model ls-60td - Multiquip Service &

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.
Proposition
65 Warning
LS-60TD
PUMP
— TABLE OF CONTENTS
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 DRA
WINGS
DRAWINGS
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
PAGE 4 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
www.multiquip.com
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Order via Internet (Dealers Only):
Best Deal!
Effective:
January 1st, 2006
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
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.*
Goto www.multiquip.com and click on
Order Parts to log in and save!
Note: Discounts Are Subject To Change
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
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
Order via Phone: Domestic (US) Dealers Call:
1-800-427-1244
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
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
❒
Specify Preferred Method of Shipment:
✓ UPS/Fed Ex
✓ DHL
■ Priority One
✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
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
TABLE 1. PUMP SPECIFICATIONS
Model
LS-60TD
Pumping Rate
Up to 60 cu. yds. per hour*
Pumping Method
Reciprocating Piston
Maximum Aggregate Size
1-1/2 in. minus (38mm)
Ver tical Pumping Height
Up to 250 ft. (76m)
Piston Face Pressure
950 PSI
Horizontal Pumping Distance
1000 ft. (305m)*
Cylinder Lubrication Box Capacity
2 Gallons (7.6 Liters)
Hydraulic Fluid Capacity
50 Gallons (189 Liters)
Fuel Tank Capacity
40 Gallons (76 Liters)
Hopper Capacity
10 cu. ft. with optional fwd/rev remixer
Material Hose
3 in., 4 in., 5 in. dia.
(76.2mm, 101.6 mm, 127 mm)
Engine Model
Deutz Turbo Diesel BF4L914
Weight (with fluids)
5,190 lbs. (2,354 kg)
Weight (dry/shipping)
4,760 lbs. (2,159 kg)
Tire Size
7.35 in. x 14 in. (187 mm x 356 mm)
Options
Wireless Remote Control, Hopper Screen Vibrator
*Volume output will vary depending on mix design, slump, line size used and job site condititons
TABLE 2. ENGINE SPECIFICATIONS
Model
Deutz BF4L914
Diesel Engine
Type
4 stroke, Air-cooled Diesel
No. of Cylinders
4
Bore x Stroke
4.19 in. x 5 in.
(106 mm x 127 mm)
Rated Output
99.9 HP@ 2350 rpm
Displacement
167 cu. in. (2.73 L)
Starting
Electric 12VDC
Lube Oil Capacity
9.5 gal. (2.5 liters)
Fuel Type
#2 Diesel Fuel
Battery
12V BCI Group 27
PAGE 6 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — DIMENSIONS
TABLE 3. DIMENSIONS
REF.
DIMENSIONS
A
43 in. (109.2 cm.)
B
173 in. (436.8 cm.)
C
24 in. (61 cm.)
D
70 in. (177.8 cm.)
E
68 in. (172.2 cm.)
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 pump. Refer
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.
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
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.
WARNING - EXPLOSIVE FUEL
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.
Diesel fuel is extremely flammable, and
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.
WARNING - BURN HAZARDS
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
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.
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)
LS-60TD PUMP — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep fingers,
hands, hair and clothing away from all
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.
CAUTION - RESPIRATORY HAZARDS
ALWAYS wear approved respiratory
protection.
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS wear approved eye and
hearing protection.
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.
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
serious injury or even death! This equipment is to be
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.
■ 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 respiratory (mask), hearing and
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.
■ 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 hot! components can
cause serious burns.
■ The engine section of this
pump requires an
adequate free flow of
cooling air. NEVER
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 DEADLY
carbon monoxide gas.
■ ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
■ ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool.
■ NEVER smoke around or near the
machine. Fire or explosion could result from
fuel vapors, or if fuel is spilled on a hot!
engine.
■ NEVER operate the pump in an explosive atmosphere or
near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
■ ALWAYS remove the ignition key when leaving the pump
unattended.
■ ALWAYS block the wheels on the unit when using on a
slope.
■ ALWAYS maintain this equipment in a safe operating
condition at all times.
■ ALWAYS stop the engine before servicing, adding fuel or
oil.
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 inexperienced and unauthorized people away
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.
■ Check all fasteners periodically for tightness. Also check
towing tongue bolt, lock nut and wheel lug nuts for wear.
■ Test the pump's ON/OFF switch. The purpose of this
test is to shut down the engine.
■ Refer to the DEUTZ Engine Owner's Manual for engine
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.
TRANSPORTING
■ 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.
