Multiquip LS60TD, LS600 User Manual

LS60TD and LS600 (Deutz Engine)

Control Box Replacement

The following instructions are intended to assist the user in the installation of the replacement control box on the
LS60TD and LS600 Concrete Pump. Please read all instructions before installing the control box and relay kit.

REQUIRED TOOLS/COMPONENTS

 Crimping Tool
 Wire Cutter Tool
 Wire Stripper Tool
 Two 12-10 AWG Butt Splice
 One 14-16 AWG Butt Splice

 One 12-10 AWG Spade Lug

PARTS

Verify that parts are accounted for. See Figure 1 and Table 1.

2

5

3

4

WORK SAFELY!

Only a qualified service technician with proper training
should perform this installation. Follow all shop safety rules
when performing this installation.

PREPARATION

1. Place the pump in an area free of dirt and debris.

2. Disconnect negative battery cable from the battery.

3. Disconnect the 4 plugs from the receptacles on the
rear of the control box currently installed on the pump
(see Figure 2). Mark and tag the plugs for reference
when new control box is installed. Remove the fuse
from the rear of the control box and keep the nut and
washers. They will be used to reinstall the fuse on the
new control box.

4. Remove the existing control box as shown in Figure 2.
Keep the hex bolts, flat washers and lock nuts. They
will be used in the installation of the new control box.

OPEN HATCH

1

Figure 1. Required Parts

Table 1. Required Parts

Item

No.

Part No. Description QTY. Remarks

1 EM517648A Digital Control Box 1

2 EM515799 Relay Kit 1

3 ___ 10/32" Hex Nut 1 Not Provided

4 ___ #10 Lock Washer 1 Not Provided

5 ___ #10 Flat Washer 1 Not Provided

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 1

PLUGS (4)

FUSE

FLAT
WASHER (8)

HEX BOLT (4)

LOCK NUT (4)

SCREW (2)

OLD

CONTROL

PANEL

Figure 2. Removing Existing Control Box

INSTALLATION

CONNECTIONS

1. Install the replacement digital control box on the pump
using the existing hardware. See Figure 3.

CONTROL BOX REAR VIEW

HARNESS

RELAY

STUD

LOCK

WASHER

FLAT WASHER

HEX NUT

HATCH

PLUGS

Refer to Figure 5 for connections from the relay to the plugs .

1. Connect #86 purple 12 AWG wire from Relay K1 to
terminal #6 on Plug P1 using a spade connector.

2. Connect #85 black wire from Relay K1 to starter ground
point using a butt splice.

3. Connect #87 purple 10 AWG wire from Relay K1 to
terminal #4 on Plug P1 using a butt splice.

4. Cut wire from terminal #4 on Plug P4 flush to the plug.
Terminal will not be used.

5. Connect #30 red wire from Relay K1 to the other end
of the cut wire using a butt splice.

6. Reconnect the 4 plugs to the corresponding receptacles
on the new control box. See Figure 4 for location of
receptacles. Receptacle J5 will not be used.

NOTICE

Use extreme care when connecting the control box rear
receptacle plugs to make sure that correct orientation
is followed.

HEX BOLT (4)

FLAT
WASHER (8)

LOCK NUT (4)

SCREW (2)

Figure 3. Replacement Digital Box Installation

NEW
CONTROL
PANEL

2. Attach the relay kit to the digital control box by securing
it to the stud shown in Figure 3, using the appropriate
hardware (user provided).

Relay

Fuse

J1
J2
J3
J4

J5

(Not Used)

Figure 4. Control Box Rear Receptacles

Receptacles

7. Install the fuse to the rear of the new control box.

8. After all connections are made, reconnect the battery.
Turn the control panel ignition switch to the ON position.
The control box panel should light. You will see and
hear the engine fuel solenoid energize.

9. Perform control box programming instructions.

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 2

86

BLACK 16 AWG

30

85

REAR VIEW

+ 12V DC

Power

87

Relay Connector

IN

OUT

Butt Splice

Relay K1

STARTER
GROUND
POINT

PURPLE 10 AWG

PURPLE 12 AWG

ORANGE 10 AWG

Butt Splice

RED 10 AWG

Plugs

P1

P4

Existing Fuse

6

4

Spade Lug

Cut Flush

Butt Splice

4

TO

START/STOP

SOLENOID

Figure 5. Connections Between Control Box and Relay

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 3

Plug P1

Plug P1

Outside Terminal # 6

(Ignition B+)

12 AWG Purple Wire

#86 #87

Outside Terminal # 4 Splice

B+ Power (Fuse)

10 AWG Purple Wire

#85 #30

16 AWG Black Wire

Starter Ground Point

Figure 6. Relay P/N EM515799 Relay Schematic Diagram

10 AWG Red Wire

Plug P4 Terminal # 4

(Cut Wire Flush)

Opposite End to Deutz

Start/Stop Solenoid

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 4

CONTROL BOX PROGRAMMING

NOTICE

Control boxes come pre-programmed from the factory
and configured to Model LS300. It is necessary to
reprogram the model configuration to match your unit.

6. Once the language is selected, place the CONTROL

switch to the center off position.

7. Turn the IGNITION switch to OFF then ON again to

memorize final configuration.

Machine Model Configuration

See Figure 7 to identify control box switches.

Digital Screen

Reset Switch

SCROLL

RESET

SET

VOLUME

DECREASE INCREASE

FLOW

DIRECTION CONTROL

FORWARD REVERSE LOCAL

AUTOMATIC JOG

MULTIQUIP INC. CARSON, CALIFORNIA 90746 USA
310-537-3700 800-421-1244 WWW.MULTIQUIP.COM

Automatic/Jog

Switch

Flow Direction

Switch

CENTER

OFF

CYLINDER STROKE

JOG “A” JOG “B”

Control Switch

Ignition Switch

OFF

IGNITION

REMOTE

Cylinder Stroke

Switch

ON

START

1. Turn the IGNITION switch to the ON position. Do not

start engine.

2. Place the FLOW DIRECTION switch to reverse.

3. Place the AUTOMATIC/JOG switch to jog.

4. Place the CONTROL switch to remote.

5. Manually hold the CYLINDER STROKE switch to the

jog B position. While holding the switch to the jog B
position, toggle the RESET switch down 5 times. After

the fifth time, move the CYLINDER STROKE switch
to the jog A position. While holding the switch to the

jog A position, toggle the RESET switch down to the
desired model (LS60TD or LS600).

6. Once the model is selected, place the CONTROL

switch to the center off position.

7. Turn the IGNITION switch to OFF then ON again to

memorize final configuration.

Figure 7. Control Box Switches

Language Selection

1. Turn the IGNITION switch to the ON position. Do not
start engine.

2. Place the FLOW DIRECTION switch to reverse.

3. Place the AUTOMATIC/JOG switch to jog.

4. Place the CONTROL switch to remote.

5. Manually hold the CYLINDER STROKE switch to the
jog B position. While holding the switch to the jog B
position, toggle the RESET switch down 5 times. On
the fifth time, the digital screen will display the current
set language. Toggle RESET switch again to change
language, if desired.

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 5

CONTROL PANEL COMPONENTS

5

12

13

0

0

0

1

0

5

7

0

0

5

0

ACCUMULATOR

PRESSURE

0

0

0

1

0

5

7

0

0

5

0

PUMPING

PRESSURE

4

1

2

5

0

1

5

0

0

11

2

0

0

0

1

2

5

0

1

5

0

0

2

0

0

0

Figure 8. Digital Control Panel Components

SCROLL

VOLUME

DECREASE

FLOW

7

DIRECTION

FORWARD

AUTOMATIC

1. Emergency Stop Button — Press emergency stop
button to stop pump in an emergency. Turn knob
counterclockwise to disengage the stop button.

2. Ignition Switch — Insert the ignition key here to start
the engine. Turn the key clockwise to the ON position,
then continue turning clockwise to the START position
and release. To stop the engine turn the key fully
counterclockwise to the STOP position.

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

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

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

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

7. Direction Control Switch — This 2-position switch
controls the direction of flow for any mix in the pump.
The leftmost position sets the pumping direction to
forward and the rightmost position sets the pumping
direction to reverse.

8. Pumping Control Switch — This 3-position switch
controls the pumping of the pump. The rightmost
position (REMOTE) is for use with the remote control
unit, the leftmost position (LOCAL) is for normal
pumping operation, and the center most position
(CENTER OFF) prevents pumping.

3

RESET

SET

INCREASE

1

C

N

Y

E

G

S

R

T

O

E

P

M

E

ON

OFF

START

2

CONTROL

REMOTE

LOCAL

REVERSE

JOG

9

CYLINDER STROKE

JOG “A”

CENTER

OFF

10

JOG “B”

IGNITION

8

REMOTE

6

9. Cylinder Stroke Control Switch — This 2-position
switch controls the pumping function. The leftmost
position (AUTOMATIC) sets the pump to automatic
cycling. Set the switch to this position for normal pump
operation.

The rightmost position (JOG) changes the pump from

automatic to manual cycling. This allows the cylinders
to be manually cycled using the Manual Cylinder
Jogging Switch.

10. Manual Cylinder Jogging Switch — This 2-position
switch allows the operator to manually jog the cylinders
to assist in clearing material line packs and is used to
test pumping pressure.

The leftmost position jogs Cylinder “A” and the

rightmost position jogs Cylinder “B”.

