MULTIQUIP MAYCO LS400 Operation And Parts Manual
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MULTIQUIP MAYCO LS400 Operation And Parts Manual

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OPERATION AND PARTS MANUAL
SERIES
MODELS LS400/LS500
CONCRETE PUMPS
(DEUTZ F4L2011, BF4L2011 DIESEL ENGINES)
Revision #6 (09/19/11)
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION AND PARTS MANUAL SERIES MODELS LS400/LS500 CONCRETE PUMPS (DEUTZ F4L2011, BF4L2011 DIESEL ENGINES) Revision #6 (09/19/11) THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: Proposition 65 Warning

    — 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)

  • Page 4: Table Of Contents

    Specification and part number are subject Appendix - Recommended Shotcrete Accessories ..82-83 to change without notice Explanation Of Codes In Remarks Column .... 84 Suggested Spare Parts ........... 85 PAGE 4 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 5: Safety Message Alert Symbols

    NEVER operate the engine with heat shields or heat guards removed. CAUTION 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)
  • Page 6 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...

  • Page 7: Rules For Safe Operation

    ■ NEVER use accessories or attachments, which are not oil. recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result. PAGE 8 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 8 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. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 9...
  • Page 9 To avoid eye irritation, always wear safety glasses. emergency. Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery: PAGE 10 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 10 NOTES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 11...

  • Page 11: Specifications

    . l a e t i l ) s r l e s e t t PAGE 12 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 12: Dimensions

    LS400/LS500 PUMP — DIMENSIONS . n i . n i . n i . n i Figure 1. Dimensions MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 13...

  • Page 13: Important Hand Signals

    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)

  • Page 14: General Information

    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...
  • Page 15 530 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. PAGE 16 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 16: How It Works

    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...

  • Page 17: Pump Components

    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)
  • Page 18 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. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 19...

  • Page 19: Digital Control Panel Components

    (LOCAL) is for normal pressure rating is 4400 PSI ± 50. pumping operation, and the centermost position (CENTER OFF) prevents pumping. PAGE 20 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 20 RADIO ADDRESS STROKE CTR: 0000 COMMUNICATING PRESS RESET TO PRESS RESET TO ZERO STROKE CTR LEARN A NEW ONE MESSAGE OR IINSTRUCTION INFORMATION OR MESSAGE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 21...
  • Page 21 Starter/Solenoid – This engine uses a 12 VDC , 2.7kW the V-belt. When replacing V-belt, use only recommended (3.7 HP) starter motor with solenoid. type V-belt. PAGE 22 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 22: Inspection

    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...
  • Page 23 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)
  • Page 24 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...
  • Page 25 ALWAYS retract rear stabilizer jacks prior to towing. ALWAYS retract rear stabilizer jacks prior to servicing to relieve load (working pressure). Figure 16. Rear Stabilizer Jack PAGE 26 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 26 In warm weather let engine warm up for 5 minutes. In cold weather let engine warm up for 10 minutes. REMOTE LOCAL CENTER Figure 21. Pumping Control Switch (OFF) MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 27...
  • Page 27 However, make sure that some slurry is left on the hopper YDS/HR 0.0 when concrete is first discharged from the ready-mix truck. Figure 28. Strokes Per Minute Display PAGE 28 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 28 Figure 31. Hopper Remixer Control Lever MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 29...
  • Page 29 VOLUME WIRELESS REMOTE NOTE: OLDER MODELS FLOW MODULE MAY INDICATE VOLUME INSTEAD OF CONNECTOR Figure 35. Installing Remote Control Module Figure 37. Radio Remote Control PAGE 30 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 30 CABLE REMOTE CONTROL UNIT 25 FT. CABLE 25 FT. CABLE PUMP REV PUMP ON/OFF TO CONTROL BOX TO CONTROL BOX CONNECTOR CONNECTOR Figure 38. Cable Remote Control MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 31...
  • Page 31 When the pump is stopped, the stiff, harsh mixes, or extremely long pumping distances. material can flow slowly down, due to gravity, and cause the hose to collapse. PAGE 32 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 32 5 minutes. If the shut pump hopper after the slurry procedure is completed and down time becomes too long, wash out immediately . you are ready to start pumping. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 33...
  • Page 33 Clean it out by pushing water cause blockages. through the first hose off the pump, then continue progressing through all the hoses, until all the system is clean. PAGE 34 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 34 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...

  • Page 35: Maintenance (Pump)

    4. Carefully disconnect the first hose joint at the shuttle ZERO. ALWAYS make tube discharge elbow. sure the accumulator circuit pressure reads zero prior to performing any maintenance on the pump. PAGE 36 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 36 Grease Type: Lithium Based EP herein, refer to the engine manufacturer’s instruction manual. Texaco Multitak 20 Lubriplate ED-2 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 37...
  • Page 37 (Figure 39). If necessary add only distilled water in a Wheel bearings and seals should be well-ventilated area. 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)
  • Page 38 If you do not read 1100 PSI, the accumulator may require charging Figure 40. Cleaning the Lubrication Box or bladder replacement. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 39...
  • Page 39 3. When the output volume at the end of the delivery line decreases in pressure 4. Unusual frequent material packs in the Shuttle tube Figure A. Wear Plate and Cutting Ring PAGE 40 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 40 Remove the two tie rod nuts and the four eyebolt nuts bolt heads with silicon sealant. Torque all three securing the hopper to the pump frame. bolts equal at 55 ft. lbs. each. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 41...
  • Page 41 Clean out all concrete build up in and around the nun- plate 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)
  • Page 42 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. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 43...

  • Page 43: Maintenance (Trailer)

    7. Repeat the above procedure on all brakes. property damage, injury or death. 8. Lower the trailer to the ground. PAGE 44 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 44  After removing the dust cap, cotter pin, spindle nut motion will be limited by the cotter pin). and spindle washer, remove the hub and drum to inspect the bearings for wear and damage. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 45...
  • Page 45 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)

  • Page 46: Trailer Safety Guidelines

    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...
  • Page 47 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)
  • Page 48 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...
  • Page 49 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)
  • Page 50 • The load is secured to the trailer when the battery is running both the trailer lights and tow • The trailer lights are connected and checked. vehicle lights. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 51...
  • Page 51 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...
  • Page 52 SAE 30W motor oil. Keep the ball socket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism. PAGE 52 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 53 In the open position, the coupler is and continue retracting the jack to its fully retracted posi- able to drop fully onto the hitch ball. tion. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 53...
  • Page 54 Replace the breakaway brake battery (if equipped) at intervals specified by manu- facturer. PAGE 54 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 55 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...
  • Page 56 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)
  • Page 57 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...
  • Page 58 From high- est 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)
  • Page 59  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...
  • Page 60 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)
  • Page 61 Check the wire harness for cuts, fraying or other damage. If can cause collisions. it needs replacing, contact your dealer. Check all lights before each tow. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 61...

  • Page 62: Troubleshooting (Pump)

    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...

  • Page 63: Troubleshooting (Brake System)

    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...

  • Page 64: Troubleshooting (Electrical)

    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)
  • Page 65 . l a MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 65...
  • Page 66 PAGE 66 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 67 . d i e r i i t c t r o e r i l t c e r r o i t MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 67...
  • Page 68 . r o e t l . r o n i l t l e . t l n i r . t n PAGE 68 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 69 UNLOADER SOLENOID PROXIMITY SWITCH “B” ALTERNATOR “A” “B” V-BELT PROXIMITY SWITCH “A” INTERNAL THROTTLE SOLENOID 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...

