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manual LS600 PUMP —TRAILERHITCH ASSY
Models:
LS600
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Troubleshooting
Specs
Install
Parts list
Trailer to Tow Vehicle Wiring Diagram
Cylinder Cup Replacement Procedure
Warranty
Dimension
Maintenance
Connecting Trailer Lights
Page 100
Image 100
LS600 PUMP
—TRAILER
HITCH ASSY.
PAGE 100 — MAYCO LS600 PUMP — OPERATION AND PARTS MANUAL — REV. #4 (9/15/11)
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Contents
OPERATION AND PARTS MANUAL
MODEL LS600
SERIES
CONCRETE PUMP
Diesel engine exhaust and some of
NOTES
LS600 PUMP —TABLEOF CONTENTS
COMPONENT DRAWINGS
MAYCO LS600
CONCRETE PUMP
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Ordering parts has never been easier
Choose from three easy options
LS600 PUMP — SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY AND THE SAFETY OF OTHERS
LS600 PUMP — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEEDCONDITIONS
LS600 PUMP — RULES FOR SAFE OPERATION
GENERAL SAFETY
MAINTENANCE SAFETY
LS600 PUMP — RULES FOR SAFE OPERATION
TRANSPORTING
Towing
LS600 PUMP — RULES FOR SAFE OPERATION
BATTERY
EMERGENCIES
NOTES
LS600 PUMP — SPECIFICATIONS
TABLE 2. ENGINE SPECIFICATIONS
TABLE 1. PUMP SPECIFICATIONS
Displacement
LS600 PUMP — DIMENSIONS
TABLE 3. DIMENSIONS
DIMENSIONS
Figure 1. Dimensions
LS600 PUMP — IMPORTANT HAND SIGNALS
Figure 2. Operation Hand Signals
LS600 PUMP — GENERAL INFORMATION
CONCRETE MIX DESIGN
LS600 PUMP — GENERAL INFORMATION
REGIONAL DIFFERENCES
Figure 4. Pumping Cycle
LS600 PUMP — HOW IT WORKS
Figure 3. Pumping Cycle
LS600 PUMP — PUMP COMPONENTS
Figure 5. Major Pump Components
LS600 PUMP — PUMP COMPONENTS
LS600 PUMP — DIGITAL CONTROL PANEL COMPONENTS
input cable into this connector
11 7
various readout screens
LS600 PUMP — DIGITAL READOUT SCREEN
PRIMARY SCREEN Screen
Screen
SECONDARY SCREENS Screen
LS600 PUMP — ENGINE COMPONENTS
Figure 7. Deutz BF4L914 Diesel Engine Components
LS600 PUMP — INSPECTION
FUEL CHECK
WARNING - EXPLOSIVE FUEL
BEFORE STARTING
ENGINE OIL CHECK
LS600 PUMP — INSPECTION
HYDRAULIC OIL CHECK
Figure 13. Hydraulic Oil Filler Hole
LS600 PUMP — INSPECTION
Figure 14. Filling the Lubrication Box
LS600 PUMP — SET-UP
WARNING - REAR STABILIZER SAFETY
LOCATION OF PUMP
REAR STABILIZER JACKS
STARTING PROCEDURE
LS600 PUMP — START-UPPROCEDURE
St o p
LS600 PUMP — OPERATION
WARNING - SAFETY GLASSES
HOSE LUBRICATION
PUMPING
Figure 29. Hydraulic Oil Temperature Gauge
LS600 PUMP — OPERATION
CAUTION - HOSE/LINE BLOCKAGE
Figure 30. Accumulator Pressure Gauge
REMOTE CONTROL OPTIONAL
Radio Remote Control
Radio Remote Control Buttons Operation
LS600 PUMP — OPERATION
LS600 PUMP — OPERATION
Cable Remote Control
Cable Remote Control Operation
Figure 38. Cable Remote Control
LS600 PUMP — PUMPING INFORMATION
REMIXTURES
DOWNHILL PUMPING
VERTICAL PUMPING
SNAP-JOINTCOUPLINGS
