADAPTOR , 0101-08-08 1 VALVE 1/2 IN. 1 CAP 1/2 IN. 1 GAUGE, LEVEL & TEMP. ..................................... 1 ........... REPLACES EM16478 GAUGE 3000PSI, ACCUMULATOR 1 GAUGE 5000 PSI, MAIN 1 ADAPTER 2 HOSE, 4000 PSI MAIN GAUGE 1 HOSE, 4000 PSI ACCUMULATOR GAUGE 1 STRAIGHT MALE ADAPTER 0102-24-16 1 RETURN FILTER ASSY. .......................................1 ........... S/N 281101 AND BELOW ELEMENT, RETURN FILTER ................................1 ........... S/N 281102 AND ABOVE 90° FITTING 1 DIFFUSER 1 BOLT 3/8 X 1-1/4 IN. 4 WASHER, FLAT 3/8 IN. 4 TEE FITTING 1 BOLT 2 BUSHING 1 ADAPTOR 3903-16-16 1 VALVE NEEDLE 1 PIPE 1-1/2" ...........................................................1 ...........S/N 281101 AND BELOW ADAPTOR 063T-16-16 1 HOSE 1 HOSE 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 127 LS400/LS500 PUMP — ENGINE ASSY. LS-40TD/LS-50TD ENGINE ASSY. PAGE 128 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. ........................................... 4............ REPLACES 492600 WASHER, LOCK 1/2 IN. ......................................... 4............ REPLACES 492626 AIR DUCTING CLAMP 2 AIR DUCTING CLAMP 2 AIR DUCTING DUCTING 1 CLAMP 3 CONNECTOR, AIR FILTER 1 HOSE, ELBOW 90° 1 AIR CLEANER ASSY. ............................................. 1............ INCLUDES ITEMS W/ * HOOD, AIR CLEANER 1 INSERT, AIR FILTER 1 CARTRIDGE, SAFETY AIR 1 DUST EJECTOR 1 BOLT 5/16 X 1-1/2 IN. 2 WASHER, LOCK 5/16 IN. 2 WASHER, FLAT 5/16 IN. 4 NUT, HEX 5/16 IN. G5 2 REDUCTION TUBE, EXHAUST 1 BOLT 5/16 NC X 3 IN. G5 2 WASHER, FLAT 5/16 IN. ......................................... 4............ REPLACES 492597 SPACER, EXHAUST 2 WASHER, LOCK 5/16 IN. ........................................ 2............ REPLACES 492623 HEX NUT 5/16 IN. G5 .............................................. 2............ REPLACES 492553 CAP, EXHAUST 2-1/2 IN. 1 FILTER, OIL (ENGINE) 1 FILTER, FUEL (ENGINE) 1 PIPE EXHAUST ASSY. 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 129 LS400/LS500 PUMP — THROTTLE ASSY. THROTTLE ASSY. PAGE 130 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 .............. REPLACES 492596 WASHER 1/4 IN. ............................................... 4 .............. REPLACES 492622 PISTON SPACER 2 BLOCK 1 COIL, 12V 1 VALVE 1 ELBOW ADAPTER 90° MALE 3 STRAIGHT ADAPTER 1 HOSE 20 IN. 2 ELBOW ADAPTER 90° MALE 1 ELBOW ADAPTER 90° MALE 1 HOSE 17-1/2 IN. 1 ELBOW ADAPTER 90° MALE 1 HOSE 10 IN. 1 ELBOW ADAPTER 90° MALE 1 HYDRAULIC CYLINDER 1 NUT, HEX 1/4 IN. 2 THROTLE CONTROL PLATE 1 THROTTLE CABLE GUIDE 1 SLEEVE, THROTTLE 1 BOLT 8 X 1/4 IN. 1 CABLE, THROTTLE 1 BOLT 5/16 X 1-1/2 IN. 1 HEX NUT 5/16 IN. ............................................. 1 .............. REPLACES 492553 THROTTLE BLOCK ASSY. ............................... 1 .............. INCLUDES ITEMS W/ * MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 131 LS400/LS500 PUMP — WATER SEPARATOR ASSY. WATER SEPARATOR ASSY. PAGE 132 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 133 LS400/LS500 PUMP — HYD. PUMP ASSY. HYDRAULIC PUMP ASSY. PAGE 134 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 ............ REPLACES 492626 SUCTION PIPE ADAPTER, 40 SPECIAL 1 CLAMP 2 IN. ................................................................ 2 HOSE, SUCTION 2 IN. 1 ADAPTER, SUCTION PIPE 32 1 FLANGE, SUCTION PIPE .......................................... 1 ............ INCLUDES ITEMS W/% BOLT 1/2 X 1-1/2 IN. 4 WASHER, LOCK 1/2 IN. .............................................. 4 ............ REPLACES 492626 O-RING 1 COUPLER, ENGINE ASSY. 1 BOLT 1/2 X 1-1/2 IN. 2 PUMP, MAIN 60CC, PARKER P1-60 SERIES ............ 1 ............ USED ON LS400 ONLY PUMP, MAIN 75CC, PARKER P1-75 SERIES ............ 1 ............ USED ON LS500 ONLY FLOW CONTROL VALVE 1 BOLT 7/16 X 3 IN. 4 GASKET 1 PUMP, SECONDARY 1 BOLT 3/8 X 1 IN. .......................................................... 2 ............ REPLACES 492375 WASHER, LOCK 3/8 IN. .............................................. 2 ............ REPLACES 492624 STRAIGHT ADAPTER 1 ELBOW ADAPTER 1 HOSE, 4000 PSI SENSOR ......................................... 1 ............ USED ON LS400 ONLY HOSE, 4000 PSI SENSOR ......................................... 1 ............ USED ON LS500 ONLY ELBOW ADAPTER 1 STRAIGHT ADAPTER 1 STRAIGHT ADAPTER 1 ELBOW ADAPTER 90° MALE 2 ELBOW ADAPTER 1 HOSE 2000 PSI, REMIX VALVE 1 MOTORIZED FLOW CONTROL MANIFOLD ASSY. 1 HOSE, MAIN MANIFOLD 1 ELBOW 1 VALVE, MAIN RELIEF 1 HOSE 1 ELBOW 1 ELBOW ADAPTER 1 * EM98128 EM510902 EM517674 EM98256 EM98273 EM506953 EM16190 EM98107 EM963610 0166 A EM25498 EM25429 EM514599 EM516875 EM25429 EM491372 EM25498 EM16524 506200 EM514601 EM517649 EM517038 EM509353 TBD EM514608 EM25459 EM25429 4 * MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 135 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. #6 (09/19/11) 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. ........................................... 4 .......... REPLACES 492626 MANIFOLD ASSY COMPLETE ............................... 1 .......... REPLACES EM98109 ............................................................................................... INCLUDES ITEMS W/ % CYCLING VALVE, SWING W/PILOTS ...................... 1 .......... INCLUDES ITEMS W/ # BOLT, SHCS 1/2" x 2-1/4" 12 PILOT VALVE, SHUTTLE 1 BOLT, SHCS 1/2" X 1-1/4" 8 CYCLING VALVE, MAIN ........................................... 1 .......... INCLUDES ITEM W/ & PILOT VALVE, MAIN CYLINDER 1 CHECK VALVE 1 COIL, 12VDC ACCUMULATOR 1 ACCUMULATOR UNLOADER CARTRIDGE ASSY 1 ADAPTER 1 ADAPTER 3 ADAPTER 1 ADAPTER 2 UNLOADING RELIEF VALVE, SHUTTLE 1 ADAPTER 2 ADAPTER 2 ADAPTER 1 ADAPTER 1 ADAPTER 2 ADAPTER 3 ADAPTER 1 CHECK VALVE 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 137 LS400/LS500 PUMP — CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 138 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 ................ REPLACES 492597 NUT 5/16 IN. .................................................... 4 ................ REPLACES 492582 OVERLAY, CONTROL PANEL 1 IGNITION SWITCH ASSY. 1 KEY, IGNITION 1 EMERGENCY STOP SWITCH ASSY. 1 CONTACT BLOCKS, EMERGENCY SWITCH 3 FLOW DIRECTION SWITCH ASSY. 1 MAIN CONTROL SWITCH ASSY. 1 AUTO/JOG SWITCH ASSY. 1 JOG A/B SWITCH ASSY. 1 RECEPTACLE, REMOTE 1 VOLUME SWITCH ASSY. 1 SCROLL SWITCH ASSY. 1 RESET SWITCH ASSY. 1 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 139 LS400/LS500 PUMP — CONTROL BOX HARNESSES ASSY. CONTROL BOX HARNESSES ASSY. PAGE 140 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. #6 (09/19/11) — PAGE 141 LS400/LS500 PUMP — REMOTE CONTROL CABLE ASSY. REMOTE CONTROL CABLE ASSY. PAGE 142 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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 ................ INCLUDES ITEMS W/ * MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 143 LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL) PAGE 144 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. 2 2 2 1 3 5 1 1 1 1 7 3 2 1 1 2 1 2 2 8 REMARKS MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 145 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. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier. b. MINIMUM ORDER The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement. RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed, subject to the following provisions: 1. 2. A Returned Material Authorization must be approved by Multiquip prior to shipment. Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.) Any parts with a limited shelf life (such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date. c. Any line item with an extended dealer net price of less than $5.00. d. Special order items. e. Electrical components. f. Paint, chemicals, and lubricants. g. Decals and paper products. h. Items purchased in kits. 7. The sender will be notified of any material received that is not acceptable. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned. 8. Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense. a. The parts numbers and descriptions must match the current parts price list. 9. b. The list must be typed or computer generated. Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge. c. The list must state the reason(s) for the return. d. The list must reference the sales order(s) or invoice (s) under which the items were originally purchased. e. The list must include the name and phone number of the person requesting the RMA. 3. A copy of the Return Material Authorization must accompany the return shipment. 4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point. 10. In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date. A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier. LIMITATIONS OF SELLER’S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages. LIMITATION OF WARRANTIES No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof. Effective: February 22, 2006 11. Credit issued will be applied to future purchases only. PRICING AND REBATES Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change. PAGE 146 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) 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. Manufacturer will, at its option, replace or repair at a point designated by the Manufacturer any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate the Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair the of the defective parts. 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 or 2000 hours after the date of delivery to the original retail purchaser. The Manufacturer will, at its option, replace or repair at a point designated by Manufacturer any part or parts which shall appear to the satisfaction of Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair of the defective parts. This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect its performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear. THIS WARRANTY AND MANUFACTURER’S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect it’s performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear. THIS WARRANTY AND MANUFACTURER’S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 147 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: [email protected] MQ Parts Department Tel. (800) 421-1244 Fax (800) 537-3927 Service Department 800-421-1244 310-537-3700 800-427-1244 310-537-3700 Fax: 800-672-7877 Fax: 310-637-3284 Warranty Department Fax: 310-537-4259 800-421-1244 310-537-3700 Fax: 310-943-2249 Technical Assistance 800-478-1244 Fax: 310-943-2238 MEXICO UNITED KINGDOM MQ Cipsa Multiquip (UK) Limited Head Office Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: [email protected] Tel: (52) 222-225-9900 Fax: (52) 222-285-0420 Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinfield, Cheshire SK16 4UJ Contact: [email protected] Tel: 0161 339 2223 Fax: 0161 339 3226 CANADA Multiquip 4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: [email protected] Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664 © COPYRIGHT 2011, MULTIQUIP INC. Multiquip Inc, the MQ logo and the Mayco logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission. This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations. Your Local Dealer is: