Multiquip LS-60TD User Manual

OPERATION AND PARTS MANUAL

SERIES

MODEL LS-60TD

STRUCTURAL 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.

LS-60TD PUMP — TABLE OF CONTENTS

Proposition 65 W arning

Diesel engine exhaust and some of

PAGE 2 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

NOTES

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 3

TABLE OF CONTENTS

MAYCO LS-60TD

STRUCTURAL CONCRETE PUMP

Proposition 65 Warning ............................................. 2

Table of Contents ...................................................... 4

Parts Ordering Procedures ...................................... 5

Specifications ............................................................ 6

Dimensions ............................................................... 7

Safety Message Alert Symbols .............................. 8-9

Rules for Safe Operation ...................................10-12

Operation and Safety Decals ............................. 14-15

Important Hand Signals .......................................... 16

General Information ...........................................17-18

How it Works ........................................................... 19

Pump Components ............................................ 20-21

Control Box Components ........................................ 22

Engine Components ............................................... 23

Inspection ...........................................................24-26

Start-Up Procedure ............................................27-29

Shut-Down Procedure ............................................. 29

Operating Procedures ........................................30-36

Trailer Safety Precautions ....................................... 37

Towing Information ............................................. 38-39

Trailer Hitch Connections ........................................ 40

Maintenance (Pump) .........................................41-47

Maintenance (Trailer) ......................................... 48-50

Wiring Diagram (Tail Lights) .................................... 51

Wiring Diagram (Electrical) ..................................... 52

Wiring Diagram (Control Panel) .............................. 53

Wiring Diagram (Terminal Blocks)........................... 54

Wiring Diagram (Terminal Blocks to Comp.) ........... 55

Wiring Diagram (Harness Connect) ........................ 56

Wiring Diagram (Optional Hopper Vibrator) ............ 57

Wiring Diagram (Start/Shutdown Solenoid Relay).. 58

Hydraulic System Diagram ..................................... 59

Manifold Block Ports ............................................... 60

Appendix — Concrete Mix Information .............. 61-62

Appendix — Slump Test Procedure ........................ 63

Appendix — Recommended

Specification and part number are subject to
change without notice.

Shotcrete System ..........................64-65

Appendix — Recommended

Shotcrete Accessories ...................66-67

Troubleshooting (Pump).....................................68-69

Troubleshooting (Engine) ........................................ 70

Troubleshooting (Brake System)............................. 71

Explanation Of Codes In Remarks Column ............ 72

Suggested Spare Parts ........................................... 73

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Name Plate and Decals ..................................... 74-75

Frame Assy. ....................................................... 76-77

Axle Assy. ........................................................... 78-79

Brake Line Assy. ................................................ 80-81

Brake Lights Assy. .............................................. 82-83

Trailer Hitch Assy. ............................................... 84-85

Battery Assy. ...................................................... 86-87

Hopper Assy. ...................................................... 88-89

Hopper Attachment Assy. .................................. 90-91

Hopper Interior Assy. ......................................... 92-93

Shuttle Cylinder Assy. ........................................ 94-97

Lubrication Pistons Assy. ................................... 98-99

Fuel Tank Assy. .............................................. 100-101

Heat Exchanger Assy. .................................... 102-103

Accumulator Assy........................................... 104-105

Remixer Control Assy. .................................... 106-107

Lubrication Panel Assy. .................................. 108-109

Engine Cover Assy. ........................................ 110-111

Hydraulic Tank Assy. (Old Style)..................... 112-113

Hydraulic Tank Assy. (New Style) ...................114-115

LS-60TD Engine Assy. ................................... 116-117

LS-60TD Engine Air Cleaner Assy. ................ 118-119

Throttle Assy. ................................................. 120-121

Water Separator Assy. ................................... 122-123

Hydraulic Pump Assy. (Old Style)................... 124-125

Hydraulic Pump Assy. (New Style) ................. 126-127

Manifold Assy. ................................................ 128-129

Control Box Assy. ...........................................130-131

Control Box Harness Assy. ............................ 132-133

Remote Control Cable Assy. .......................... 134-135

Terms and Conditions of Sale - Parts ................... 136

Mayco Pump Warranty.......................................... 137

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

r

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

st

, 2006

Best Deal!

Order via Internet

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 Par ts

Order via Fax

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.

(Dealers Only)

to log in and save!

(Dealers Only)

:

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.*

Note: Discounts Are Subject To Change

:

Domestic (US) Dealers Call:

1-800-427-1244

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

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

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 uc k

■ Ground

■ Next Day

■ Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 5

LS-60TD PUMP — SPECIFICATIONS

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PAGE 6 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

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LS-60TD PUMP — DIMENSIONS

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Figure 1. Dimensions

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 7

LS-60TD 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

LS-60TD Structural Concrete

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.

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.

pump. Refer

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

WARNING - EXPLOSIVE FUEL

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.

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.

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 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 8 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

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.

LS-60TD 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.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

This

pump

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

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 9

LS-60TD 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 LS-60TD structural 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.

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
cause serious burns.

■

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
carbon monoxide gas.

■

ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.

hot!

components can

NEVER

DEADLY

■

■

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

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.

respiratory

(mask),

hearing

and

■

■

■

■

■

■

■

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

engine.
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
unattended.

ALWAYS block the
slope.

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

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

smoke

around or near the

, or if fuel is spilled on a

bodily harm or even death.

ignition key

wheels

when leaving the pump

on the unit when using on a

hot!

PAGE 10 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD 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 all 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.

■

Keep hands out of the hopper when the engine is running.

■

DO NOT disconnect hose couplings or nozzle while under
pressure. Relieve pressure by manually activating
pressure relief valve at manifold.

■

Unauthorized equipment modifications will void all
warranties.

inexperienced

and

unauthorized

people away

TRANSPORTING

■

■

■

Towing

■

■

■

■

■

■

■

■

■

ALWAYS shutdown engine before transporting the pump.
Tighten fuel tank cap securely and close fuel valve to

prevent fuel from spilling.
Drain fuel when transporting pump over long distances

or bad roads.

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,

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..

always

have rear tail lights ON.

■

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

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 11

switch. The purpose of this

for engine

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.

LS-60TD PUMP — RULES FOR SAFE OPERATION

BATTERY

The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation,
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 glasses.

EMERGENCIES

■

ALWAYS know the location of the
nearest

■

ALWAYS know the location of the
nearest and

■

In emergencies
nearest phone or
Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an
emergency.

fire extinguisher

first aid kit

always

.

.

know the location of the

keep a phone on the job site

and

fire department

.

. This

■■

■

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 12 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

NOTE PAGE

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 13

LS-60TD PUMP — OPERATION AND SAFETY DECALS

Machine Safety Decals

The LS-60TD structural concrete pump is equipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. Figure 2 below illustrates these decals as they appear on the machine. Should any of these decals
become unreadable, replacements can be obtained from your dealer.

Figure 2. LS-60TD Operation and Safety Decals

PAGE 14 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — OPERATION AND SAFETY DECALS

Figure 2. LS-60TD Operation and Safety Decals (Continued)

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 15

LS-60TD PUMP — IMPORTANT HAND SIGNALS

Figure 3 display's the basic hand signals commonly used in concrete pumping operations.

Figure 3 Operation Hand Signals

PAGE 16 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD 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 LS-60TD 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

Procedures

Operating

section of this manual.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 17

LS-60TD 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.

5. The proper amount of water to make a workable slump and
plasticize the mix.

In addition, this Mayco Structural 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 set-up.)

3. “Mud Jacking”, high pressure grouting.

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.

PAGE 18 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD 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 located in 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

SLAVE

OIL

A

B

SHUTTLE TUBE MOTION

HIGH PRESSURE

OIL FROM PUMP

PROXIMITY

SWITCH

CONCRETE
CYLINDERS

PISTON

CUP

SHUTTLE TUBE

Figure 5. 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 4).

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 5), 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 transfered 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 durration of the operation.

Figure 4. Pumping Cycle 1

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 19

LS-60TD PUMP — PUMP COMPONENTS

Figure 6 illustrates the location of the major components for
the LS-60TD Structural 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– Turn handle and lift door to
access the Hydraulic Manifold Block.

4. Hydraulic Manifold Block – Aluminum 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 durring the cycle phase.

Figure 6. Major Pump Components

PAGE 20 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — PUMP COMPONENTS

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
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.

50 psi cold

19. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell)

20. Throttle Control Knob – This is a variable speed type

21. Stroke Volume Control Dial – Turns CW/CCW to

22. Lubrication Box – This box is empty when shipped

23. Rear Running Lights – ALWAYS check and make sure

24. Remixer Motor – Drives the remixer paddles inside

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

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

27. Air Filter – Prevents dirt and other debris from entering

holds approximately 40 gallons (176 liters). DO NOT
top off fuel. Wipe up any spilled fuel immediately

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. Use the fine
tune adjustment knob to fine tune the engine rpm's.

To place the engine in idle, press the top button inward
all the way..

increase or decrease the number of strokes per minute
of the pump.

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.

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

the hopper. The motor direction is controled 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.

the fuel system. Release the latches on the side of the
air filter cover to gain access to the 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.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 21

LS-60TD PUMP — CONTROL BOX COMPONENTS

Figure 7. Pump Control Box Components

1. Emergency Stop Button – Press emergency stop
button to stop pump in an emergency. Turn knob counter
clockwise 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. Engine Tachometer – Monitors the engine RPM’s and
hours of operation for the engine.

4. Engine Hour meter – Display's the number of hours
the engine has been in use.

5. Pump Hour meter – Display's the number of hours
the pump has been in use.

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

7. Battery Indicator Lamp– Indicates a low battery
charge. Replace or charge battery. NEVER operate the
pump when this lamp is on.

8. Oil Pressure Indicator Lamp – Indicates incorrect
operational pressure for running the pump. NEVER
operate the pump if this lamp is ON.

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

left most

forward and the
direction to reverse.

position sets the pumping direction to

right most

position sets the pumping

10. Pumping Control Switch – This 3-position switch

11. Cylinder Stroke Control Switch - This three position

12. Manual Cylinder Jogging Switch – This 2 position

13. Accumulator Pressure Gauge - This gauge monitors

14. Main Pressure Gauge - This gauge monitors the

controls the pumping of the pump. The
position is for use with the remote control unit, the

most

position is for normal pumping operation, and the

center most

switch controls the pumping function. The
position sets the pump to
switch to this position for normal pump operation.

The

right most

automatic to
to be manually cycled using the

Jogging Switch

switch allows the operator to manually jog the cylinders
to assist in clearing material line packs and is used to
test pumping pressure (See
section of this manual for testing procedure).

The

left most

most

position jogs Cylinder “B”.

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 3200 PSI ± 50.

position (OFF) prevents pumping.

automatic cycling

position changes the pump from

manual cycling

.

. This allows the cylinders

Initial Start-up Procedure

position jogs Cylinder “A” and the

right most

left

left most

. Set the

Manual Cylinder

right

PAGE 22 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — ENGINE COMPONENTS

Figure 8. Deutz BF4L914 Diesel Engine Components

The engine (Figure 8) 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 Seperator – 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.

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.
See Pump Components, Item 27.

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.

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

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 23

LS-60TD PUMP — INSPECTION

CAUTION - GENERAL SAFTEY 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

5. Check the fuel gauge built into the fuel tank cap
(Figure 9) to determine if the pump's engine fuel is low.
Refuel as needed

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.
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.

is extremely flammable, and

See Figures 6, 7, 8 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
larly 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 mixer if the engine
is hot or running. ALWAYS allow engine to
refueling.

entire pump

air filter

, removing dirt and dust, particu-

for dirt and dust. If air filter is dirty,

mishandled. DO NOT

flammable

smoke

cool

before

and

while

Figure 9. Fuel Cap Gauge

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

diesel fuel

(Figure 10).

Figure 10. Adding Diesel Fuel

#2

PAGE 24 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — INSPECTION

ENGINE OIL CHECK

7. Remove the engine oil dipstick from its holder

(Figure 11).

Figure 11. Engine Oil Dipstick

8. Make sure pump/engine is placed on level ground.

9. Pull the engine oil dipstick (Figure 12) from its holder.

12 The oil listed in Table 4 is recommended to ensure better

engine performance. Use class CD or higher grade motor
oil.

HYDRAULIC OIL CHECK

13. Determine if the hydraulic oil level is low by observing
the level of the oil in the Hydraulic Oil Sight Glass
(Figure 13).

Figure 12. Engine Oil Dipstick

10. Verify that oil level (Figure 12) is maintained between
the two notches on the dipstick.

11. If the pump's engine oil is low, fill engine crankcase
with lubricating oil through filler hole, but DO NOT overfill.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 25

Figure 13. Hydraulic Oil Sight Glass

LS-60TD PUMP — INSPECTION

14. If the hydraulic oil level is low, remove the cap just above
the oil level sight glass (Figure 14) 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 14. Hydraulic Oil Filler Hole

15. Check the oil level in the
with up to 3 gallons of SAE #30 motor oil (Figure 15).
The oil level must be checked daily. The lubrication box
should be serviced as described in the maintenance
section.

lubrication box

. If low, fill

REAR STABILIZER STAND

To reduce excessive vibration and rocking of the pump, set
the rear stabilizers as follows:

15. Locate both the left and right rear stabilizer stands
(Figure 16).

Figure 16. Locatiing Rear Stabilizer Stands

16. Remove the
and then
stand (Figure 17).

17. Position both rear stabilizers stands on firm (not loose)

level

ground (Figure 18).

18. Align the hole on the stabilizer stand with the hole on
the frame body and

cotter pin

pull

the handle tee to release the stabilizer

from the handle tee bolt eye,

insert

handle tee bolt.

Figure 15. Filling the Lubrication Box

19. Insert the cotter pin into handle tee bolt eye to lock the
stabilizer stand.

Figure 17. Rear Stablizer Stand

Figure 18. Rear Stablizer Stand Deployment

PAGE 26 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — START-UP PROCEDURE

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.

1. Place all switches on the Control Box in the OFF position.

2. Locate the Emergency Stop Switch (Figure 19) on the
Hydraulic Pump Control Box. Turn the Emergency Stop
switch counter-clockwise (open). This will allow the
engine to start.

4. Observe that the
indicator lights are ON (Figure 21).

A. Turn the key to the START position and listen for

B. In warm weather let engine warm-up for 5 minutes.

C. The

Battery

Figure 21. Status Indicator Lights

the engine to start.

In cold weather let engine warm-up for 10 minutes.

Oil Pressure

(Figure 21) should be OFF.

If any of the status indicator lights
referenced in the ignition section
(step 4) are ON, turn off the
engine. DO NOT continue to run
the engine.

and

Oil Pressure

and

Battery indicator

status

lights

Figure 19. Emergency Stop 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).

3. To start the engine, insert the key (Figure 20) into the
ignition switch and turn the key to the ON position.

Figure 20. Ignition Switch

5. Turn the
the AUTOMATIC position.

6. Place the
(Figure 23) for normal pumping operation. Place the
switch in the REM. position for remote control operation
of the LS-60TD pump.

Cylinder Stroke Control switch

Figure 22. Cylinder Stroke

Control Switch (Automatic)

Pumping Control Switch

to the ON position

(Figure 22) to

Figure 23. Pumping Control Switch (On)

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 27

LS-60TD PUMP — START-UP PROCEDURE

7. Turn the Volume Control (Figure 24),

lock nut

A. Unlock the throttle cable. To unlock the throttle cable,
counterclockwise (CCW) to release the volume control
knob.

KNOB (COARSE)

Figure 24. Volume Control

8. Use the volume control, to set the pump volume to

Figure 27. Throttle Control Knob (Un-locking)

B. Push the outermost button (coarse adjustment)
approximately 10 strokes per minute. Turning the

volume control clockwise (CW) will
volume,and counterclockwise (CCW) will

pump

volume.

