Multiquip LS600 User Manual 2

OPERATION AND PARTS MANUAL

SERIES

MODEL LS600

CONCRETE PUMP

(DEUTZ BF4L914 DIESEL ENGINE)

Revision #4 (09/15/11)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

LS600 PUMP — PROPOSITION 65 WARNING

Proposition 65 W arning

Diesel engine exhaust and some of

PAGE 2 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

NOTES

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 3

LS600 PUMP —TABLE OF CONTENTS

MAYCO LS600 CONCRETE PUMP

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 (Engine Start/Shutdown Relay) .. 74

Wiring Diagram (Optional Hopper Vibrator) .......... 75

Hydraulic System Diagram ................................... 76

Manifold Block Ports ............................................. 77

Appendix - Concrete Mix Information .............. 78-79

Appendix - Slump Test Procedure......................... 80

Appendix - Recommended Shotcrete

System ............................................................. 82-83

Appendix - Recommended Shotcrete

Accessories ...................................................... 84-85

Explanation Of Codes In Remarks Column .......... 86

Suggested Spare Parts ......................................... 87

COMPONENT DRAWINGS

Name Plate and Decals ................................... 88-91

Frame Assy. ..................................................... 92-93

Axle Assy. ......................................................... 94-95

Brake Line Assy. .............................................. 96-97

Brake Lights Assy. ............................................ 98-99

Trailer Hitch Assy. ......................................... 100-101

Battery Assy. ................................................ 102-103

Hopper Assy. ................................................ 104-105

Hopper Attachment Assy. ............................ 106-107

Hopper Interior Assy. ................................... 108-109

Shuttle Cylinder Assy. .................................. 110-111

Lubrication Pistons Assy. ............................. 112-115

Fuel Tank Assy. ............................................ 116-117

Heat Exchanger Assy. .................................. 118-119

Accumulator Assy. ........................................ 120-121

Remixer Control Assy. .................................. 122-123

Lubrication Panel Assy. ................................ 124-125

Engine Cover Assy. ...................................... 126-127

Hydraulic Tank Assy. .................................... 128-129

Engine Assy.................................................. 130-131

Engine Air Filter ........................................... 132-133

Throttle Assy. ............................................... 134-135

Water Separator Assy. ................................. 136-137

Hydraulic Pump Assy. .................................. 138-139

Manifold Assy. .............................................. 140-141

Control Box Assy. ......................................... 142-143

Control Box Harness Assy. .......................... 144-145

Remote Control Cable Assy. ........................ 146-147

Hydraulic Stabilizer Assy. (Optional) ............ 148-149

Terms and Conditions of Sale - Parts ................. 150

Mayco Pump Warranty ........................................ 151

Specification and part number are subject to change without notice.

PAGE 4 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Parts

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)

Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact you 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.*

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

When ordering parts, please supply:

❒ 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

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Tr uck

■ Ground

■ Next Day

■ Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 5

LS600 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 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.

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.

LS600 Concrete

pump. Refer to the

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:

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 - 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

Diesel fuel

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.

is extremely flammable, and

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 6 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

WARNING - BURN HAZARDS

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.

LS600 PUMP — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hands, hair

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.

and clothing away from all

fingers

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

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.

ALWAYS wear approved protection.

This machine is capable of producing noise levels above 85 dB. Hearing protection is required.

Always wear eye protection.

respiratory

This

pump

, other property, or the surrounding environment could be damaged if you do not follow instructions.

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 7

LS600 PUMP — RULES FOR SAFE OPERATION

■

DANGER - READ OPERATION AND PARTS

Failure to follow instructions in this manual may lead to

death!

serious injury or even 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 LS600 concrete pump:

This equipment is to be

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 components can cause serious burns.

hot!

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.

■

The engine section of this pump requires an adequate free flow of cooling air. 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

■

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 machine. Fire or explosion could result from

fuel vapors

hot!

engine.

NEVER

smoke

around or near the

, or if fuel is spilled on a

DEADLY

carbon monoxide gas.

■

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),

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.

PAGE 8 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

hearing

and

■

NEVER operate the pump in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

Topping-off to filler port is dangerous, as it tends to spill fuel.

■

ALWAYS remove the pump unattended.

■

ALWAYS block the a slope.

■

ALWAYS maintain this equipment in a safe operating condition at all times.

■

ALWAYS stop the engine before servicing, adding fuel or oil.

bodily harm or even death.

ignition key

wheels

on the unit when using on

when leaving the

LS600 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 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.

inexperienced

and

unauthorized

people away

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.

■

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 test is to shut down the engine.

■

Refer to the 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.

pump's ON/OFF

DEUTZ Engine Owner's Manual

switch. The purpose of this

for engine

■

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.

MAINTENANCE SAFETY

■

NEVER lubricate components or attempt service on a running pump .

■

ALWAYS allow the pump a proper amount of time to cool before servicing.

■

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.

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 9

LS600 PUMP — RULES FOR SAFE OPERATION

BATTERY

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses. Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

■■

■

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

wear safety

EMERGENCIES

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

■

In emergencies the nearest phone or

site

nearest

department

in the case of an emergency.

fire extinguisher

first aid kit

always

know the location of

keep a phone on the job

. Also know the phone numbers of the

ambulance, doctor

. This information will be invaluable

and

fire

■■

■

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 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.

clothing or skin

, rinse skin or clothing

PAGE 10 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

NOTES

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 11

LS600 PUMP — SPECIFICATIONS

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ledoMenignE419L4FBleseiDobruTztueD

)sdiulfhtiw(t

)gnippihs/yrd(thgieW)gk951,2(.sbl067,4

eziSeriT)mm183(.ni51

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)mm721,mm6.101,mm2.67(

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PAGE 12 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 PUMP — DIMENSIONS

.FERSNOISNEMID

A).mc2.901(.ni34

B).mc8.634(.ni371

C).mc16(.ni42

D).mc8.771(.ni07

E).mc2.271(.ni

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 13

SNOISNEMID.3ELBAT

Figure 1. Dimensions

LS600 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 LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 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 selflubrication. 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 selftroweled 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

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 15

LS600 PUMP — GENERAL INFORMATION

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 LS600 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.

3. Sufficient cement to produce the required design

Use a minimum of:

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:

4. Admixture pump-aid if necessary.

5. The proper amount of water to make a workable slump

In addition, this Mayco Concrete Pump can be used to

1. Pea rock (1/2" minus) pump with mixes being as low

2. Shortening pea rock when used with an air compressor

3. “Mud Jacking”, high pressure grouting.

strength of the concrete and provide the lubricating binder to pump the concrete through the delivery system.

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.

and plasticize the mix.

pump a large aggregate hard rock as follows:

as 30% rock and 70% sand. (See page 44, for comments on cleaning the pump.)

and nozzle. (See back pages for recommended setup.)

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.

PAGE 16 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 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.

TO TANK

HYDRAULIC CYLINDERS

HIGH PRESSURE

OIL FROM PUMP

PROXIMITY

SWITCH

SLAVE

OIL

CONCRETE

SHUTTLE TUBE MOTION

CYLINDERS

PISTON

CUP

SHUTTLE TUBE

Figure 3. Pumping Cycle 1

Figure 4. Pumping Cycle 2

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.

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 17

LS600 PUMP — PUMP COMPONENTS

Figure 5. Major Pump Components

PAGE 18 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 PUMP — PUMP COMPONENTS

Figure 5 illustrates the location of the major components for the LS600 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

psi cold

tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

before operation. DO NOT bleed air from

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.

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.

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 19

22. Rear Running Lights – ALWAYS check and make

23. Remixer Motor – Drives the remixer paddles inside

24. Hopper/Hood – Lift hood to fill. Concrete from a Redi-

25. Tow End Jack Stand – Use this jack stand to level

sure both the right and left running lights are functioning correctly before towing the pump.

the hopper. The motor direction is controlled by the remixer control lever.

Mix 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.

and support the tow end of the pump.

LS600 PUMP — DIGITAL CONTROL PANEL COMPONENTS

ACCUMULATOR

PRESSURE

PUMPING

PRESSURE

DECREASE

FORWARD

AUTOMATIC

RESET

SET

VOLUME

FLOW

DIRECTION

INCREASE

REVERSE

JOG

SCROLL

Figure 6. Pump Digital Control Panel Components

1. Emergency Stop Button – Press emergency stop

9. Cylinder Stroke Control Switch – This 2-position

button to stop pump in an emergency. Turn knob counterclockwise to disengage the stop button.

2. 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.

3. Digital Readout Screen – Displays and monitors the various functions of the machine.

10. Manual Cylinder Jogging Switch – This 2-position

4. Scroll Switch – Allows the operator to scroll the various readout screens.

5. Reset Switch – Allows the operator to reset the stroke counter.

6. Remote Cable Connector – Insert the remote control input cable into this connector.

7. Direction Control Switch – This 2-position switch controls the direction of flow for any mix in the pump. The

leftmost

forward and the

position sets the pumping direction to

rightmost

position sets the pumping

direction to reverse.

11. Stroke Volume Control Switch – Increases or

12. Accumulator Pressure Gauge – This gauge monitors

8. 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 pumping operation, and the

leftmost

position (LOCAL) is for normal

centermost

position

13. Main Pressure Gauge – This gauge monitors the

(CENTER OFF) prevents pumping.

OFF

START

CONTROL

REMOTE

LOCAL

CENTER

OFF

CYLINDER STROKE

JOG “B”

JOG “A”

switch controls the pumping function. The position (AUTOMATIC) sets the pump to

cycling

. Set the switch to this position for normal pump

IGNITION

REMOTE

leftmost

automatic

operation. The

rightmost

automatic to cylinders to be manually cycled using the

Cylinder Jogging Switch

position (JOG) changes the pump from

manual cycling

. This allows the

Manual

switch allows the operator to manually jog the cylinders to assist in clearing material line packs and is used to test pumping pressure (See

Procedure

section of this manual for testing

Initial Start-up

procedure). The

leftmost

rightmost

position jogs Cylinder “A” and the

position jogs Cylinder “B”.

decreases the number of strokes per minute of the pump.

the internal pressure of the Accumulator tank. Normal internal pressure should read approximately 1750 PSI during pumping.

system pressure while pumping material. The maximum pressure rating is 4400 PSI ± 50.

PAGE 20 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 PUMP — DIGITAL READOUT SCREEN

PRIMARY SCREEN

Screen 5

Displays the ON/OFF electrical signal status of the various

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.

12 volt solenoids (Swing A circuit, Main A circuit, Main B circuit).

INDICATES

SWING A CIRCUIT IS OFF

Indicates electrical malfunction - Refer to Troubleshooting section.

INDICATES

MAIN B CIRCUIT IS OFF

Screen 6

Displays the ON/OFF electrical signal status for the Proximity Switch A, Proximity Switch B, Engine Fuel Solenoid, and Unloader Solenoid.

INDICATES

SECONDARY SCREENS

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 VOLUME SWITCH IS NOT IN

THE - POSITION

FLOW DEC OFF FLOW INC ON

INDICATES VOLUME SWITCH IS IN THE + POSITION

INDICATES UNLOADER 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 THROTTLE IS ON

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 PUMP HAS BEEN USED

INDICATES NO. OF FAULTS DETECTED

INDICATES NO. OF HOURS ENGINE HAS BEEN USED

MESSAGE OR INSTRUCTION

E HRS: 00000.0 PMP HRS: 00000.0 FAULTS: 00000000 RESET TO CLEAR

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.

INDICATES THE NO. OF YARDS PER HOUR

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.

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,

INDICATES A RUNNING COUNT OF NO. OF STROKES

STROKE CTR: 0000

PRESS RESET TO ZERO STROKE CTR

MESSAGE OR INFORMATION

use the reset switch on the control panel.

IINSTRUCTION OR MESSAGE

SWING A OFF

MAIN A OFF MAIN B OFF

PROX A OFF PROX B ON FUEL SOL OFF UNLOADER OFF

THROTTLE ON STROKES: 20 STROKES/MIN 8.2 YDS/HR 10.7

TO TEST FUEL SOL PRESS RESET FUEL SOL OFF

RADIO ADDRESS COMMUNICATING PRESS RESET TO LEARN A NEW ONE

INDICATES

MAIN A CIRCUIT IS OFF

INDICATES PROXIMITY B CIRCUIT IS ON

INDICATES

FUEL SOLENOID CIRCUIT IS OFF

INDICATES THE NUMBER OF STROKES

INDICATES THE NO. OF STROKES PER MINUTE

INSTRUCTION

OR MESSAGE

INDICATES THAT RADIO REMOTE IS ON

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 21

LS600 PUMP — ENGINE COMPONENTS

Figure 7. Deutz BF4L914 Diesel Engine Components

The engine (Figure 7) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturers Engine manual for instructions & details of operation and servicing.

1. Fuel Filter/Water Separator – 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. Crankcase Drain Plug – Remove this plug to drain engine oil from the engine crankcase. For best results drain engine oil when oil is warm.