  • Page 70: Wiring Diagram (Control Box)

    OUTSIDE CONTROL CONTROL CONTROLLER BLACK POTTED ENGINE SPEED SOLENOID 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)
  • Page 71 LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) “A” “B” 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...
  • Page 72 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)
  • Page 73 LS400/LS500 PUMP — WIRING DIAGRAM (CONTROL BOX) “A” “B” 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...
  • Page 74 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)

  • Page 75: Hydraulic System Diagram

    1750 PSI ACCUMULATOR GAUGE RELIEF 1000 PSI 4400 PSI RELIEF 1000 PSI OPTIONAL AGITATOR AND HYDRAULIC OUTRIGGERS 14CC MAIN PRESSURE GAUGE Figure 66. Hydraulic System Diagram MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 75...

  • Page 76: Manifold Block Ports

    Figure 67. Manifold Block Ports PAGE 76 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 77: Appendix - Concrete Mix Information

    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. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 77...
  • Page 78 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)

  • Page 79: Appendix - Slump Test Procedure

    1-½ minutes. Discard 2/3 FULL 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...

  • Page 80: Appendix - Recommended Shotcrete System

    APPENDIX — RECOMMENDED SHOTCRETE SYSTEM Figure 69. Recommended Shotcrete System PAGE 80 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 81 ■ 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...

  • Page 82: Appendix - Recommended Shotcrete Accessories

    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)
  • Page 83 NOZZLE TIP, 1-3/8", SHORT EM23807 NOZZLE TIP, 1-1/4", LONG EM911076 STREET ELBOW AIR HOSE ............. NOT SUPPLIED BY MAYCO EM23808 NOZZLE ASSEMBLY ...... 1 ..INCLUDES ITEMS W/ MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 83...
  • Page 84 Multiquip. Other entries will for sale through Multiquip. be clarified in the “Remarks” Column. PAGE 84 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)

  • Page 85: Suggested Spare Parts

    ........... 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...

  • Page 86: Nameplate And Decals

    PLACE DECAL ON LS400 MODELS ONLY. 800-30-MAYCO PLACE DECAL ON LS500 MODELS ONLY. CAUTION USE THIS DECAL (OPTION) WHEN HYDRAULIC STABILIZER JACKS ARE INSTALLED. EM98000 PAGE 86 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 87 35137 DECAL, CAUTION READ MANUAL 517907 DIGITAL CONTROL PANEL LOGO EM955 DECAL, DANGER CHARGING ACCUM. DCL304 DECAL, DANGER IMPROPER CHARGING DCL301 DECAL, SHUTTLE TUBE DANGER MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 87...
  • Page 88 LS400/LS500 PUMP — NAMEPLATE AND DECALS PAGE 88 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 89 DECAL, CAUTION - TOWING DECAL DCL302 DECAL, WARNING BURN HAZARD SERIAL PLATE ............1 ..CONTACT DISCOUNT-EQUIPMENT DECAL, TIRE LOADING 49002 DECAL, WARNING COUPLER DECAL, VIN IDENTIFICATION MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 89...

  • Page 90: Frame Assy

    LS400/LS500 PUMP — FRAME ASSY. FRAME ASSY. PAGE 90 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 91 NUT 3/8" ..............2 ..REPLACES 492583 517124 BOLT 3/4" NC X 1" G5 EM923350 WASHER, LOCK 3/4 IN..........10 ..REPLACES EM492628 517092 SUPPORT PLATE, RIGHT 517095 SUPPORT PLATE, LEFT MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 91...

  • Page 92: Axle Assy

    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)
  • Page 93 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...

  • Page 94: Brake Line Assy

    LS400/LS500 PUMP — BRAKE LINE ASSY. BRAKE LINE ASSY. PAGE 94 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 95 BRAKE LINE ASSY. PART NO. PART NAME QTY. REMARKS 34566 KIT, MAIN BRAKE LINE EM512877 ADAPTOR, STRAIGHT EM512876 ADAPTOR, ELBOW 34565 KIT, WHEEL BRAKE LINE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 95...

