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PAGE 82 — MAYCO LS600P CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)

HYDRAULIC SYSTEM LOCATOR DIAGRAM

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Summary of Contents for LS600P

Page 1: ...MANUAL THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES Revision 1 09 09 19 SERIES MODEL LS600P CONCRETE PUMP Perkins 1104D 44TA DIESEL ENGINE T o o r d e r g o t o D i s c o u n t E q u i p m e...

Page 2: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 3: ...PAGE 2 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PROPOSITION 65 WARNING T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 4: ...r reproductive harm If you are unfamiliar with the risks associated with the particular process and or material being cut or the composition of the tool being used review the material safety data shee...

Page 5: ...delines 55 69 Appendix Concrete Mix Information 70 72 Troubleshooting Pump 73 74 Troubleshooting Engine 75 Troubleshooting Hydraulic Brakes 76 Troubleshooting Electrical 77 Control Box Component Locat...

Page 6: ...FETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY WARNING Indicates a hazardous situation which if not avoided COULD result in DEATH or SE...

Page 7: ...doctor and fire department This information will be invaluable in the case of an emergency PUMP SAFETY DANGER NEVER pump volatile explosive flammable or low flash point fluids These fluids could ignit...

Page 8: ...lt lock nut and wheel lug nuts for wear Test the pump s emergency stop switch The purpose of this test is to shut down the engine in the event of an emergency Refer to the Engine Owner s Manual for en...

Page 9: ...DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If...

Page 10: ...ated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air...

Page 11: ...Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product Recyclers and manufacturers alike promote the p...

Page 12: ...Weight with fluids 5 190 lbs 2 354 kg Weight dry shipping 4 760 lbs 2 159 kg Tire Size 16 in 406 mm Option Wireless Remote Control Hopper Screen Vibrator Volume output will vary depending on mix desi...

Page 13: ...AL REV 1 09 09 19 PAGE 13 A B E D C Table 3 Pump Dimensions Reference Letter Dimensions in mm A 43 1 092 B 173 4 394 C 24 610 D 72 1 828 E 68 1 727 Figure 1 Dimensions DIMENSIONS T o o r d e r g o t o...

Page 14: ...TE UP CHUTE DOWN STOP START PUMP SPEED UP SLOW PUMP DOWN STOP PUMP LITTLE BIT ADD WATER 4 GALLONS ALL DONE CLEAN UP DRIVE IN BACK UP PULL FORWARD BACK IN IMPORTANT HAND SIGNALS Figure 2 Operation Hand...

Page 15: ...ith 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...

Page 16: ...can be used to pump a large aggregate hard rock as follows Pea rock 1 2 minus pump with mixes being as low as 30 rock and 70 sand reference maintenance for recommendations on cleaning the pump Shorte...

Page 17: ...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 all hose it is recommended not to go higher than 50...

Page 18: ...es turn off 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 GENERAL INFORMATION 3 If it is necessary to wait 10...

Page 19: ...her 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 walk the hose until you find the point of t...

Page 20: ...of a pry bar 24 length of reinforcing steel rod under the latch of the hose clamp and flip it up 4 Carefully knock the end of the hose away from the reducer 5 Chip the concrete out of the reducer wit...

Page 21: ...Cycle 1 TO TANK HIGH PRESSURE OIL FROM PUMP PROXIMITY SWITCH HYDRAULIC CYLINDERS PISTON CUP CONCRETE CYLINDERS SHUTTLE TUBE SLAVE OIL SHUTTLE TUBE MOTION A B Figure 4 Pumping Cycle 2 In the first cycl...

Page 22: ...22 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 Figure 5 Pump Components View 1 12 1 10 9 8 7 3 2 6 5 13 14 4 11 PUMP COMPONENTS T o o r d e r g o t o D i s c o u n t E q u i p m e n t c...

Page 23: ...e rear end of the pump during operation NEVER deploy on un level ground and always check for firmness of ground 8 Tires This trailer uses two ST235 80R16 type tires Tire inflation pressure is the most...

Page 24: ...CRETE PUMP OPERATION MANUAL REV 1 09 09 19 PUMP COMPONENTS CONTINUED Figure 6 Pump Components View 2 17 16 27 9 21 25 15 28 18 20 23 22 11 19 24 29 30 31 26 32 33 T o o r d e r g o t o D i s c o u n t...

Page 25: ...mmended coolant Radiator coolant capacity is 4 5 gallons 17 liters 25 Volume Control This device is electronically controlled by the cylinder stroke switch located on the front panel of the control bo...

Page 26: ...p 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 c...

Page 27: ...OUNT OF NO OF STROKES MESSAGE OR INFORMATION Screen 5 Displays the ON OFF electrical signal status of the various 12 volt solenoids Swing A circuit Main A circuit Main B circuit Screen 6 Displays the...

Page 28: ...ary Fuel Filter Prevents dirt and other debris from entering the fuel system Service the fuel filter as recommended in the maintenance section of this manual 10 Fuel Injection Pump Provides equal fuel...

Page 29: ...intenance service on the pump NOTICE ReferenceFigures5 6 and7forthelocationofanycontrol or component referenced in this section DANGER Handle fuel safely Motor fuels are highly flammable and can be da...

Page 30: ...through filler hole but DO NOT overfill 5 The oil listed in Table 4 is recommended to ensure better engine performance Use class CD or higher grade motor oil DIPSTICK Hydraulic Oil Check 1 Determine...

Page 31: ...ting level Use Shell oil Tellus 68 or Mobil oil DFE26 Figure 14 Adding Hydraulic Oil Filler Hole 3 Check the oil level in the lubrication box Figure 15 If low fill with up to 3 gallons of SAE 30 motor...

Page 32: ...n firm not loose level ground Figure 18 Figure 18 Rear Stabilizer Stand Deployment 4 Align the hole on the stabilizer jack with the hole on the frame body and insert handle tee bolt 5 Insert the cotte...

Page 33: ...ot start To start the engine make sure the emergency stop switch is in the OPEN position fully extended AUTOMATIC JOG LOCAL REMOTE CENTER OFF 4 Place the direction control switch to the FORWARD positi...

Page 34: ...crete DO NOT discharge concrete into hopper at this time NOTICE 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 F...

Page 35: ...g in a clockwise direction forward To make the blades rotate in a counterclockwise direction reverse push the hopper remixer control lever upward Figure 32 Figure 33 Hopper Remixer Blade Rotation 9 Pl...

Page 36: ...1 Remove the two screws Figure 34 on the digital control panel that secure the front panel to the control box Figure 34 Removing The Control Box NOTICE When pumping long distance or pumping stiff mix...

Page 37: ...R CABLE CONTROL BOX CONNECTOR REAR OF CONTROL BOX LOCAL REMOTE CENTER OFF Remote pumping operation can be performed by the hand held radio remote control Figure 39 Figure 39 Radio Remote Control The b...

Page 38: ...The remote control cable Figure 40 has the following controls Pump ON OFF Starts and stops the forward pumping Pump REV Starts pumping in reverse direction Connect the remote control cable Figure 40 t...

Page 39: ...Condition X Check for Leaks X Check for Loosening of Parts X Replace Engine Oil and Filter 1 X Clean Air Filter X Check Fuel Filter Water Separator Bowl X Clean Unit Inside and Outside X Change Fuel...

Page 40: ...negative battery cable from battery before servicing WARNING Some maintenance operations may require the engine to be run Ensure that the maintenance area is well ventilated Exhaust contains poisonou...

Page 41: ...T INNER ELEMENT OPTION EVACUATOR VALVE ARROW MARK CASE NOTICE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and fa...

Page 42: ...for recommended oil viscosity 1 Prepare a waste oil collector to drain the oil into 2 Remove the oil filler cap while draining the oil to allow the engine to drain easil Figure 45 Oil Service Compone...

Page 43: ...s which can cause severe burns Table 7 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F 50 37 34 108 226 Radiator Maintenance 1 Check radiator for leaks that woul...

Page 44: ...CE In Line Fuel Filter Replace the engine in line fuel filter Figure 50 every year or 300 hours Figure 50 In Line Fuel Filter Oil And Fuel Lines 1 Check the oil and fuel lines and connections regularl...

Page 45: ...trical system and never spark battery terminals to test for charge CAUTION Battery Safety Wear safety glasses or face mask protective clothes and rubber gloves when working with battery If the pump wi...

Page 46: ...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 NOTICE NEVER use muriatic acid to clean the pump Acid will dissolve the ch...

Page 47: ...t We recommend using a 30 weight motor oil 2 As the rubber piston cups naturally wear fine cement particles will accumulate in the box Once the concrete paste reaches a height of about inch from the b...

Page 48: ...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 accumulat...

Page 49: ...wo 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...

Page 50: ...lt heads with silicon sealant Torque all three bolts equal at 55 ft lbs each 1 Remove the two hydraulic hoses connected to the remix motor Plug the ports with fittings not provided to prevent hydrauli...

Page 51: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 52: ...4300 4400 PSI Figure 59 Pumping Pressure Gauge LongTerm Storage Pump Remove the battery Drain the fuel tank completely Treat with a fuel stabilizer if necessary Clean exterior with a cloth soaked in...

Page 53: ...e adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Your trailer maybe equipped with...

Page 54: ...Replace and correct Dragging Brakes Brake lining thickness incorrect or not adjusted correctly Install new shoes and linings Enough brake fluid or correct fluid Replace rubber parts fill with dot 4 f...

Page 55: ...he trailer falling thus causing equipment damage and severe bodily harm even death DANGER When performing trailer inspection and maintenance activities you must jack up the trailer using jacks and jac...

Page 56: ...ith a trailer is 4 times the passing distance without the trailer Shift your automatic transmission into a lower gear for city driving ALWAYS use lower gears for climbing and descending grades DO NOT...

Page 57: ...lighting conditions deteriorate Always check for local trailer tow speed limits in your area WARNING Do not transport people on the trailer The transport of people puts their lives at risk and may be...

Page 58: ...of it WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision Before each tow check that the tail lights brake lights...

Page 59: ...without the trailer coupled Some of the trailer weight will be transferred from the trailer to the tow vehicle axles and an axle scale weighs all axles including the tow vehicle axles TOW VEHICLE The...

Page 60: ...Pintel Eye Coupler BALL HITCH COUPLER A ball hitch coupler Figure C connects to a ball that is located on or under the rear bumper of tow vehicle This system of coupling a trailer to a tow vehicle is...

Page 61: ...t can result in uncoupling leading to death or serious injury Be sure the hitch ball is tight to the hitch before coupling the trailer the trailer tongue Wood or concrete blocks may also be used Coupl...

Page 62: ...es or loops specifically for that purpose Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose Breakaway Brake System If the c...

Page 63: ...ects to a pintle hook hitch that is located on or under the rear bumper of the tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as a lunette eye tow ring or G I...

Page 64: ...e towing and may result in death or serious injury Before coupling trailer inspect the pintle hitch hook for wear corrosion and cracks Replace worn or damaged pintle hitch hook CouplingTrailer toTow V...

Page 65: ...trailer dealer tighten the lug nuts to the proper torque WARNING Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off leading to death or seri...

Page 66: ...r See Figure I The weight of cargo should never exceed XXX kg Or XXX lbs TIRE FRONT REAR SPARE SIZE COLD TIRE PRESSURE TIRE AND LOADING INFORMATION SEE OWNER S MANUAL FOR ADDITIONAL INFORMATION Determ...

Page 67: ...You may not find this information on all tires because it is not required by law M S The M S or M S indicates that the tire has some mud and snow capability Most radial tires have these markings henc...

Page 68: ...ure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits Tire SafetyTips Slow down if you have to go over a pothole o...

Page 69: ...tire skidding Avoid sudden stops when possible and adjust brakes WARNING ALWAYS wear safety glasses when removing or installing force fitted parts DO NOT attempt to repair or modify a wheel DO NOT in...

Page 70: ...20 25 35 40 50 65 13 20 25 35 40 50 65 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 Replace any broken or burned out lamps as necessary Check the wire harness for cuts fraying or...

Page 71: ...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 20...

Page 72: ...600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PAGE 71 APPENDIX CONCRETE MIX INFORMATION A S T M STANDARD SPECIFICATION FOR GRADING AGGREGATE T o o r d e r g o t o D i s c o u n t E q u i p m e n...