A

thumping

sound (cylinder stroke) should be heard.

decrease

pump

increase

C. Turn the unlocking knob (figure 28) clockwise to lock

The thumping sound represents the number of strokes
per minute (volume) of the pump.

turn the inner most knob counter clockwise
(Figure 27.)

UNLOCKING

THROTTLE

UNLOCK

ADJUSTMENT

(PUSH/PULL)

LOCK

THROTTLE

ADJUSTMENT

KNOB (FINE)

(TURN CW/CCW)

KNOB

inward, then pull outward until engine RPM reaches
desired speed (Figure 28).

engine RPM in place.

PUSH-IN, THEN PULL

TO SET THROTTLE

(RPM’s)

9. Let the pump cycle until the hydraulic oil temperature
(Figure 25) is approximately 50 to 60 degrees fahrenheit.

Figure 28. Throttle Control Knob (RPM Adjust)

Figure 25. Hydraulic Oil Temperature Gauge

10. While monitoring the tachometer, (Figure 26) use the
Engine Throttle Control to set the engine speed to 2550
RPM by following steps 10A-10C.

PUSH ALL THE WAY IN

TO IDLE ENGINE

Figure 26. Engine Tachometer

PAGE 28 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — START-UP/SHUT-DOWN PROCEDURE

11. The Accumulator Pressure

Gauge (Figure 29) should read

approximately 1750 pounds per
square inch (psi).

Figure 29. Accumulator

Pressure Gauge

12. Turn the

position (Figure 30). The pump is now ready to be
operated. Refer to the
of this manual for priming and operating instructions.

Cylinder Stroke Control switch

Operating Procedures

to the OFF

section

EMERGENCY SHUTDOWN PROCEDURE

In the event of an emergency, to shut down the pump:

1. Depress the

Emergency Stop Switch

(Figure 19)

Figure 30. Pumping Control

Switch (Off)

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 29

LS-60TD PUMP — OPERATING PROCEDURES

OPERATING PROCEDURES

WARNING - SAFETY GLASSES

Safety glasses MUST be worn at
all times when operating the pump.
Failure follow safety guidelines can
result in

A well-planned location of the pump and rout­ing of the hose before starting a pour may
save subsequent moves throughout the job.

PRESSURE TEST

1. To determine the pressure of the Hydraulic System, set
the

Cylinder Stroke Control switch

JOG possition.

serious

injury.

(Figure 31) to the

HOSE LUBRICATION

This procedure lubricates the hose and 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).

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.

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. (
operate the throttle when starting,

NOT REMOTELY)

Manually

Figure 31. Manual Cylinder Jogging Switch

2. Turn and hold the Manual Cylinder Jogging Switch
(Figure 32) to either JOG “A” or JOG “B” position to
test the pressure of that cylinder.

Figure 32. Manual Cylinder Jogging Switch

13. The Pumping Pressure Gauge
(Figure 33) should read
approximately 3200 ± 50 PSI.

Figure 33. Pumping

Pressure Gauge

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,
for the first hose. Pour 5 gallons of water into the second
hose and push in your clean out ball and reconnect.
This will help hold back the prime.

2. There are several things you can use for the prime. A
few examples are Cement and lime at a 50/50 mixture,
slick pac, bentonite clay.

The bentonite is not compatible with concrete.
DO NOT pump it into the forms discharge it
out of the formed area.

3. Mix the prime 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.

except

5. Pour approximately two 5 gallon buckets of prime into
the first hose and connect it to the pump.

PAGE 30 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — OPERATING PROCEDURES

6. With the pump in FORWARD at 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
cycle, the pump pressure could straighten out the kink
or force out the blockage. This rapid surge of material
could cause the lines to
that could cause injury to personnel.

7. 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.

8. 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.

kinked

WARNING - TRANSPORTING PUMP

blocked

when starting up or during the pumping

for any reason, or if the

whip

or

move

in a manner

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

B. MBVR – air entraining, acts as a lubricant.
C. Calcium Chloride – commonly referred to as C.C.,

D. Super Plasticizers – acts as an accelerator. The

E. Red Label – acts as a water retarder and an

F. Fly Ash – is used to help increase the strength of

retarder and a lubricant. On a lean mix, long pushes,
stiff mixes, and vertical pushes, Pozzolith 300R
helps pumpability.

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.

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.

accelerator. Red label will be used mainly on com­mercial jobs.

the concrete and decrease the cement content per
yard. This is one of the most common admixtures
used.

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
concrete can cause
the axle and axle springs, excess strain and pressure
on the hub and bearing assembly.

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.

Leaking manifold seals or hose coupling gas­kets which leak water can cause separation
and subsequent jamming at that point.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 31

severe damage

full hopper

or breakage of

of

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.

LS-60TD PUMP — OPERATING PROCEDURES

DOWN-HILL PUMPING

Down-hill pumping can be a difficult procedure on some jobs.
The slurry procedure would be the same as explained

Priming The Pump With Slurry Mixture

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 down-hill 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
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
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.

section of this manual.

all hose

, it is recommended

steel pipe

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.

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.

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.

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.

It is strongly recommended that
used on all vertical pumping for safety and
convenience.

steel pipe

be

PAGE 32 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — OPERATING PROCEDURES

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

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 (
affecting the concrete :

A. How old is the concrete?

B. Is there an accelerator, calcium chloride, red label,

etc., in the concrete?

C. The temperature of the day, 80, 90, degrees?

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
much water into the hopper, as this could cause separa­tion of the concrete in the hopper.

redi-mix

immediately

A through D

driver wash too

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.

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.

2. If the

shutdown

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.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 33

period exceeds 2 to 3 minutes, turn off

Over-greasing any
pump will not damage the bearing.

bearing

on your Mayco

LS-60TD PUMP — OPERATING PROCEDURES

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.

CLEARING CONCRETE BLOCKAGE

WARNING - BLOCKAGES

If you repeatedly pull the throttle all the way out and
try to force your pump to push through
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,
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.

WARNING - HOSE LINE PRESSURE

blockages

walk the hose

until you find

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.

Use extreme care! The hose line is under
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 down-stream 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.

pressure

Damaged hoses with internal restrictions can
cause blockages.

PAGE 34 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — OPERATING PROCEDURES

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
3200 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 prodedures to
clear the shuttle tubes.

WARNING - SHUTTLE TUBES

DO NOT open any of the delivery system joint clamps.

“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.

E. Chip the concrete out of the reducer with the pry

F. Remove the reducer. From the discharge end, chip

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

bar.

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.

“Reverse” Pumping Procedure to relieve pressure
on the shuttle tubes.

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.

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 themself beside the

reducing elbow at the pump outlet. Wearing

glasses

reinforcing steel rod) under the latch of the hose
clamp and flip it up.

, slip the end of a pry bar (24" length of

safety

D. Carefully knock the end of the hose away from the

reducer.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 35

LS-60TD PUMP — OPERATING PROCEDURES

HOPPER REMIXER CONTROL

The Hopper Remixer Control lever is located to the left of
the Hydraulic Temperature gauge is (Figure 34).

Figure 34. Hopper Remixer Control Lever

1. Push the Hopper Remixer Control lever DOWNWARD
(Figure 35) and observe that the blades (Figure 37) inside
the hopper are turning in a clockwise direction (forward).

RADIO REMOTE CONTROL (OPTIONAL)

The MAYCO LS-60TD 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
method (Figure 36) or a hardwire method, which utilizes a
25-ft. extension cable.

The manual remote cord (Figure 37) should be installed under
the main control box. Contact your MAYCO representative
for further information.