Towing
■ 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, always have rear tail lights ON.
■ 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..
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.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 11
LS-60TD PUMP — RULES FOR SAFE OPERATION
BATTERY
EMERGENCIES
The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
■ ALWAYS know the location of the
nearest fire extinguisher.
■ ALWAYS know the location of the
nearest and first aid kit.
■ 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.
■ In emergencies always know the location of the
nearest phone or keep a phone on the job site.
Also know the phone numbers of the nearest
ambulance, doctor and fire department. This
information will be invaluable in the case of an
emergency.
■ ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
■ 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 clothing or skin, rinse skin or clothing
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.
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 Operating
Procedures 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.
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.
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.
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.
HIGH PRESSURE
OIL FROM PUMP
TO TANK
PROXIMITY
SWITCH
HYDRAULIC
CYLINDERS
SLAVE
Figure 5. Pumping Cycle 2
OIL
CONCRETE
CYLINDERS
A
B
SHUTTLE TUBE MOTION
PISTON
CUP
SHUTTLE TUBE
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.
6.
7.
Hopper Discharge Sleeve – Connect hoses or steel
pipes to the discharge sleeve for pouring concrete.
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.
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.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
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 50 psi cold
before operation. DO NOT bleed air from tires when
they are hot. Check inflation pressure weekly during
use to insure the maximum tire life and tread wear.
Battery – This unit uses a +12 VDC type battery.
ALWAYS use gloves and eye protection when handling
the battery.
Hydraulic Pump – This unit incorporates an axial
variable displacement hydraulic piston pump.
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.
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.
Remixer Control Lever – Controls the forward/reverse
motion of the hopper remixer paddles.
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.
Hydraulic Oil Tank/Cap– Remove cap to add hydraulic
fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if
level is low.
Accumulator Pressure Gauge– Used to monitor
accumulator pressure. Pressure should read at least
1750 psi for correct pump operation.
Pumping Pressure Gauge – Used to monitor pressure
in the concrete cylinders and shuttle tube.
Control Box – Contains the electrical components
required to run the pump. See Control Box Components
section for component callouts.
19. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell)
holds approximately 40 gallons (176 liters). DO NOT
top off fuel. Wipe up any spilled fuel immediately
20. Throttle Control 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. 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..
21. Stroke Volume Control Dial – Turns CW/CCW to
increase or decrease the number of strokes per minute
of the pump.
22. Lubrication Box – This box is empty when shipped
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.
23. Rear Running Lights – ALWAYS check and make sure
both the right and left running lights are functioning
correctly before towing the pump.
24. Remixer Motor – Drives the remixer paddles inside
the hopper. The motor direction is controled by the
remixer control lever.
25. Hopper/Hood – Lift hood to fill. Concrete from a RediMix 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.
26. Tow End Jack Stand – Use this jack stand to level
and support the tow end of the pump.
27. Air Filter – Prevents dirt and other debris from entering
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.
2.
3.
4.
5.
6.
7.
8.
9.
Emergency Stop Button – Press emergency stop
button to stop pump in an emergency. Turn knob counter
clockwise to disengage the stop button.
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.
Engine Tachometer – Monitors the engine RPM’s and
hours of operation for the engine.
Engine Hour meter – Display's the number of hours
the engine has been in use.
Pump Hour meter – Display's the number of hours
the pump has been in use.
Remote Cable Connector – Insert the remote control
input cable into this connector.
Battery Indicator Lamp– Indicates a low battery
charge. Replace or charge battery. NEVER operate the
pump when this lamp is on.
Oil Pressure Indicator Lamp – Indicates incorrect
operational pressure for running the pump. NEVER
operate the pump if this lamp is ON.
Direction Control Switch– This 2 position switch
controls the direction of flow for any mix in the pump.
The left most position sets the pumping direction to
forward and the right most position sets the pumping
direction to reverse.
10. Pumping Control Switch – This 3-position switch
controls the pumping of the pump. The right most
position is for use with the remote control unit, the left
most position is for normal pumping operation, and the
center most position (OFF) prevents pumping.
11. Cylinder Stroke Control Switch - This three position
switch controls the pumping function. The left most
position sets the pump to automatic cycling. Set the
switch to this position for normal pump operation.
The right most position changes the pump from
automatic to manual cycling. This allows the cylinders
to be manually cycled using the Manual Cylinder
Jogging Switch.
12. 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 (See Initial Start-up Procedure
section of this manual for testing procedure).