Page 73: ...e layer Figure O Slump Test 2 3 Full 5 Fill cone to overflowing Figure P Rod this layer 25 times with rod penetrating into but not through the second layer Distribute rodding evenly over the entire cr...

Page 74: ...temPressure Check the system pressure reading Verify it is approx 1750 PSI Contaminated Relief Valve Check the manifold for a contaminated Relief Valve Swing Solenoid not engergizing Check for burned...

Page 75: ...hose pack Machine does not deliver volume and pressure Low engine speed Check engine RPM Volume control set to low Adjust control to full open setting Main hydraulic pressure too low Check for proper...

Page 76: ...ect type of oil for winter environment Defective battery Replace battery Engine fires but stops soon as starter is switched off Fuel filter blocked Replace fuel filter Fuel supply blocked Check the en...

Page 77: ...correct fluid Fill with DOT 4 fluid Brakes squeak chatter or chuck Overheated wheel bearing Replace wheel bearing and pack with grease Low brake fluid Fill and bleed brake system Siezed acutator maste...

Page 78: ...oid coil resistance It should read 6 ohms Replace burnt solenoid Wire connection broken Replace broken wire Swing SHORTED The 12 volt cycling solenoid is shorted directly to ground Measure solenoid co...

Page 79: ...IGNITION REMOTE CONTROL FLOW DIRECTION VOLUME LOCAL FORWARD AUTOMATIC JOG RESET SET DECREASE INCREASE SCROLL JOG A CYLINDER STROKE JOG B REVERSE CENTER OFF REMOTE START E m ergency S t o p A B C DIGIT...

Page 80: ...BROWN DECREASE FWD BLACK BLACK 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 J4 REMOTE LOCAL WHITE REMOTE CONNECTOR BLUE 1 2 3 JOG A JOG B BLK RED J1 CONTROLLER BLACK POTTED BOX BLACK RED WHITE BLUE YELLOW GREEN BR...

Page 81: ...PAGE 80 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 HOPPER VIBRATOR LOCATOR OPTION E D H CONTROL BOX HOPPER F B A C G T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 82: ...ODULE 2 2 2 FUEL SOLONOID 12 AWG RED 12VDC 12VDC OUTPUT J3 4 E STOP J1 7 12VDC 12 AWG BRN 12VDC INPUT J1 10 J1 9 RED WHT CONTROLLER BLACK POTTED BOX FUEL SOLENOID SHUT DOWN 12VDC POWER OUT 12VDC RED C...

Page 83: ...AGE 82 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 HYDRAULIC SYSTEM LOCATOR DIAGRAM E C B A F D E G J K S T P N L M R Q I O T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 84: ...FILTER HEAT EXCHANGER REMIX MOTOR REMIX DIRECTIONAL VALVE REMIX PUMP PUMP ACCUMULATOR MAIN PUMP SHUTTLE HYDRAULIC CYLINDER SWING VALVE MAIN VALVE MAIN A HYDRAULIC CYLINDER FLOW CONTROL A B D C E F MAI...

Page 85: ...AGE 84 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 WIRING DIAGRAM LOCATOR 1 EXTERNAL CONTROL BOX H E B E D C F J L K M A G I T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o...

Page 86: ...ONTROL BOX OUTSIDE CONTROL BOX YELLOW WHITE FUSE HOLDER A A A IGNITION SWITCH A A P2 A F P2 CONTROLLER BLACK POTTED BOX C THROTTLE BLOCK 12 AWG RED FUEL SOLENOID SHUT DOWN 12VDC OUTPUT E STOP BLK 12VD...

Page 87: ...86 MAYCO LS600P CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 WIRING DIAGRAM LOCATOR 2 EXTERNAL CONTROL BOX E A P F G C D E J K L M N O I H B T o o r d e r g o t o D i s c o u n t E q u i p m e n t c...

Page 88: ...PROXIMITY SWITCH A G F FLOW CONTROL NOT USED NOT USED NOT USED NOT USED A 12VDC OUT BLUE INDICATOR RED ACTIVE BETWEEN GND 800 mV A B A J4 MALE INTERFACE CONNECTOR WHITE 12 VDC 14 AWG RED 14 AWG BLACK...

Page 89: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

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