  • Page 96: Brake Lights Assy

    LS400/LS500 PUMP — BRAKE LIGHT ASSY. BRAKE LIGHT ASSY. PAGE 96 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 97 LS400/LS500 PUMP — BRAKE LIGHT ASSY. BRAKE LIGHT ASSY. PART NO. PART NAME QTY. REMARKS 29242 BRAKE LIGHT ASSY. 29207 HARNESS ASSY. W/RECEPTACLES MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 97...

  • Page 98: Trailer Hitch Assy

    LS400/LS500 PUMP — TRAILER HITCH ASSY. TRAILER HITCH ASSY. PAGE 98 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 99 WASHER, FLAT 1/2 EM492584 NUT, LOCK 1/2 EM507658 BOLT, HEX HEAD 5/8 NC X 4-1/2 EM492586 NUT, LOCK 5/8 16137 TOW RING, 3 IN. LUNETTE EYE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 99...
  • Page 100 LS400/LS500 PUMP — BATTERY ASSY. PAGE 100 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 101 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 102: Battery Assy

    BATTERY ASSY. PART NO. PART NAME QTY. REMARKS EM34506 BATTERY BOX W/ BELT EM16738 BATTERY 12V 125A 514856 BATTERY CABLE POSITIVE 513577 BATTERY CABLE NEGATIVE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 101...

  • Page 103: Hopper Assy

    LS400/LS500 PUMP — HOPPER ASSY. HOPPER ASSY. PAGE 102 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 104 516787 REMIX SHAFT COUPLER EM500264 SQUARE KEY 3/8" 516776 DRIVE MEMBER COUPLER 516775 MOTOR SHAFT COUPLER EM516786 COUPLER ASSY ........1 ....INCLUDES ITEMS W/% MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 103...

  • Page 105: Hopper Attachment Assy

    LS400/LS500 PUMP — HOPPER ATTACHMENT ASSY. HOPPER ATTACHMENT ASSY. PAGE 104 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 106 HEX NUT 1/2 IN..........3 .....REPLACES 492556 492379 SCREW CAP 3/8" 3019092 WASHER FLAT 3/8" 515395 BOLT 7/16 NC X 4" G5 492584 NUT LOCK 1/2" EM969013 NUT NYLOC MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 105...

  • Page 107: Hopper Interior Assy

    LS400/LS500 PUMP — HOPPER INTERIOR ASSY. HOPPER INTERIOR ASSY. PAGE 106 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 108 WASHER, LOCK 3/4 IN......2 ....REPLACES EM492628 EM151 BOLT, HEX HEAD 3/4-10 X 2 IN. EM264 BOLT, COUNTER SUNK 1/2-13 x 3 IN. EM517700 O-RING MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 107...

  • Page 109: Shuttle Cylinder Assy

    LS400/LS500 PUMP — SHUTTLE CYLINDER ASSY. SHUTTLE CYLINDER ASSY. PAGE 108 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 110 COVER, SHUTTLE CYLINDER 0202 BOLT ............. 3 .... REPLACES 492364 EM923023 WASHER, FLAT ..........3 .... REPLACES 492597 2105164 NUT, HEX ............3 .... REPLACES 492582 MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 109...

  • Page 111: Lubrication Pistons Assy

    LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 110 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 112 514208 BAR,PROXIMITY SWITCH SUPPORT EM98163 SWITCH, PROXIMITY W/CABLE EM98135 CABLE HOUSING, FEMALE EM98134 SEAL, CONNECTOR HOUSING EM98138 TERMINAL PIN, FEMALE 514611 GROMMMET 504505 WRAP TIE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 111...
  • Page 113 LS400/LS500 PUMP — LUBRICATION PISTONS ASSY. LUBRICATION PISTONS ASSY. PAGE 112 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 114 IN., BLACK OXIDE G8 EM25497 FITTING, 90° EM25474 HOSE, HYDRAULIC SLAVE EM16459 PIN, WRIST EM505723 PIN, COTTER EM491701 FITTING, GREASE EM517126 LOCK WASHER EM513352 SEAL, SQUARE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 113...