The left most position jogs Cylinder “A” and the right
most position jogs Cylinder “B”.
13. Accumulator Pressure Gauge - This gauge monitors
the internal pressure of the Accumulator tank. Normal
internal pressure should read approximately 1750 PSI
during pumping.
14. Main Pressure Gauge - This gauge monitors the
system pressure while pumping material. The maximum
pressure rating is 3200 PSI ± 50.
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.
3.
4.
5.
6.
Oil Filter – Prevents dirt and other debris from entering
the engine. Service the oil filter as recommended in
the maintenance section of this manual.
Crankcase Drain Plug – Remove this plug to drain
engine oil from the engine crankcase. For best results
drain engine oil when oil is warm.
Dip Stick – Remove dipstick to determine if the engine
oil level is low. If low add oil as specified in Table 4.
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.
V-Belt Cover – Remove this cover to gain access to
the V-belt. When replacing V-belt , use only
recommended type V-belt.
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.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 23
LS-60TD PUMP — INSPECTION
CAUTION - GENERAL SAFTEY GUIDELINES
FUEL CHECK
5.
NEVER operate the pump in a
confined area or enclosed area
structure that does not provide ample
free flow of air.
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 is extremely flammable, and
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.
ALWAYS wear approved eye and
hearing protection before
operating the pump .
NEVER operate the pumps's engine
with the engine hood removed. The
possibility exists of hands, long hair,
and clothing becoming entangled with
the V-belt, causing injury and bodily
harm.
NEVER place hands or feet inside the hopper .
ALWAYS make while the engine is running. ALWAYS
shut-down the engine before performing any kind of
maintenance service on the pump.
See Figures 6, 7, 8 for the location of any
control or component referenced in this
section.
Figure 9. Fuel Cap Gauge
BEFORE STARTING
1. Read safety instructions at the
beginning of manual.
6.
If fuel is low, remove fuel filler cap and fill with #2
diesel fuel (Figure 10).
2. Clean the entire pump, removing dirt and dust, particularly the engine cooling air inlet, and heat exchanger.
3. Check the air filter for dirt and dust. If air filter is dirty,
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 flammable and
can be dangerous if mishandled. DO NOT smoke while
refueling. DO NOT attempt to refuel mixer if the engine
is hot or running. ALWAYS allow engine to cool before
refueling.
Figure 10. Adding Diesel Fuel
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).
12 The oil listed in Table 4 is recommended to ensure better
engine performance. Use class CD or higher grade motor
oil.
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.
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 13. Hydraulic Oil Sight Glass
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
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 lubrication box. If low, fill
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.
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 cotter pin from the handle tee bolt eye,
and then pull the handle tee to release the stabilizer
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 insert handle tee bolt.
19. Insert the cotter pin into handle tee bolt eye to lock the
stabilizer stand.
Figure 15. Filling the Lubrication Box
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
4. Observe that the Battery and Oil Pressure status
indicator lights are ON (Figure 21).
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.
Figure 21. Status Indicator Lights
A. Turn the key to the START position and listen for
the engine to start.
B. In warm weather let engine warm-up for 5 minutes.
In cold weather let engine warm-up for 10 minutes.
C. The Oil Pressure and Battery indicator lights
(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.
Figure 19. Emergency Stop Switch
5. Turn the Cylinder Stroke Control switch (Figure 22) to
the AUTOMATIC position.
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 22. Cylinder Stroke
Control Switch (Automatic)
6. Place the Pumping Control Switch to the ON position
(Figure 23) for normal pumping operation. Place the
switch in the REM. position for remote control operation
of the LS-60TD pump.
Figure 20. Ignition Switch
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
counterclockwise (CCW) to release the volume control
knob.
A. Unlock the throttle cable. To unlock the throttle cable,
turn the inner most knob counter clockwise
(Figure 27.)
THROTTLE
ADJUSTMENT
KNOB (COARSE)
(PUSH/PULL)
UNLOCK
UNLOCKING
KNOB
LOCK
THROTTLE
ADJUSTMENT
KNOB (FINE)
(TURN CW/CCW)
Figure 24. Volume Control
8. Use the volume control, to set the pump volume to
approximately 10 strokes per minute. Turning the
volume control clockwise (CW) will decrease pump
volume,and counterclockwise (CCW) will increase
pump volume.
A thumping sound (cylinder stroke) should be heard.
The thumping sound represents the number of strokes
per minute (volume) of the pump.