LS600 PUMP — PUMPING INFORMATION
NEW PUMPS
CLEARING THE SYSTEM AFTER MIX SET UP
LS600 PUMP — PUMPING INFORMATION
WARNING - HOSE/LINE PRESSURE
CLEARING CONCRETE BLOCKAGE
“REVERSE” PUMPING PROCEDURE
SHUTTLE TUBE INSPECTION PROCEDURE
LS600 PUMP — PUMPING INFORMATION
CLEARING SHUTTLETUBE BLOCKAGE
CLEANING THE PUMP AND DELIVERY SYSTEM
LS600 PUMP — MAINTENANCE PUMP
DANGER - AMPUTATION RISK
LS600 PUMP — MAINTENANCE PUMP
WARNING - ACID CLEANING
HYDRAULIC OIL SYSTEM MAINTENANCE
WARNING - HYDRAULIC OIL
LS600 PUMP — MAINTENANCE PUMP
BATTERY MAINTENANCE
BRAKE SYSTEM
CAUTION - MASTER BRAKE CYLINDER
LS600 PUMP — MAINTENANCE PUMP
CAUTION - SAFETY GUIDELINES
CLEANINGTHE LUBRICATION BOX
CYLINDER LUBRICATION BOX
LS600 PUMP — MAINTENANCE PUMP
WEAR PLATE AND CUTTING RING
replace the rubber energizer ring
Figure A. Wear Plate and Cutting Ring
CYLINDER CUP REPLACEMENT PROCEDURE
LS600 PUMP — MAINTENANCE PUMP
DANGER - AMPUTATION RISK
LS600 PUMP — MAINTENANCE PUMP
Wear Plate and Ring Replacement Procedure
Wear Plate Installation
Wear Ring installation
LS600 PUMP — MAINTENANCE PUMP
WHEEL BEARINGS
EXTENDED STORAGE INSTRUCTIONS
PRESSURE TEST
LS600 PUMP — MAINTENANCE TRAILER
Manually Adjusting the Brakes
Trailer Brakes
Hydraulic Brakes
LS600 PUMP — MAINTENANCE TRAILER
Adjustable Channel
Wheel Hub Adjustment
Wheel Bearings Hubs
LS600 PUMP — MAINTENANCE TRAILER
Danger - Raising the Trailer
DANGER - Trailer Inspection
Torsion Suspension
LS600 PUMP —TRAILERSAFETY GUIDELINES
TRAILER SAFETY INFORMATION
Common Causes for Loss of Trailer
Trailer Towing Guidelines
LS600 PUMP —TRAILERSAFETY GUIDELINES
CAUTION - Local Towing Regulations
Driving Conditions
WARNING - Transporting Personnel
LS600 PUMP —TRAILERSAFETY GUIDELINES
Reporting Safety Defects
Inoperable Brakes, Lights or Mirrors
Trailer Towing Tips
LS600 PUMP —TRAILERSAFETY GUIDELINES
Trailer VIN Tag
LS600 PUMP —TRAILERSAFETY GUIDELINES
Electrical Connector
Safety Chains
Trailer Lighting and Braking Connector
LS600 PUMP —TRAILERSAFETY GUIDELINES
Figure 52. Ball Hitch Coupler Adjustable Tongue
Coupler Types
Ball Hitch Coupler
LS600 PUMP —TRAILERSAFETY GUIDELINES
WARNING - Defective Hitch Ball
WARNING - Uncoupled Hitch Ball
Figure 53. Ball Hitch Coupling Mechanism
LS600 PUMP —TRAILERSAFETY GUIDELINES
Attaching Safety Chain
WARNING - Safety Chains Rigging
Breakaway Brake System
LS600 PUMP —TRAILERSAFETY GUIDELINES
Connecting Trailer Lights
TIRE SAFETY
Uncoupling the Ball Hitch
LS600 PUMP —TRAILERSAFETY GUIDELINES
WARNING - Lug Nut Loosening
Determining Load Limit of Trailer
WARNING - Improper Lug Nut Torque
LS600 PUMP —TRAILERSAFETY GUIDELINES
Step
Step
Determining Load Limit of Tow Vehicle Step
LS600 PUMP —TRAILERSAFETY GUIDELINES
Uniform Tire Quality Grading Standards UTQGS
LS600 PUMP —TRAILERSAFETY GUIDELINES
Tire Safety Tips
Tire Repair
Replacing Worn or Damaged Tires
LS600 PUMP —TRAILERSAFETY GUIDELINES