Figure 35. Hopper Remixer Blades (Rotation)

2. Push the Hopper Remixer Control lever UPWARD
(Figure 34) and observe that the blades (Figure 35) inside
the hopper are turning in a counter-clockwise direction
(REVERSE).

Figure 36. Handheld Receiver/Transmitter

Figure 37. Handheld Remote Cable Unit

PAGE 36 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — TOWING SAFETY PRECAUTIONS

TOWING SAFETY PRECAUTIONS

CAUTION - LOCAL TOWING REGULATIONS

■

Check wheel mounting lug nuts with a torque wrench.
Torque wheel lug nuts as described in the "

Torque

Check with your county or state safety towing
regulations department before towing your

pump

.

To reduce the possibility of an accident while transporting
the pump on public roads, always make sure that the trailer
and the towing vehicle are in good operating condition and
both units are mechanically sound.

The following list of suggestions should be used when towing
the pump:

■

Make sure that the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER
tow the light tower's trailer with defective hitches,
couplings, chains etc.

concrete

■

Make sure brakes are synchronized and functioning
properly.

■

Check tightness of suspension hardware (nuts and bolts).

■

Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Retract wheel stand when transporting.

CAUTION - DAMAGED TRAILER COUPLER

If the trailer coupler is deformed replace entire coupler.
NEVER tow the pump with a defective trailer coupler.
There exist the possibility of the trailer separating from
the towing vehicle.

Requirements

", Table 6.

Lug Nut

■

CHECK the tire air pressure on both the towing vehicle
and the trailer. Also check the tire tread wear on both
vehicles.

■

ALWAYS make sure the trailer section of the pump is
equipped with a "Safety Chain".

■

ALWAYS attach trailer's safety chain to frame of towing
vehicle.

■

ALWAYS make sure that the vehicle and trailer directional,
backup, brake, and trailer lights are connected properly
and are working properly.

■

Remember in most cases the maximum speed unless
otherwise posted for highway towing is 55 MPH, however
before towing your pump, check your local state, and
county vehicle towing requirements. Recommended off­road towing is not to exceed 15 MPH or less depending
on type of terrain.

■

Place

rolling,

■

Depending on soil conditions and location it may be
necessary to place
bumper to prevent

■

Inflate tires to correct pressure, inspect tires for cuts,
and excessive wear. See Table 5 (Tire Wear
Troubleshooting).

chocked blocks

while parked.

underneath wheel to prevent

support blocks

tipping

, while parked.

underneath the trailer's

PUMP TRAILER VEHICLE CONNECTION

1. Check the vehicle hitch ball, and trailer coupler for signs

2. Use only the 2-inch ball diameter with a towing capability

3. Be sure the coupler is secured to the hitch ball and the

4. Attach safety chains as shown in Figure 40. Remember

5. After towing for about 50 miles recheck the entire towing

RECOMMENDED MAINTENANCE

1. Smear ball socket and clamp face with chassis grease.

2. When parking or storing the concrete pump, keep the

of wear or damage. Replace any parts that are worn or
damaged before towing.

of 6,000 lbs. (2,720 kg) as indicated on the trailer's
coupler. Use of any other ball diameter will create an
extremely dangerous condition which can result in
separation of the coupler and ball or ball failure.

lock lever is down (locked).

to

cross

the safety chains.

system for tightness.

Periodically oil pivot points and wear surfaces of coupler
with SAE 30 W motor oil.

coupler off the ground so dirt and other debris will not
build up in the ball socket.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 37

LS-60TD — TOWING INFORMATION

TOWING INFORMATION

WARNING - LIFTING TRAILER TOUNGE

Use jack stand to lift tongue. DO NOT lift by hand as
back injury could result.

CAUTION - TRAILER BALL CAPACITY

The ball capacity must be greater than or equal to the
trailer GVWR. Do not use a worn hitch ball, it is unsafe
and must be replaced. USE 2" BALL ONLY

Take care not to damage the actuator when
backing up the towing vehicle for hook-up.

1. Position actuator ball socket above 2" ball.

CAUTION - TRAILER RELEASE LEVER

The release lever will close freely with finger pressure
when the ball is properly inserted into ball socket. If
the release lever does not close freely, do not tow the
pump. DO NOT force the release handle into the closed
position.

5. To make sure that the coupler is securely latched onto
the ball, extend the trailer tongue jack to the ground and
lift the truck and trailer combination 2" to 4". If the ball
does not disengage, the coupler is securely attached.

6. Insert a padlock or bolt through the lock hole for added
protection.

7. Connect the break-away cable solidly to the bumper or
frame of the tow vehicle as near to the center as possible.
The cable must hang clear of the trailer tongue and be
long enough to permit short radius turns without pulling
the breakaway cable forward.

2. Hold the release lever in the open position (Figure 38).

3. Lower the trailer tongue until the ball rests in the ball
socket.

4. Close the release lever.

RELEASE LEVER

UNLOCK POSITION

(OPEN)

Figure 38. Trailer Hitch Release Lever

Check the location of the breakaway cable
periodically during each trip. The indicator
should rest against the rear stop. Accidental
application will cause the brakes to drag and
heat up, causing a failure.

PAGE 38 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD — TOWING INFORMATION

8. Test the brakes by pulling the emergency stop lever
(Figure 39) forward until it locks into its second notch
position. Attempt to rotate the wheels in a forward
direction.

If any wheels rotate, the brakes must be adjusted. Return
the emergecny stop lever to its release position to adjust
the wheel brakes. Repeat step 8 as needed until brakes
prevent all wheel movement.

EMERGENCY BRAKE LEVER

RELEASE POSITION

10. Retract the jack fully. Remove and store the caster, if

11. Check for proper truck-trailer hook-up; the tow vehicle

applicable.

and trailer should be level with a positive tongue load.
For further information, consult a dealer.

CAUTION - SHARP TURNS WHILE TOWING

Avoid sharp turns. This could bend, create extreme
stress or fracture either the actuator or trailer tongue.

Figure 39. Trailer Emergency Brake Lever

9. Cross the safety chains under the tongue and securely
attach them to the bumper or frame of the tow vehicle.
Check with local and state laws for proper compliance.

CAUTION - SAFETY CHAINS

Safety chains must ALWAYS be used.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 39

LS-60TD PUMP — TRAILER HITCH CONNECTIONS

Figure 40 shown below illustrates the typical towing
application that should be used when towing the pump.

Figure 40. Trailer Hitch Connections

PAGE 40 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — MAINTENANCE (PUMP)

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DANGER - AMPUTATION RISK

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, stop
the engine by turning off the ignition switch and remove

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

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 relieve the accumulator

2. Pump concrete until the opening of the concrete cylinder

circuit to zero pressure
prior to performing any
maintenance on the
pump.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 41

3. Stop the pump.

4. Carefully disconnect the first hose joint at the shuttle

procedure, ensure that there is no blockage in the hose
and line or in the shuttle tube (using the Shuttle Tube
Inspection Procedure). If a blockage exists, clear it.

intake in the hopper is visible.

tube discharge elbow.

LS-60TD 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 the shuttle tube
inspection plate (follow the Shuttle Tube Inspection
Procedure) and remove all remaining concrete.

9. When the pump has been used to pump large aggregate
concrete (¾" to 1 ½") follow the instructions in step 8
once per week.

WARNING - ACID CLEANING

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
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.)

under 50°F

.,

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 BF4L914 Diesel Engine

This pump is equipped with a Deutz BF4L914 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: Shell Oil Tellius 68 or

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 - 1 Place

■

Suttle cylinders - 2 Place

■

“S” tube outlet flange - 3 Place

Grease Type: Lithium Based EP

Mobil DFE 26
Texaco Rand HDC

Texaco Multitak 20
Lubriplate ED-2

PAGE 42 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — MAINTENANCE (PUMP)

BATTERY MAINTENANCE

CAUTION - BATTERY MAINTENANCE SAFETY

Wear
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:















safety glasses

Be careful not to let the battery electrolyte come in
contact with your body or clothing.