Figure 27. Throttle Control Knob (Un-locking)
B. Push the outermost button (coarse adjustment)
inward, then pull outward until engine RPM reaches
desired speed (Figure 28).
C. Turn the unlocking knob (figure 28) clockwise to lock
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.
PUSH ALL THE WAY IN
TO IDLE ENGINE
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.
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).
EMERGENCY SHUTDOWN PROCEDURE
In the event of an emergency, to shut down the pump:
1. Depress the Emergency Stop Switch (Figure 19)
Figure 29. Accumulator
Pressure Gauge
12. Turn the Cylinder Stroke Control switch to the OFF
position (Figure 30). The pump is now ready to be
operated. Refer to the Operating Procedures section
of this manual for priming and operating instructions.
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 serious injury.
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 (Figure 31) to the
JOG possition.
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.
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).
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. ( Manually
operate the throttle when starting,
NOT REMOTELY)
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.
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, except
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.
Figure 32. Manual Cylinder Jogging Switch
13. The Pumping Pressure Gauge
(Figure 33) should read
approximately 3200 ± 50 PSI.
Figure 33. Pumping
Pressure Gauge
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.
5. Pour approximately two 5 gallon buckets of prime into
the first hose and connect it to the pump.
PAGE 30 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — OPERATING PROCEDURES
6. With the pump in FORWARD at 25-30 strokes per minute,
slowly discharge the concrete from the ready-mix truck
into the hopper and completely fill it. Keep the pump
running continuously until concrete is discharging at the
end of the delivery system. If the pump is stopped during
this procedure, a blockage may occur.
CAUTION - HOSE/LINE BLOCKAGE
If hoses or lines are blocked for any reason, or if the
lines are kinked when starting up or during the pumping
cycle, the pump pressure could straighten out the kink
or force out the blockage. This rapid surge of material
could cause the lines to whip or move in a manner
that could cause injury to personnel.
7. It is important that once the slurry procedure is
completed, and concrete is flowing through the hose,
DO NOT stop the pour until all the slurry is pumped out
and the concrete has reached the end of the hose. The
only time to stop the pump during the priming procedure
is if a blockage occurs.
8. If it is necessary to replace or add a section of delivery
system, after the initial lubrication procedure, wet the
inside area of the hose, pipe or elbow with 5 gallons of
water per 25 foot length, before adding it to the system.
WARNING - TRANSPORTING PUMP
It will be necessary at times to move your pump from
one job site location to another. Before moving the
pump, make sure to pump the remaining concrete out
of the hopper. Moving the pump with a full hopper of
concrete can cause severe damage or breakage of
the axle and axle springs, excess strain and pressure
on the hub and bearing assembly.
REMIXTURES
Remixtures that are designed into the concrete mix by the
redi-mix company or an architectural engineering company.
This section lists common admixtures and a brief explanation of their functions:
A. Pozzolith 300 – or the equivalent acts as a water
retarder and a lubricant. On a lean mix, long pushes,
stiff mixes, and vertical pushes, Pozzolith 300R
helps pumpability.
B. MBVR – air entraining, acts as a lubricant.
C. Calcium Chloride – commonly referred to as C.C.,
is used as an accelerator. When pumping a load with
calcium chloride, it is recommended that you wash
out if the waiting time between delivery trucks
becomes too long.
D. Super Plasticizers – acts as an accelerator. The
concrete will look very wet after the super plasticizer
is added, but will begin to set up very fast. Wash out
immediately if you do not have a truck waiting. Super
plasticizers are used mainly on commercial jobs.
E. Red Label – acts as a water retarder and an
accelerator. Red label will be used mainly on commercial jobs.
F. Fly Ash – is used to help increase the strength of
the concrete and decrease the cement content per
yard. This is one of the most common admixtures
used.
All admixtures will be shown on the redi-mix
concrete ticket. Before starting the pumping
job, ask the driver of the redi-mix truck to see
the concrete ticket and note the admixtures
that exist and take the proper action.
When pumping long distance or pumping stiff mixes, you can
expect a drop in volume compared to shorter lines and wetter
mixes due to the change in valve efficiency or cavitation.
Leaking manifold seals or hose coupling gaskets which leak water can cause separation
and subsequent jamming at that point.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 31
LS-60TD PUMP — OPERATING PROCEDURES
DOWN-HILL PUMPING
Down-hill pumping can be a difficult procedure on some jobs.
The slurry procedure would be the same as explained
PrimingThe PumpWith Slurry Mixture section of this manual.