11. Stroke Volume Control Switch — Increases or
decreases the number of strokes per minute of the
pump (not used on model LS60TD).

12. Accumulator Press ure Gau g e — This gauge
monitors the internal pressure of the Accumulator tank.
Normal internal pressure should read approximately
1750 PSI during pumping.

13. Main Pressure Gauge — This gauge monitors
the system pressure while pumping material. The
maximum pressure rating is 4400 PSI ± 50.

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 6

DIGITAL READOUT SCREENS

Screen 5

Primary Screen

Screen 1

Indicates the various modes of the switch settings.

Monitors engine RPM - Idle speed 900, High speed

2550. Battery charge indicator - Normal charge 13+ volts.
Indicates electrical malfunction.

Secondary Screens

Screen 2 (not used on Model LS60TD)

Displays the position of the VOLUME CONTROL switch
by indicating whether the increase or decrease position
is on or off.

INDICATES VOLUME
SWITCH IS NOT IN

THE - POSITION

FLOW DEC OFF
FLOW INC ON

Screen 3

Displays the number of hours the engine and pump
have been used and the number of faults the pump has
registered. All three indicators can be reset to zero by the
RESET switch on the control panel.

INDICATES NO.
OF HOURS
ENGINE HAS
BEEN USED

MESSAGE OR
INSTRUCTION

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

Screen 4

Displays the number of strokes the main hydraulic cylinders
have gone through. This indicator can be reset to zero by
the RESET switch on the control panel.

INDICATES A
RUNNING
COUNT OF
NO. OF STROKES

STROKE CTR: 0000
PRESS RESET TO
ZERO STROKE CTR

2

INDICATES VOLUME
SWITCH IS IN THE
+ POSITION

INDICATES NO.
OF HOURS
PUMP HAS

3

BEEN USED

INDICATES NO.
OF FAULTS
DETECTED

4

MESSAGE OR
INFORMATION

Displays the ON/OFF electrical signal status of the various
12 volt solenoids (Swing A circuit, Main A circuit, Main B
circuit).

INDICATES

SWING A
CIRCUIT IS OFF

INDICATES

MAIN B
CIRCUIT IS OFF

SWING A OFF

MAIN A OFF
MAIN B OFF

5

INDICATES

MAIN A
CIRCUIT IS OFF

Screen 6

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

INDICATES

PROXIMITY A
CIRCUIT IS OFF

INDICATES
UNLOADER
CIRCUIT IS OFF

PROX A OFF
PROX B ON
FUEL SOL OFF
UNLOADER OFF

6

INDICATES

FUEL SOLENOID
CIRCUIT IS OFF

INDICATES
PROXIMITY B
CIRCUIT IS ON

Screen 7

Displays the number of times the main hydraulic cylinders
stroke and the yards per hour output. This indicator can be
reset to zero by the RESET switch on the control panel.

INDICATES
THROTTLE
IS ON

INDICATES THE
NO. OF YARDS
PER HOUR

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

INDICATES THE
NUMBER OF
STROKES

7

INDICATES THE
NO. OF STROKES
PER MINUTE

Screen 8

Displays the electrical status of the engine fuel solenoid. To
test the 12-Volt solenoid status, activate with the RESET
switch on the control panel.

TO TEST FUEL
SOL PRESS RESET

FUEL SOL OFF
INDICATES THE
FUEL SOLENOID
IS OFF

8

INSTRUCTION
OR MESSAGE

Screen 9

Displays the communication status of the (optional) radio
remote control. To activate a new remote control connection,
use the reset switch on the control panel.

INDICATES
THAT RADIO

9

REMOTE IS ON

IINSTRUCTION
OR MESSAGE

RADIO ADDRESS

COMMUNICATING

PRESS RESET TO

LEARN A NEW ONE

LS60TD AND LS600 — CONTROL BOX REPLACEMENT — REV. #1 (03/23/12) — PAGE 7

HERE’S HOW TO GET HELP

© COPYRIGHT 2012, MULTIQUIP INC.

Multiquip Inc

the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this document are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published

LS60TD and LS600

Control Box Replacement

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Office MQ Parts Department

18910 Wilmington Ave.
Carson, CA 90746
Contact: [e-mail]

Service Department Warranty Department

800-421-1244
310-537-3700

Technical Assistance

800-478-1244 Fax: [phone]

Tel. [phone]
Fax [phone]

Fax: [phone]

800-427-1244
310-537-3700

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Fax: [phone]
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Fax: [phone]

mexico United Kingdom

MQ Cipsa Multiquip (UK) Limited Head Office

Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [e-mail]

Tel: [phone]
Fax: [phone]

Unit 2, Northpoint Industrial Estate,
Globe Lane,
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Contact: [e-mail]

Canada

Multiquip

4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [e-mail]

Tel: [phone]
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Fax: [phone]

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