  • Page 115: Fuel Tank Assy

    LS400/LS500 PUMP — FUEL TANK ASSY. FUEL TANK ASSY. PAGE 114 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 116 34507 CAP, FUEL W\GAUGE EM514559 ADAPTOR 506208 CLAMP EM514536 HOSE, FUEL RETURN 5/16 IN. EM20426 ADAPTER EM514536 HOSE, FUEL FILTER 5/16 IN. EM20763 FILTER, FUEL MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 115...

  • Page 117: Heat Exchanger Assy

    LS400/LS500 PUMP — HEAT EXCHANGER ASSY. HEAT EXCHANGER ASSY. PAGE 116 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 118 EM25497 ADAPTER EM514607 HOSE 4000 PSI EM25566 ADAPTER EM509345 ADAPTER EM514606 HOSE 2000 PSI EM509401 ADAPTER EM514604 HOSE, 2000 PSI EM98264 MOTOR AND FAN ASSY MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 117...

  • Page 119: Accumulator Assy

    LS400/LS500 PUMP — ACCUMULATOR ASSY. ACCUMULATOR ASSY. PAGE 118 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 120 WASHER, FLAT 3/8 0166A WASHER, LOCK 3/8 DIA. EM509425 FITTING, STRAIGHT EM509353 FITTING, 90° ELBOW EM514603 HOSE, ACCUMULATOR EM98009 ACCUMULATOR REPAIR KIT EM98052 ACCUMULATOR TEST/CHARGE KIT MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 119...

  • Page 121: Remixer Control Assy

    LS400/LS500 PUMP — REMIXER CONTROL ASSY. REMIXER CONTROL ASSY. PAGE 120 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 122 BOLT 5/16 X 2-1/2 EM923343 WASHER, LOCK 5/16 IN....... 2 ....REPLACES 492623 2105164 NUT, HEX 5/16 IN.......... 2 ....REPLACES 492553 EM98015 COUPLING EM98014 TEST PORT MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 121...
  • Page 123 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)

  • Page 124: Lubrication Panel Assy

    LS400/LS500 PUMP — LUBRICATION PANEL LUBRICATION PANEL ASSY. PART NO. PART NAME QTY. REMARKS EM491701 GREASE FITTING EM508812 CONNECTOR EM510684 CONNECTOR EM505516 HOSE, PLASTIC EM510487 HOSE, STEEL MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 123...

  • Page 125: Engine Cover Assy

    LS400/LS500 PUMP — ENGINE COVER ASSY. ENGINE COVER ASSY. PAGE 124 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 126 LOCK WASHER 1/4 IN.........14 ..REPLACES 492596 2101402 WASHER 1/4 IN........... 16 ..REPLACES 492622 EM517730 COVER, FRONT ENGINE 492541 NUT 5/16" NC G2 TK6737260 DOCUMENT CYLINDER MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 125...

  • Page 127: Hydraulic Tank Assy

    LS400/LS500 PUMP — HYDRAULIC TANK ASSY. HYDRAULIC TANK ASSY. PAGE 126 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 128 TEE FITTING BOLT 516813 BUSHING 409401 ADAPTOR 3903-16-16 EM16414 VALVE NEEDLE 16516 PIPE 1-1/2" ............1 ...S/N 281101 AND BELOW 509344 ADAPTOR 063T-16-16 514604 HOSE 514604 HOSE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 127...
  • Page 129 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)

  • Page 130: Engine Assy

    2105164 HEX NUT 5/16 G5 ..........2.... REPLACES 492553 EM510897 CAP, EXHAUST 2-1/2 01174416 FILTER, OIL (ENGINE) 01174696 FILTER, FUEL (ENGINE) EM516434 PIPE EXHAUST ASSY. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 129...