It is suggested that a sponge approximately 2”x 4”x 6” in size
be placed in the hose before the start of pumping.
Wet the sponge before placing it in the hose to keep the slurry
from running too far ahead of the concrete, which will reduce
the possibility of separation. When the pump is stopped, the
material can flow slowly down, due to gravity, and cause the
hose to collapse.
When pumping is resumed, you can expect blockage at the
point of hose collapse. To prevent this from happening, the
hose can be “kinked off” at the discharge end when the pump
is stopped to prevent the gravity flow of the material in the
hose.
The use of stiffer mixes when pumping down-hill will decrease gravity flow of the material in the hose and will assure
a smoother operation between the cam roller bearing and
cam plate. As with any job, make sure that the hose and the
couplings are in good workable shape.
VERTICAL PUMPING
When pumping vertically up the side of a building, above 40
feet, we would recommend the installation of steel pipe
securely fastened at intervals as necessary to support the
pipe. Ninety degree, long radius pipe sweeps should be
installed at the top and bottom of the steel line.
Use a 25 ft. hose, or short section, off the pump; and for the
balance of the horizontal distance to the vertical line, use
steel pipe. This type of installation has been satisfactory on
many jobs being pumped in excess of 100 feet high. Line
pressures are always less using steel pipe as compared to
hose.
When pumping vertically, using all hose, it is recommended
not to go higher than 50 feet with hose. The hose should be
tied off at intervals of 10 feet, if possible. Special attention
should be given when tieing the hose off at the top as the hose
will have a tendency to stretch when filled with concrete. This
will increase the possibility of a blockage at the point where
the hose is tied off. To avoid this, a long radius of 90º elbow
is recommended. The suggested place to tie off is on the
hose, under the clamp.
It is strongly recommended that steel pipe be
used on all vertical pumping for safety and
convenience.
HOSE PULSATION
A slight pulsation of the hose will always be noticeable near
the pump. Excessive pulsation of the hose near the pump is
normally due to higher than average line pressures caused by
stiff, harsh mixes, or extremely long pumping distances.
The use of 2 -1/2” I.D. hose in these extreme cases reduces
line pressures or the addition of slight amounts of water to the
mix, if permissible, will permit easier pumping. The use of
certain pumping admixtures may help.
If excessive pulsation exists in the hose, it is advisable to
use burlap or some means of wear protection under the hose
at points where the hose may wear through the outer cover;
e.g. over forms, steel or sharp curbs.
SNAP-JOINT COUPLINGS
When using Snap-Joint couplings with gaskets to join hose,
see that they are washed clean after each job. Keeping the
hose ends clean (heavy duty) is very important for the best
job setup. A thin coat of grease on the rubber gasket or
dipping both coupling and gasket in water before coupling the
hose will make for easier installation.
NEW PUMPS
All new pumps are ‘water pressure tested” at the factory This
procedure permits a thorough inspection of entire drive
system and valving under simulated full load conditions. The
pump owner can do the same by making an adapter to couple
to the end of the discharge cone: e.g., the use of a standard
2" pipe cap with a 3/8" drilled hole in the center, screwed on
to the end of hinged cone or reducer at the pump.
Fill the hopper with water after making sure that all sand and
rock have been removed from manifold. Operate pump at full
throttle and the 3/8" diameter hole restriction will create
sufficient back pressure to make thorough inspection of all
moving parts.
PAGE 32 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — OPERATING PROCEDURES
THE EFFECTS OF HEAT AND EXCESSIVE
TIME ON CONCRETE:
Hot concrete, commonly referred to as a hot load, is concrete
that has been in the redi-mix truck in excess of 2 to 3 hours.
On a hot day, this amount of time is even less.
A brief explanation of why heat and time affect concrete:
Concrete starts setting by drying up through a chemical
reaction. The catalyst to this reaction is heat. When
pumping a hot load, it is important to remember that
when you have to stop pumping for any reason, add
water to the concrete in the hopper and hand mix and
move concrete in the hose every 5 minutes. If the shut
down time becomes too long, wash out immediately.
If it is necessary to wait 1/2 hour or more for another load
of concrete, to prevent setting of the mix in the system, it is
advisable to consider the following factors (A through D)
affecting the concrete :
A. How old is the concrete?
B. Is there an accelerator, calcium chloride, red label,
etc., in the concrete?
C. The temperature of the day, 80, 90, degrees?
D. How much system you have out and how stiff was
the mix you were pumping?
