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)
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