4. Dip Stick – Remove dipstick to determine if the engine oil level is low. If low add oil as specified in Table 4.

5. Engine Throttle Knob– This is a variable speed type control. Turning the throttle lock (CCW) left unlocks the throttle allowing the throttle control cable to be pulled out to the desired position. Once the desired throttle position (speed) has been achieved, turning the throttle lock to the (CW) right locks it in place.

6. V-Belt Cover – Remove this cover to gain access to the V-belt. When replacing V-belt , use only recommended type V-belt.

7. Alternator – Provides power to the electrical system. Replace with only manufacturers recommended replacement parts.

8. Air Intake – Attach the Air Filter Hose to the Air Intake.

9. Muffler – Used to reduce noise and emissions. NEVER touch the muffler while it is hot! Serious burns can result. NEVER operate the engine with the muffler removed.

10. Oil Filler Port/Cap – Remove this cap to add engine poil to the crankcase. Fill with recommended type of oil as specified in the maintenance section of this manual.

11. Starter/Solenoid – This engine uses a 12 VDC ,

2.7kW (3.7 HP) starter motor with solenoid.

PAGE 22 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

LS600 PUMP — INSPECTION

CAUTION - GENERAL SAFETY GUIDELINES

NEVER operate the pump in a

confined area or enclosed area structure that does not provide ample

free flow of air

NEVER operate the pumps's engine

with the engine hood removed. The possibility exists of and

clothing

the V-belt, causing injury and bodily harm.

NEVER place hands or feet inside the ALWAYS make while the engine is running. ALWAYS

shut down the engine before performing any kind of maintenance service on the pump.

ALWAYS wear approved

hearing

operating the pump .

hands, long hair

becoming entangled with

protection before

eye

and

hopper

FUEL CHECK

1. 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

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.

is extremely flammable,

See Figures 5, 6, and 7 for the location of any control or component referenced in this section.

BEFORE STARTING

1. Read safety instructions at the beginning of manual.

2. Clean the ticularly the engine cooling air inlet, and heat exchanger.

3. Check the 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 can be dangerous if refueling. DO NOT attempt to refuel pump if the engine is hot or running. ALWAYS allow engine to refueling.

entire pump

air filter

mishandled. DO NOT

, removing dirt and dust, par-

for dirt and dust. If air filter is dirty,

flammable

smoke

cool

before

and

while

Figure 8. Fuel Cap Gauge

2. If fuel is low, remove fuel filler cap and fill with

diesel fuel

(Figure 9).

Figure 9. Adding Diesel Fuel

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 23

LS600 PUMP — INSPECTION

ENGINE OIL CHECK

1. Remove the engine oil dipstick from its holder (Figure 10).

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.

6. The oil listed in Table 4 is recommended to ensure better engine performance. Use class CD or higher grade motor oil.

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).

Figure 11. Engine Oil Level

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 LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

NORMAL OIL LEVEL

HYDRAULIC OIL TEMPERATURE

MINIMUM OIL LEVEL

Figure 12. Hydraulic Oil Sight Glass

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

LS600 PUMP — INSPECTION

3. Check the oil level in the

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

lubrication box

. If low, fill

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 25

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:

LS600 PUMP — SET-UP

1. Locate both the left and right rear stabilizer jacks

Figure 17. Rear Stabilizer Stand Deployment

(Figure 15).

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

2. Push up the middle control lever (see Figure 18) to

3. Push down the rightmost control lever (see Figure 18)

4. Push up the rightmost control lever (see Figure 18) to

Figure 15. Locating Rear Stabilizer Jacks

2. Remove the and then jack (Figure 16).

3. Position both rear stabilizers jacks on firm (not loose)

level

ground (Figure 17).

cotter pin

pull

the handle tee to release the stabilizer

from the handle tee bolt eye,

MIDDLE CONTROL LEVER (CONTROLS RIGHT

HYDRAULIC STABILIZER)

extend the right hydraulic rear stabilizer.

retract the right hydraulic rear stabilizer.

to extend the left hydraulic rear stabilizer.

retract the left hydraulic rear stabilizer.

LEFT HYDRAULIC STABILIZER JACK

4. Align the hole on the stabilizer jack with the hole on the frame body and

insert

handle tee bolt.

RIGHT HYDRAULIC STABILIZER JACK

5. Insert the cotter pin into handle tee bolt eye to lock the stabilizer jack.

COTTER PIN

HANDLE T-BOLT

REAR STABILIZER STAND

BOLT EYE

Figure 18. Control Levers for Hydraulic Rear

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).