Always wear
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 41). If necessary add only distilled water in a
well-ventilated area.

eye protection

or

face mask

and

rubber gloves

,

, since

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. See Figure 16 for troubleshooting tips.

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 41. Battery Electrolyte Levels

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 43

LS-60TD PUMP — MAINTENANCE (PUMP)

CYLINDER LUBRICATION BOX

WARNING - FREEZING CONDITIONS

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.

ACCUMULATOR CIRCUIT

DANGER - ACCUMULATOR CHARGING

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

CAUTION - SAFETY GUIDELINES

charge the accumulator.
Contact your Mayco

Before checking lubrication level, stop the engine and
remove the engine starter key.

service department or your
local Hydac representative
for proper charging
procedure.

1. The lubrication level should be checked everyday prior

The accumulator circuit has two functions in the hydraulic system.

to pumping and maintained at a height of 5 inches or

■

about ½ the concrete cylinder height. We recommend
using a SAE 30 weight motor oil.

2. As the rubber piston cups naturally wear, fine cement

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.

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 47)
located at the bottom of the box and fully drain the inside

The accumulator circuit is equipped with a
bladder type accumulator (Figure 43)
charged with 1100 PSI of dry nitrogen. The
accumulator stores one gallon of hydraulic
oil, which is, under 1750 PSI of pressure.

Figure 43. Accumulator

of the box.

dry nitrogen

to

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 42).

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.

4. When the box is clean replace drain plug, add new
lubrication and install the top cover.

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

pressure gauge

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

Figure 42. Cleaning the Lubrication Box

PAGE 44 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

or bladder replacement.

accumulator

(Figure 29) should read 1750 PSI.

LS-60TD PUMP — MAINTENANCE (PUMP)

CHANGING THE CONCRETE CYLINDER PISTON CUPS

The Rubber piston cups will occasionally require replacement
depending on the following factors.

■

The fluid level and cleanliness of the lubrication box.

■

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.

WARNING - AMPUTATION RISK

To prevent accidental cylcling of any pump
components, ALWAYS relieve the accumulator circuit
to ZERO pressure prior
to performing any
maintenance on the
pump.

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.

8. 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.

9. The new “O” ring must now be modified. Using a sharp

knife cut four oil passage grooves into the ring. the
grooves should be placed at a distance of 90
The cut should be a v-shaped design, 0.059” deep and

0.157” wide at the top.

10. Install the “O” Ring around the oiler plate. Install the

plate into the concrete cylinder utilizing the studs for
alignment.

o

apart.

Felt ring must be saturated with 30 wt. oil
prior to installation.

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.

4. Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.

5. 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.

11. Install the felt holder over the oiler plate. Install felt ring
into felt holder. Install the bronze ring.

12. 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.

13. 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 LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 45

LS-60TD PUMP — MAINTENANCE (PUMP)

CHANGING THE WEAR PLATE AND RING

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. 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.

4. Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.

5. Remove the four 1/2” 1-¼” bolts that hold the shuttle
tube to the nun-plate and remove shuttle tube.

Using two small pry bars remove the rubber energizer
ring, steel insert ring and wear ring.

Wear Plate Installation

1. Install the two cylinder “O” rings.

2. 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 re-assembled by reversing steps 1 through
5 of the Wear Plate and Ring Replacement Procedure.

HEAT EXCHANGER COOLING FAN

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.

CAUTION - HYDRAULIC OIL TEMPERATURE

If the hydraulic oil temperature exceeds 170 degrees

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. Clean out all concrete build up in and around the nun­plate area with a wire brush.

7. Inspect the wear components for indications of wear.
The wear plate has two wear surfaces.

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.

PAGE 46 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — MAINTENANCE (PUMP)

WHEEL BEARINGS

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.

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
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.

to 1/4 turn or to the nearest

EXTENDED STORAGE INSTRUCTIONS

The following preventative maintenance is recommended
for extended periods of storage.

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.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 47

LS-60TD PUMP — MAINTENANCE (TRAILER)

TRAILER SAFETY PRECAUTIONS

CAUTION - TRAILER INSPECTION

ALWAYS make sure that the trailer is in good

operating condition. Check the tires for proper inflation
and wear. Also check the wheel lug nuts for proper
tightness.

This section is intended to provide the user with trailer
service and maintenance information. Remember periodic
inspection of the trailer will ensure safe towing of the
equipment and will prevent damage to the equipment and
personal injury.

It is the purpose of this section to cover the major
maintenance components of the trailer. The following trailer
components will be discussed in this section:

■

Tires

■

Lug Nut Torquing

■

Suspension

■

Electrical

8. Wheel Hub – The wheel hub is connected to the trailer's
axle.

9. Tire Rim – Tires are mounted on a tire rim. The tire rim
must match the size of the tire.

10. Lug Nuts – Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug nuts.
See Table 7and Figure 38 for lug nut tightening and
sequence.

11. Axle – This trailer employes a torsion bar type suspen­sion, which can support 6,000 lbs.

12. Electrical – Electrical connectors (looms) are provided
with the trailer so that brake lights and turn signal lights
can be connected to the towing vehicle. See Figure 40 for
proper wiring connections.

WARNING - SAFETY GLASSES

ALWAYS

when removing or installing
force fitted parts. Failure to
comply may result in serious
injury.

wear safety glasses

The following list defines the major trailer components:

1. Frame Length – This measurement is from the ball hitch
to the rear bumper (reflector).

3. Frame Width – This measurement is from fender to
fender.

4. Jack Stand – Trailer support device with maximum
pound requirement from the tongue of the trailer.

5. Coupler – Type of hitch used on the trailer for towing. This
unit employes a 2" ball.

6. Tires Size – Indicates the diameter of the tire in inches
(10, 12, 13, 14, etc. ), and the width in millimeters (175,
185, 205 etc.). The tire diameter must match the
diameter of the tire rim. This unit employes 7.35" X 14"
tires.

7. Tires Ply – The tire ply (layers) number is rated in letters;
2-ply, 4-ply, 6-ply, 8-ply, 10-ply etc. This unit employes
6-ply tires.

SUSPENSION

(Figure 44) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
immediately.

Figure 44. Torsion Bar Suspension Components

The torsion bar suspension and associated hardware

PAGE 48 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — MAINTENANCE (TRAILER)

TRAILER ACTUATOR

The following maintenance steps should be performed
before towing the pump:

1. Frequently check actuator brake fluid levels. (Fluids

must be approved, clean, and uncontaminated). Use

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very important and critical compo­nents of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.

DOT 3 or 4 brake fluid.

CAUTION - TRAILER WHEEL MAINTENANCE

2. Make sure actuator mounting bolts and coupler bolts

are secure.

3. Periodically check the brake system as descrubed in

the brakes owner’s manual. Consult certified brake
specialists to make necessary adjustments or repairs.
Failure to do so could result in loss of braking capa-

DO NOT attempt to repair or modify a wheel. DO
NOT install an inter-tube to correct a leak through

the rim. If the rim is cracked, the air pressure in the
inter-tube may cause pieces of the rim to explode
(break-off) with great force and can cause serious
eye or bodily injury.

bilities.

Servicing the Actuator Emergency Lever

If the actuator emergency lever is applied, disengage
using a screwdriver to lift upward on the front of the flat
emergency lever spring while pulling the lever forward until
it has been released.

TIRES WEAR/INFLATION

Tire inflation pressure is the most important factor in tire
life. Pressure should be checked 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

Replace damaged parts as follows:

1. Remove the Master Cylinder and Push Rod Assembly.

Be careful not to get dirt into the master cylinder. A

and tread wear.
Table 6 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

new Master Cylinder Gasket should be used when re­installing.

2. Remove the Cable S-hook from the Emergency Lever,

TABLE 6. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN SOLUTION

the Emergency Lever Guide, and the Flat Emergency
Lever Spring, then pull the lever out of the actuator
outer case through the cross-slot at the top of the
case.