  • Page 131: Throttle Assy

    LS400/LS500 PUMP — THROTTLE ASSY. THROTTLE ASSY. PAGE 130 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 132 BOLT 5/16 X 1-1/2 IN. 2105164 HEX NUT 5/16 IN..........1 ....REPLACES 492553 EM98168 THROTTLE BLOCK ASSY........ 1 ....INCLUDES ITEMS W/ MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 131...

  • Page 133: Water Separator Assy

    LS400/LS500 PUMP — WATER SEPARATOR ASSY. WATER SEPARATOR ASSY. PAGE 132 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 134 BOLT 5/16 X 1 IN. 2105164 HEX NUT 5/16 IN..........3 ....REPLACES 492582 EM514559 ELBOW ADAPTER 90° MALE EM506208 CLAMP, HOSE EM514536 HOSE 5/16 IN. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 133...

  • Page 135: Hydraulic Pump Assy

    LS400/LS500 PUMP — HYD. PUMP ASSY. HYDRAULIC PUMP ASSY. PAGE 134 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 136 HOSE 2000 PSI, REMIX VALVE EM517649 MOTORIZED FLOW CONTROL MANIFOLD ASSY. 1 EM517038 HOSE, MAIN MANIFOLD EM509353 ELBOW VALVE, MAIN RELIEF EM514608 HOSE EM25459 ELBOW EM25429 ELBOW ADAPTER MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 135...

  • Page 137: Manifold Assy

    LS400/LS500 PUMP — MANIFOLD ASSY. MANIFOLD ASSY. FRONT OF MACHINE PAGE 136 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 138 EM514488 ADAPTER EM25459 ADAPTER EM98226 UNLOADING RELIEF VALVE, SHUTTLE EM514231 ADAPTER EM514489 ADAPTER EM491372 ADAPTER 506193 ADAPTER EM25462 ADAPTER EM509353 ADAPTER EM25429 ADAPTER CHECK VALVE MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 137...

  • Page 139: Control Box Assy

    LS400/LS500 PUMP — CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 138 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 140 MAIN CONTROL SWITCH ASSY. EM98121 AUTO/JOG SWITCH ASSY. EM98122 JOG A/B SWITCH ASSY. EM97068 RECEPTACLE, REMOTE VOLUME SWITCH ASSY. SCROLL SWITCH ASSY. RESET SWITCH ASSY. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 139...

  • Page 141: Control Box Harness Assy

    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)
  • Page 142 FUSE, 30 AMP EM514636 WIRE HARNESS 2 EM514637 WIRE HARNESS 3 EM514638 WIRE HARNESS 4 509588 POLY FLEX TUBE 1/2 IN. BLACK 16716 CONDUCTIVE DIVIDER 3/8 IN. MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 141...

  • Page 143: Remote Control Cable Assy

    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)
  • Page 144 CORD, MX P/E 25 FT. EM26793 ADAPTER, CORD GRIP 1/2 IN. EM97065 ADAPTER, CORD 100 FT. EM97099 COMPLETE CORD ASSY 25 FT ....1 ....INCLUDES ITEMS W/ MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 143...

  • Page 145: Hydraulic Stabilizer Assy. (Optional)

    LS400/LS500 PUMP — HYDRAULIC STABILIZER ASSY. (OPTIONAL) PAGE 144 — MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11)
  • Page 146 512655 FITTING 90° 25509 FITTING STRAIGHT EM516382 HYDRAULIC STABILIZER 517107 FITTING STRAIGHT 517105 HOSE 517100 HOSE 517106 HOSE 517153 BOLT 517154 BOLT 490957 SNAP RING MAYCO LS400/LS500 PUMP — OPERATION AND PARTS MANUAL — REV. #6 (09/19/11) — PAGE 145...

  • Page 147: Mayco Pump Warranty

    ANY WARRANTIES OF MERCHANTABILITY OR FITNESS PUMP OR PART TO OPERATE PROPERLY, INCLUDING FOR A PARTICULAR PURPOSE. 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...
  • Page 148 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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