WARNING - Flying Objects
Wheel Rims
Wheels, Bearings and Lug Nuts
Figure 60. Trailer to Tow Vehicle Wiring Diagram
LS600 PUMP —TRAILERSAFETY GUIDELINES
WARNING - Trailer Lights
LS600 PUMP — TROUBLESHOOTING PUMP
TABLE 9. PUMP TROUBLESHOOTING
DANGER - AMPUTATION RISK
WARNING - HYDRAULIC SYSTEM HAZARD
LS600 PUMP — TROUBLESHOOTING PUMP
TABLE 9. PUMP TROUBLESHOOTING CONTINUED
TABLE 9. PUMP TROUBLESHOOTING CONTINUED
LS600 PUMP — TROUBLESHOOTING PUMP
Problem
LS600 PUMP —TROUBLESHOOTINGENGINE
TABLE 9. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
LS600 PUMP —TROUBLESHOOTINGTRAILER BRAKE SYSTEM
TABLE 10. BRAKE SYSTEM TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
LS600 PUMP — TROUBLESHOOTING ELECTRICAL
TABLE 12. ELECTRICAL TROUBLESHOOTING
SOLUTION
PROBABLE CAUSE
LS600 PUMP — TROUBLESHOOTING ELECTRICAL
TABLE 12. ELECTRICAL TROUBLESHOOTING continued
SOLUTION
MALFUNCTION
LS600 PUMP — TROUBLESHOOTING ELECTRICAL
UNLOADER SOLENOID PROXIMITY SWITCH “B”
PROXIMITY SWITCH “A” THROTTLE INTERNAL SOLENOID
MAIN “A” SOLENOID MAIN “B” SOLENOID
LS600 PUMP — WIRING DIAGRAM CONTROL BOX
LS600 PUMP — WIRING DIAGRAM CONTROL BOX
CONNECTIONS TO J3 AND J4 CONNECTORS ON
LS600 PUMP — WIRING DIAGRAM CONTROL BOX
DIGITAL CONTROL BOX LS600
LS600 PUMP — WIRING DIAGRAM CONTROL BOX
RELAY K1
CONTROL BOX INTERIOR ENGINE START/SHUTDOWN RELAY
Figure 65. Engine Start/Shutdown Relay
Figure 66. Optional Hopper Vibrator Wiring
LS600 PUMP — WIRING DIAGRAM HOPPER VIBRATOR
Diagram
Figure 67. Hydraulic System Diagram
LS600 PUMP — HYDRAULIC SYSTEM DIAGRAM
MANIFOLD
MANIFOLD BLOCK PORTS
LS600 PUMP — MANIFOLD BLOCK PORTS
Figure 68. Manifold Block Ports
APPENDIX — CONCRETE MIX INFORMATION
APPENDIX — CONCRETE MIX INFORMATION
APPENDIX — SLUMPTEST PROCEDURE
Figure 69-C.SlumpTest Full-Overflow
Figure 69-A.SlumpTest 1/3 Full
Figure 69-B.SlumpTest 2/3 Full
NOTES
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
Figure 70. Recommended Shotcrete System
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
NO. PART NO
PART NAME
RECOMMENDED SHOTCRETE ACCESSORIES
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
HAS PASSED THROUGH THE ENTIRE HOSE LENGTH
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
PART NO
PART NAME
REMARKS
SAMPLE PARTS LIST
QTY. Column
NO. Column
PART NO. Column
LS600 PUMP — SUGGESTED SPARE PARTS
LS600
CONCRETE PUMP
1 Unit
LS600 PUMP — NAMEPLATE AND DECALS
LS600 PUMP — NAMEPLATE AND DECALS
PART NO
PART NAME
REMARKS
LS600 PUMP — NAMEPLATE AND DECALS
LS600 PUMP — NAMEPLATE AND DECALS
PART NO
PART NAME
REMARKS
LS600 PUMP — FRAME ASSY
LS600 PUMP — FRAME ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — AXLE ASSY. RIGHT/LEFT
LS600 PUMP — AXLE ASSY. RIGHT/LEFT
THE EXCEPTION OF THE BRAKE ASSEMBLY
PART NO
PART NAME
LS600 PUMP — BRAKE LINE ASSY
LS600 PUMP — BRAKE LINE ASSY
PART NO
PART NAME
34566
LS600 PUMP — BRAKE LIGHT ASSY
LS600 PUMP — BRAKE LIGHT ASSY