3. Install a new emergency lever through the cross-slot

in the actuator casing. Attach a new emergency lever
spring and emergency lever guide.

CAUSE

Center Wear

Edge Wear Under Inflation

Side Wear

Toe Wear

Over Inflation

Loss of chamber
or overloading.

Incorrect toe-in

Adjust pressure to
particular load per
tire manufacturer.

Adjust pressure to
particular load per
tire manufacturer.

Make sure load does
not exceed axle rating.
Align wheels.

Align wheels.

4. Install a new master cylinder gasket to the master

cylinder. Put the push rod assembly and master
cylinder back into the outer case of the actuator.

5. Set the S-hook onto the emergency brake cable and

insert into the emergency lever. Squeeze the s-hook
shut to secure it to the lever.

6. Add adequate brake fluid to the master cylinder and

bleed the brake system.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 49

Cupping

Flat Spots

Out-of balance

Wheel lockup &
tire skidding.

Check bearing adjust­ment and balance tires.

Avoid sudden stops
when possible and
adjust brakes.

LS-60TD PUMP — MAINTENANCE (TRAILER)

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 45. DO NOT
torque the wheel lug nuts all the way down. Tighten each
lug nut in 3 separate passes as defined by Table 7.

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eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

"3152-0204-5356-05

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5152-0206-05021-09

"

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.

NEVER use an pneumatic air gun to tighten
wheel lug nuts.

Figure 45. Wheel Lug Nuts Tightening Sequence

PAGE 50 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — WIRING DIAGRAM (TAIL LIGHTS)

Figure 46. Trailer Tail Lights Wiring Diagram

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 51

LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)

Figure 47. Control Box Wiring Diagram

PAGE 52 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)

Figure 47. Control Box Wiring Diagram

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 53

LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)

Figure 48. Control Box Wiring Diagram

PAGE 54 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)

Figure 48. Control Box Wiring Diagram

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 55

LS SERIES PUMP — WIRING DIAGRAM (TERMINAL BLOCKS TO COMP.)

Figure 49. Terminal Blocks to

Computer Wiring Diagram

PAGE 56 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS SERIES PUMP — WIRING DIAGRAM (OPTIONAL HOPPER VIBRATOR)

Figure 50. Hopper Vibrator
Wiring Diagram (Optional)

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 57

LS-60TD PUMP — WIRING DIAGRAM (START/SHUTDOWN SOLENOID RELAY)

Interior of Control Box

Figure 51. Start/Shutdown Solenoid Relay Diagram

PAGE 58 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — HYDRAULIC SYSTEM DIAGRAM

Figure 52. Hydraulic System Diagram

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 59

LS-60TD PUMP — MANIFOLD BLOCK PORTS

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Figure 53. Manifold Block Ports

PAGE 60 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

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. 6.5 designed for 2,500 lbs. in 28 days
Gallons per sack 7.1
Washed Sand-#200 wash 1.3
Organic matter-OK
Specific gravity (SSD) Sand-2.58; Pea Gravel-2.60

Sieve analysis-percent passing

Material 1.5” 1” 3/4” 3/8” #4 #8 #16 #30 #50 #100 #200
W.C. Sand 100 99.7 79.1 60.4 36.5 14.3 4.0 1.1
Pea Gravel 100 3.0
% Comb. 100 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: 17.78 cu. ft.
Specific gravity of aggregates in one cu. yard: 2.58
Weight of aggregates in one cu. yard batch: 2850 lbs.

% BATCH SPEC. GRAVITY ABS. VOL.
W.C. Sand 65 1800 2.58 11.56
PEA GRAVEL 35 1000 2.60 6.22
WATER 46 gal. 1
CEMENT 6.5 sk. 611
TOTAL 27.00
ADMIXTURE: None
SLUMP 4”
REMARKS 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 LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 61

APPENDIX — CONCRETE MIX INFORMATION

A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE

PAGE 62 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

APPENDIX — SLUMP TEST PROCEDURE

1. To obtain a representative sample (concrete), take

5. Fill cone to overflowing
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.

6. Remove the excess concrete

3. Fill the cone 1/3 full by volume (Figure 54-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

(Removing Excess Concrete)

the sample.

BULLET POINTED

STEEL ROD

(Figure 54-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.

Figure 54-C. Slump Test

(Full-Overflow)

(Figure 54-D) from the top of
the cone, using the tamping
rod as a screed.

Figure 54-D. Slump Test

FULL

(OVERFLOW)

7. Lift the cone vertically
(Figure 54-E) with a slow even
motion. DO NOT jar the con-
crete or tilt the cone during this

1/3 FULL

1/2 DIAMETER

24 INCHES LONG

FOOT
PIECE

Figure 54-A. Slump Test (1/3 Full)

4. Fill cone another 1/3 (Figure 54-B) which will make the
cone 2/3 full by volume. Rod this second layer 25 times

process. ( Invert the withdrawn
cone, and place it next to, but
not touching the slumped con­crete.

Figure 54-E. Slump Test

with the rod penetrating into, but not through, the first
layer. Distribute rodding evenly over the entire cross
section of the layer.

8. Lay a straight edge (Figure 54-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

2/3 FULL

time of 1-½ minutes. Discard
the concrete. DO NOT use it in
another tests.

Figure 54-B. Slump Test (2/3 Full)

(Cone Invert)

Figure 54-F. Slump Test (Measurement)

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 63

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

Figure 55. Recommended Shotcrete System

PAGE 64 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

RECOMMENDED SHOTCRETE SYSTEM

NO. PART NO. PART NAME QTY. REMARKS

1 EM28906 COUPLING, 5” H-D “CF”
2 EM25837 ELBOW, 5"x4”x90°
3 EM28905 COUPLING, 4” H-D w/GASKET & PIN
4 EM402552 REDUCER, 4”x2.5”x53” H-D ENDS
5 EM28061 PIPE, 2.5”x120w x 10’ H-D
6 EM289035 COUPLING, 2.5” H-D w/GASKET & PIN
7 EM28001DD REDUCER, 2.5”x2”x36” H-D
8 EM23815D REDUCER, 2.5”x2” w/AIR VIBRATOR
9 EM28902 COUPLING, 2” H-D w/GASKET & PIN
10 EMDC400 AIR VIBRATOR ASSY.
11 EM28131D 2”x2” ELBOW 90
12 EM24841 HOSE, 2”x25’ H-D w/ENDS
13 EM23808D NOZZLE ASSEMBLY, 2” H-D
14 EM23806 NOZZLE TIP, RUBBER 1-3/8”
15 EM23807 NOZZLE TIP, RUBBER 1.25”

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.

º

■

Use item #11 (steel elbow) at the edge of the pool to
prevent collapse of the rubber hose, which can cause
blockage.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 65

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

Figure 56. 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 66 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS

1 EM26107 HOPPER SCREEN ......................... 1 .......... W/AIR VIBRATOR MOUNTING

2 EM23101 AIR VIBRATOR 1
3 EM132 BOLT, 1/2-13X2 2
4 EM23407 AIR HOSE 1
5 EM23408 BUSHING 1
6 EM23411 VALVE 1
7 EM912073 NIPPLE 2
8 EM23409 COUPLING 1
9 EM923346 WASHER, 1/2 LOCK 2
10 EM406 NUT, HEX 1/2-13 2
11 EM23818 2"X25' GROOVED HOSE
11 EM24841 2"X25' RAISED HOSE
11 EM23845 2"X50' GROOVED HOSE
12
13
14
15
16
17
18
19

20 AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO

21 EM23808 NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES ITEMS W/

EM23802 VIC ADAPTER / EM23802D H.D 1

*

EM23803 GUN BODY 1

*

EM20816 “O” RING 1

*

EM23804 AIR INSERT 1

*

EM23805 NOZZLE CLAMP 1

*

EM23806 NOZZLE TIP, 1-3/8", SHORT 1

*

EM23807 NOZZLE TIP, 1-1/4", LONG 1

*

EM911076 STREET ELBOW 1

*

*

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 67

LS-60TD 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

WARNING - HYDRAULIC SYTEM HAZARD

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.

the proper repair procedure.