Figure 16. Rear Stabilizer Jack

PAGE 26 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

RIGHTMOST CONTROL LEVER (CONTROLS LEFT HYDRAULIC STABILIZER)

Stabilizers

WARNING - REAR STABILIZER SAFETY

LS600 PUMP — START-UP PROCEDURE

FORWARD REVERSE

STARTING PROCEDURE

4. Place the

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.

1. Locate the Emergency Stop Switch (Figure 19) on the

Hydraulic Pump Control Box. Turn the Emergency Stop

5. To start the engine, insert the key (Figure 23) into the

switch clockwise and release (open). This will allow the engine to start.

Figure 19. Emergency Stop Switch

Direction Control Switch

to the FORWARD

position (Figure 22).

Figure 22. Direction Control Switch

(FORWARD)

ignition switch and turn the key to the ON position.

Figure 23. Ignition Switch

If the Emergency Stop switch is in the CLOSED position (stop), engine will not start. To start 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)

3. Place the

Pumping Control Switch

to the CENTER

OFF position (Figure 21) for normal pumping operation.

LOCAL

CENTER

OFF

Figure 21. Pumping Control Switch (OFF)

REMOTE

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.

Figure 24. Primary Screen (Ignition Key ON)

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.

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 27

LS600 PUMP — OPERATION

HOSE LUBRICATION

PUMPING

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 sug-

gested 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.

1. Place the

PRIMING THE PUMP WITH SLURRY MIXTURE

position (Figure 26) for normal pumping operation. 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.

Figure 26. Pumping Control Switch (LOCAL)

1. Connect the entire delivery system to the pump. Pour

5 gallons of water and a bag of raw cement into the hopper.

2. Slide the right to increase the volume to approximately 10 strokes per minute. Sliding the volume control to the

2. Place the

Direction Control Switch

to the REVERSE

left will

position (Figure 25). This will mix the water and cement into slurry.

FORWARD

REVERSE

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.

Pumping Control Switch

LOCAL

CENTER

OFF

Volume Control Switch

decrease

pump volume.

DECREASE

VOLUME

Figure 27. Volume Control

to the LOCAL

REMOTE

(Figure 27) to the

INCREASE

VOLUME

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

3. Scroll through the

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 readymix truck.

PAGE 28 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

thumping

sound (cylinder stroke) should be heard. The thumping sound represents the number of strokes per minute (volume) of the pump.

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

STROKES: 100 STROKES/MIN 10.0 YDS/HR 0.0

Figure 28. Strokes Per Minute Display

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)

LS600 PUMP — OPERATION

Figure 29. Hydraulic Oil Temperature Gauge

5. The Accumulator Pressure Gauge (Figure 30) should read approximately 1750 pounds per square inch (psi).

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).

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 lines are

kinked

blocked

for any reason, or if the

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

move

in a manner

that could cause injury to personnel.

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.

Figure 31. Hopper Remixer Control Lever

MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11) — PAGE 29

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.

LS600 PUMP — OPERATION

REMOTE CONTROL (OPTIONAL)

The LS600 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)

4. Reinstall the control panel and tighten the 2 screws.

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.

or a hardwire method, which utilizes a 25-ft. extension cable. Contact MQ Sales Department to order remote control.

Radio Remote Control

Installation of the Radio Remote Control Assembly

KNOCK-OUT HOLE

1. Remove the two screws on the digital control panel of the pump. See Figure 33.

C R O

L L

E S E

S E

REMOVE 2 SCREWS

I N

C R E

A S E

F L

I O N

E V

E R

S E

A I C

O E N

T E

Y L

“A”

O K E

J O

G “B”

R E

M O

CONTROL BOX

Figure 33. Removing Screws from Control Panel

6. Connect the antenna cable to the connector on the

2. Tilt and slowly pull out the control panel and place on top of box to gain access inside the box. See Figure 34.

rear of the control box (Figure 36).

Radio Remote Control Buttons Operation

ANTENNA

ANTENNA CONNECTOR CABLE

Figure 36. Antenna Installation

REAR OF CONTROL BOX

CONTROL BOX CONNECTOR

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

WIRELESS REMOTE MODULE

Figure 35. Installing Remote Control Module

CONNECTOR

E-STOP

OFF

POWER LED

NOTE: OLDER MODELS MAYINDICATE

FLOW

INSTEAD OF

VOLUME

BATTERY LED

PUMP

ON/OFF

REV

VOLUME VOLUME

Figure 37. Radio Remote Control

PAGE 30 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)

+ 122 hidden pages