PART NO
PART NAME
29242
LS600 PUMP —TRAILERHITCH ASSY
PART NO
LS600 PUMP —TRAILERHITCH ASSY
PART NAME
LS600 PUMP — BATTERY ASSY
LS600 PUMP — BATTERY ASSY
PART NO
PART NAME
EM34506
LS600 PUMP — HOPPER ASSY
LS600 PUMP — HOPPER ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — HOPPER ATTACHMENT ASSY
LS600 PUMP — HOPPER ATTACHMENT ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — HOPPER INTERIOR ASSY
LS600 PUMP — HOPPER INTERIOR ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — SHUTTLE CYLINDER ASSY
LS600 PUMP — SHUTTLE CYLINDER ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — LUBRICATION PISTONS ASSY
LS600 PUMP — LUBRICATION PISTONS ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — LUBRICATION PISTONS ASSY
LS600 PUMP — LUBRICATION PISTONS ASSY
PART NO
PART NAME
492366
LS600 PUMP — FUELTANK ASSY
LS600 PUMP — FUEL TANK ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — HEAT EXCHANGER ASSY
LS600 PUMP — HEAT EXCHANGER ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — ACCUMULATOR ASSY
PART NO
LS600 PUMP — ACCUMULATOR ASSY
PART NAME
LS600 PUMP — REMIXER CONTROL ASSY
LS600 PUMP — REMIXER CONTROL ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — LUBRICATION PANEL
POSITION
LOCATION
LENGTH OF LINES
PART NO
LS600 PUMP — LUBRICATION PANEL
PART NAME
LS600 PUMP — ENGINE COVER ASSY
LS600 PUMP — ENGINE COVER ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — HYDRAULICTANK ASSY
LS600 PUMP — HYDRAULICTANK ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — ENGINE ASSY
LS600 PUMP — ENGINE ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — ENGINE AIR FILTER ASSY
LS600 PUMP — ENGINE AIR FILTER ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP —THROTTLEASSY
LS600 PUMP —THROTTLEASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — WATER SEPARATOR ASSY
LS600 PUMP — WATER SEPARATOR ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — HYD. PUMP ASSY
LS600 PUMP — HYD. PUMP ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — MANIFOLD ASSY
2 1 8 9 18 19
FRONT OF
MACHINE
LS600 PUMP — MANIFOLD ASSY
PART NO
PART NAME
REMARKS
LS600 PUMP — CONTROL BOX ASSY
CONTROL BOX ASSY
LS600 PUMP — CONTROL BOX ASSY
CONTROL BOX ASSY
PART NO
PART NAME
LS600 PUMP — CONTROL BOX HARNESSES ASSY
CONTROL BOX HARNESSES ASSY
LS600 PUMP — CONTROL BOX HARNESSES ASSY
CONTROL BOX HARNESSES ASSY
PART NO
PART NAME
LS600 PUMP — REMOTE CONTROL CABLE ASSY
REMOTE CONTROL CABLE ASSY
LS600 PUMP — REMOTE CONTROL CABLE ASSY
REMOTE CONTROL CABLE ASSY
PART NO
PART NAME
LS600 PUMP — HYDRAULIC STABILIZER ASSY. OPTIONAL
PART NO
LS600 PUMP — HYDRAULIC STABILIZER ASSY. OPTIONAL
PART NAME
TERMS AND CONDITIONS OF SALE — PARTS
SPECIAL EXPEDITING SERVICE
PAYMENT TERMS
FREIGHT POLICY
MECHANICAL DRIVE MODELS
MAYCO PUMPWARRANTY
HYDRAULIC DRIVE MODELS
HERE’S HOW TO GET HELP
NUMBER ON-HANDWHEN CALLING
Service Department
Warranty Department