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PAGE 68 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — TROUBLESHOOTING (PUMP)

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MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 69

LS-60TD 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.

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PAGE 70 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

nevyletauqedasiknattahterusnE

.noitcaevitcerrocroflaun

LS-60TD PUMP — TROUBLESHOOTING (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.

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MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 71

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. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

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.

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.

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.

Serial Number Break — Used to list an effective serial
number range where a particular part is used.

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 72 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — SUGGESTED SPARE PARTS

LS-60TD

STRUCTURAL 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 .......... EM168161A .......... 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 SEPERATOR

3 .......... 01174416 ............. FILTER, OIL (ENGINE)

3 .......... 01174696 ............. FILTER, FUEL (ENGINE)

2 .......... EM98093P ............ ELEMENT, PRIMARY

2 .......... EM98093S ............ ELEMENT, SECONDARY

1 .......... EM98163 .............. SWITCH, PROXIMITY

1 .......... EM981121 ............ ELEMENT, RETURN OIL

LS-60TD

STRUCTURAL 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 .......... EN98033 .............. OIL PLATE

4 .......... EM14408 .............. BRONZE RING

4 .......... EM16145A ............ BUSHING, SWING AXLE (BRONZE )

3 .......... EM98021A ............ WEAR PLATE

4 .......... EM168161A .......... 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 SEPERATOR

9 .......... 01174416 ............. FILTER, OIL (ENGINE)

9 .......... 01174696 ............. FILTER, FUEL (ENGINE)

6 .......... EM98093P ............ ELEMENT, PRIMARY

6 .......... EM98093S ............ ELEMENT, SECONDARY

2 .......... EM981121 ............ ELEMENT, RETURN OIL

Part numbers on this Suggested Spare Parts
List may supercede or replace the P/N shown
in the text pages of this book.

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 73

LS-60TD PUMP — NAMEPLATE AND DECALS

PAGE 74 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — NAMEPLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS

1 EM514238 DECAL, LS-60 SMALL 1

2 SERIAL PLATE ...................................................... 1 .......... CONTACT PARTS DEPT.

3 DCL302 DECAL, WARNING BURN HAZARD 1
4 EM511709 DECAL, 800-30-MAYCO 1
5 EM97072 DECAL, CAUTION - OP. INSTRUCTIONS 2
6 EM98000 DECAL, CAUTION - GREASE 2 HOURS 4
7 DCL301 DECAL, SHUTTLE TUBE DANGER 2
8 EM970 DECAL, HOPPER REX MIXER 1
9 EM511091 DECAL, MINIMUM OIL LEVEL 1
10 EM985 DECAL, HYDRAULIC OIL ONLY 1
11 DCL304 DECAL, DANGER IMPROPER CHARGING 1
12 EM97083 DECAL, WARNING - ACCUM. SAFETY 1
13 EM955 DECAL, DANGER CHARGING ACCUM. 1
14 EM97070 DECAL, ACCUMULATOR PRESSURE 1
15 EM97070 DECAL, PUMPING PRESSURE DECAL 1
16 35137 DECAL, CAUTION READ MANUAL 1
17 EM97084 DECAL, MAINTENANCE 1
18 DCL300 DECAL, DANGER LUBRICATION BOX 1
19 EM965 DECAL, VOLUME CONTROL 1
20 EM965 DECAL, THROTTLE 1
21 513580 DECAL, ENGINE RPM SETTING 1
22 EM995 DECAL, CAUTION DIESEL FUEL 1
23 34536 DECAL, OWNERS MANUAL 1
24 DCL305 DECAL, WARNING REAR STABILIZERS 1
25 EM696 DECAL, CAUTION - TOWING DECAL 1
26 514666 DECAL, LS-60 LARGE 1

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 75

LS-60TD PUMP — FRAME ASSY.

PAGE 76 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — FRAME ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM514355 FRAME, MAIN 1
2 TBD CHAIN, TRAILER HITCH, 3/8 X 40", GRADE 40 2
3 EM25610 JACK STAND, FRONT 1
4 EM70186 SUPPORT STAND 2
5 EM491686 PIN 2
6 EM491076 PIN RING 3/4" 2
7 EM490236 CHAIN 15 3.5 GALV. 2
8 EM744 PIN 2
9 EM491686 PIN, COTTER 2

10 EM491744 RIVET, POP AM-44 2
11 509562 BOLT, 3/8" NC X 5/8" G5 2

12 0166 A LOCK, WASHER 3/8" ................................................. 2 ............. REPLACES 492624

13 503112 BOLT 3/8" X 2-3/4" 1

14 3019092 WASHER 3/8" ............................................................ 2 ............. REPLACES 492598

15 EM969013 NUT 3/8" .................................................................... 1 ............. REPLACES 492583

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 77

LS-60TD PUMP — AXLE ASSY. (RIGHT/LEFT)

PAGE 78 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — AXLE ASSY. (RIGHT/LEFT)

NO. PART NO. PART NAME QTY. REMARKS

1 EM98116 AXLE, TORSION BAR ASSY. 1

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 LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 79

LS-60TD PUMP — BRAKE LINE ASSY.

PAGE 80 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — BRAKE LINE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 34566 KIT, MAIN BRAKE LINE 1
2 EM512877 ADAPTOR, STRAIGHT 2
3 EM512876 ADAPTOR, ELBOW 2
4 34565 KIT, WHEEL BRAKE LINE 1

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 81

LS-60TD PUMP — BRAKE LIGHT ASSY.

PAGE 82 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — BRAKE LIGHT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM26536 BRAKE LIGHT ASSY. 2

2 29207 HARNESS ASSY. W/RECEPTACLES ................ 1 ............. REPLACES V5425Y

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 83

LS-60TD PUMP — TRAILER HITCH ASSY.

PAGE 84 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — TRAILER HITCH ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 29228 COUPLING, TRAILER 2 IN.BALL, 6000 LBS. 1
2 19067 ACTUATOR, BRAKE 1
3 503111 BOLT, HEX HEAD 1/2 NC X 4-1/2
4 492600 WASHER, FLAT 1/2 IN. 3
5 492584 NUT, LOCK 1/2 IN. 3
6 EM507658 BOLT, HEX HEAD 5/8 NC X 4-1/2
7 492586 NUT, LOCK 5/8

8 29369 TOW RING, 3 IN. LUNETTE EYE .......................

IN. 2

IN. 3

IN. G5 2

1 ..........REPLACES

16137

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 85

LS-60TD PUMP — BATTERY ASSY.

PAGE 86 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 34506 BATTERY BOX W/ BELT 1
2 16738 BATTERY 12V 125A 1
3 514856 BATTERY CABLE POSITIVE 1
4 513577 BATTERY CABLE NEGATIVE 1

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 87

LS-60TD PUMP — HOPPER ASSY.

PAGE 88 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — HOPPER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM514354 HOPPER ASSY 1
2 EM16184 HOPPER SEAL 1
3 EM516779 REMIXER SHAFT 1
4 EM200303 FOLLOWER RING 2
5 EM200301 GRAPHITE SEAL 6
6 EM516820 COMPRESSION SPRING 2
7 EM514339 HOPPER SPRING SEAT 2
8 510717 BOLT 1/2 X 1-3/4 IN. 4
9 EM514338 SUPPORT, LEFT 1
10 EM514706 END CAP, SHAFT SUPPORT 1
11 EM902153 BEARING 2
12 EM200018 SET COLLAR 1

13 EM703 SET SCREW ............................................ 2 ................ REPLACES 492470

14 500264 KEY 3/8 IN. 1
16 EM511428 BOLT 1/2 X 3-1/2 IN. 4
17 EM516780 HOUSING 1
18 EM98108 MOTOR, REMIX 1
19 505989 BOLT 1/2 X 1-1/4 IN. 2

20 6109180 WASHER, LOCK 1/2 IN. ........................... 2 ................ REPLACES 492626

21 EM25508 ADAPTER, FITTING 2
22 EM70860-1 PISTON CUP HOLDER 1
23 EM50417 PISTON CUP 1
24 EM508830 HANDLE 1
25 492378 BOLT 3/8 X 1-3/4 IN. 4

26 0166 A WASHER, LOCK 3/8 IN. ........................... 4 ................ REPLACES 492624

29 EM514031 PADDLE ARM, END 2
30 EM514032 PADDLE ARM, MOTOR END 2
31 EM514033 PADDLE ARM, CENTER 2
32 513454 BOLT 1/2 X 3-1/4 IN. 6

33 6109180 WASHER, LOCK 1/2 IN. ........................... 6 ................ REPLACES 492626

34 492589 HEX NUT 1/2 IN. ...................................... 6 ................ REPLACES 507661

35 EM25483 HOSE ........................................................ 2 ................ CONNECT TO REMIX VALVE

36 EM70860 HANDLE ASSY. 1
37 EM515460 RETAINING RING 1
39 516799 SPACER 6MM 1
40 EM702 DOG POINT SET SCREW 3/8" 1
41 EM703 SET SCREW 3/8" 3
42 516787 REMIX SHAFT COUPLER 1
43 EM500264 SQUARE KEY 3/8" 1
44 516776 DRIVE MEMBER COUPLER 1
45 516775 MOTOR SHAFT COUPLER 1

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 89

LS-60TD PUMP — HOPPER ATTACHMENT ASSY.

PAGE 90 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — HOPPER ATTACHMENT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM514204 SPLASH PLATE 1
2 EM514620 HINGE PIN 1
3 EM491686 COTTER PIN 1/8 X 1-1/2 IN. 1
4 EM70134-2 PIN, SPLASH PLATE 1
5 EM505723 COTTER PIN 5/32 X 1-1/2 IN. 1
6 EM16166 TIE ROD 1
7 505728 NUT, HEX 1 IN. NC 6
8 EM14165 EYE BOLT 3/4 IN. 4
9 EM619 O-RING 3/4 IN. 4
10 EM968446 NUT, HEX 3/4 IN. 4
11 505121 BOLT 3/4 IN. X 3 IN. 4
12 EM968446 HEX NUT 3/4 IN. 4
13 505123 HEX BOLT 1/2 X 2-1/2 IN. 2
14 492491 HEX BOLT 1/2 X 1-1/2 IN. 1

15 6109160 HEX NUT 1/2 IN. ................................................ 3 ............. REPLACES 492556

16 492379 SCREW CAP 3/8" 2
17 3019092 WASHER FLAT 3/8" 4
18 515395 BOLT 7/16 NC X 4" G5 2
19 492584 NUT LOCK 1/2" 2
20 EM969013 NUT NYLOC 2

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 91

LS-60TD PUMP — HOPPER INTERIOR ASSY.

25

18

2

3

4

5

6

6A

7

30

1

32

29

27

14

15

11

8

19

21

20

17

28

31

10

9

12

13

16

PAGE 92 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

26

LS-60TD PUMP — HOPPER INTERIOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM16145A SWING AXLE BUSHING 2
2 EM284 STUD 1 IN. - 14 UNF 1
3 EM16175 O-RING 1
4 EM16170 RING SEAL, SHUTTLE AXLE 1
5 EM16176 O-RING 1
6 EM98022 WEAR RING HF 1
6A EM16816-1A RING, ENERGIZER RUBBER 1
7 EM16816-2 RING, INSERT STEEL 1
8 EM16804 SLEEVE 5 IN. 1

9 EM104 BOLT 5/8 X 2 IN. ....................................... 4 ............... REPLACES 503982

10 EM923348 WASHER, LOCK 5/8 IN. ............................ 4 ............... REPLACES 492627

11 EM25803 DISCHARGE PLATE BEARING 1
12 EM98065 SEAL, RUBBER 1
13 EM512212 DISCHARGE NIPPLE 1
14 491701 GREASE FITTING 3
15 EM210 BOLT 5/8 X 2 IN. 6
17 EM16811 SHUTTLE CYLINDER 1
18 EM25843 NUN PLATE 1

19 EM104 BOLT, HEX HEAD 5/8 X 2 IN. .................... 4 ............... REPLACES 503982

20 491719 PIN 1
21 EM923348 WASHER, LOCK 5/8 IN. 4
25 EM514357 HOPPER SCREEN 1

26 EM98021 PLATE, WEAR HF 1

27 EM969023 NUT, HEX 5/8 IN. NC INS. ......................... 2 ............... REPLACES 492586

28 EM265 BOLT, COUNTER SUNK 5/8-11 x 3 IN. 2
29 EM492628 WASHER, LOCK 3/4 IN. 2
30 EM151 BOLT, HEX HEAD 3/4-10 X 2 IN. 2
31 EM264 BOLT, COUNTER SUNK 1/2-13 x 3 IN. 2
32 EM517700 O-RING 2

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 93

LS-60TD PUMP — SHUTTLE CYLINDER ASSY.

PAGE 94 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — 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 ............ REPLACES 491690

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/

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
16
18
19
20 3322 FITTING, ELBOW 2

21 EM514590 HOSE............................................................ 1 ............ CONNECT TO

22 EM514591 HOSE............................................................ 1 ............ CONNECT TO

23 EM515628 COVER, SHUTTLE CYLINDER 1

24 0202 SCREW, HHC 5/16-18 X 1 ZINC ................... 3 ............ REPLACES 492364

25 EM923023 WASHER, FLAT ............................................ 3 ............ REPLACES 492597

26 2105164 NUT, HEX ...................................................... 3 ............ REPLACES 492582

27
28

EM254549 BRACKET, PIVOT 1

*

0820270000 CLEVIS PIN 3/4 IN. 1

*

0820270000 COTTER PIN 2

*

515249 NUT JAM 1"-14 1

*

EM254541 FEMALE CLEVIS 1

*

...................................................................................... MANIFOLD PORT “A1”

...................................................................................... MANIFOLD PORT “B1”

EM26126 CLEVIS PIN 1

*

EM717 COTTER PIN 2

*

*

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 95

LS-60TD PUMP — LUBRICATION PISTONS ASSY.

PAGE 96 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — LUBRICATION PISTONS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1

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

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 514197 LUBRICATION BOX 1
17 EM507895 PLUG 1
18 515796 COVER, LUBRICATION BOX 1
19 EM514610 LATCH, COVER 1
20 EM491754 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 EM492451 BOLT 3/8 - 24 X 1 IN. HEX HEAD 8
26 EM50443 SEAL, OIL BOX 8
27 EM514208 BAR,PROXIMITY SWITCH SUPPORT 1
28 EM98163 SWITCH, PROXIMITY W/CABLE 2
29 EM98135 CABLE HOUSING, FEMALE 2
30 EM98134 SEAL, CONNECTOR HOUSING 6
31 EM98138 TERMINAL PIN, FEMALE 6

32 EM514611 GROMMMET 2
33 EM504505 WRAP TIE 8

EM963064 BOLT, HEX HEAD 3/8 NC X 3-1/2 IN., BLACK OXIDE G8 6

EM16462 FELT HOLDER 2

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 97

LS-60TD PUMP — LUBRICATION PISTONS ASSY.

PAGE 98 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)

LS-60TD PUMP — LUBRICATION PISTONS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

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
44 EM185 BOLT, SOCKET HEAD 3/8 NC X 3
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 INTERNAL 6
51 EM513352 SEAL, SQUARE 1

IN., BLACK OXIDE G8 6

MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 99

LS-60TD PUMP — FUEL TANK ASSY.

PAGE 100 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)