PREVENTING MIX SET-UP AFTER PUMP SHUTDOWN
When the pump is stopped for any reason during a pour; e.g.,
moving hose, waiting for redi-mix truck, the following suggestions are offered:
1. Leave the hopper full of concrete at the time of shutdown.
It is important not to let the redi-mix driver wash too
much water into the hopper, as this could cause separation of the concrete in the hopper.
2. If the shutdown period exceeds 2 to 3 minutes, 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.
3. If it is necessary to wait 10 minutes or more for another
load of concrete, it is wise to start the pump and pump
6 or 8 strokes every 5 minutes to prevent setting of the
mix in the system. If waiting time is excessive, it would
be wise to wash out the pump and hoses and start over
when the new truck arrives.
4.
When pumping stiff mixes and there is waiting time
between redi-mix trucks, it is advisable to add some
water to the last hopper of material and “hand mix” to
ensure an easier start with the following load.
5. When the pumping job requires a stiffer mix, the following
method is suggested for starting: Take a water hose with
a nozzle on it and apply water with a fine spray to the
concrete as it comes down the redi-mix chute into the
pump hopper after the slurry procedure is completed and
you are ready to start pumping.
Using this procedure will make it easier to pump through
the clean hose. Note: Once the concrete has reached the
end of the hose, do not apply any more water in this
manner as this procedure is used for starting only.
6. Hose sizing is very important: We strongly recommend
on harsh mixes, vertical pushes, stiff concrete, shotcrete,
long pushes, that a 2 -1/2” line be used as far as possible.
The advantages of using the 2 -1/2” line are improved
pumpability, less pumping pressure and less wear on the
pump.
7. Following the pump operation, proper wash out of all
materials or “build-up” within the pump manifold and
hoses will prevent problems when starting the next job.
8. A thorough inspection of the drive components and
greasing of all bearings after each job will ensure adequate lubrication and service to the pump which is
normally operating in wet, gritty conditions.
Over-greasing any bearing on your Mayco
pump will not damage the bearing.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 33
LS-60TD PUMP — OPERATING PROCEDURES
CLEARING THE SYSTEM AFTER MIX SET UP
If, for any reason, the mix should set up in the system, the
following procedure is suggested:
1. Disconnect the hose from the pump and wash the pump
out immediately.
WARNING - HOSE/LINE PRESSURE
When disconnecting hoses, use EXTREME
CAUTION! The hose is under pressure!
2
Reconnect the hose and fill the hopper with water.
3. Reconnect the hose and fill the hopper with water. DO
NOT try to push all the concrete out of all of the hose lines
at one time.
For example: If you had 200 ft. of system out, you would
disconnect each hose. Clean it out by pushing water
through the first hose off the pump, then continue
progressing through all the hoses, until all the system is
clean.
4. If waiting time is excessive, it would be wise to wash out
the pump and hoses and start over when the new truck
arrives. This can be avoided by being observant to the
pump and system, also taking into consideration the
above actors (A through D) affecting the mix.
CLEARING CONCRETE BLOCKAGE
WARNING - BLOCKAGES
If you repeatedly pull the throttle all the way out and
try to force your pump to push through blockages
due to separation of material in the hose or manifold,
you will soon have breakdowns and costly repairs which
are not covered under warranty.
If a blockage occurs, find where it is and clear it before
further pumping. DO NOT increase the engine speed
to clear the blockage. Increasing the engine speed
will only compound the problem.
If a blockage occurs in a hose, walk the hose until you find
the point of trouble. The hose will be soft immediately past the
blockage. To clear the blockage:
1. Disconnect the hose at the first coupling past the
blockage.
WARNING - HOSE LINE PRESSURE
Use extreme care! The hose line is under pressure
and can cause serious injury.
2. Elevate the hose at that point with the blockage area
hanging down.
3. Using a hammer, you can pound the down-stream edge
of the packed area until it is free to flow. Shake all of the
sand and gravel out to the end of the hose.
4. Before reconnecting the hose, start the pump and run a
small amount of concrete out to the end of the hose. This
will assure that all of the separation is out of the hose.
Damaged hoses with internal restrictions can
cause blockages.
PAGE 34 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — OPERATING PROCEDURES
CLEARING SHUTTLE TUBE BLOCKAGE
The shuttle tube is plugged if volume at the discharge end of
the hose stops and the hydraulic oil pressure gauge reads
3200 PSI or more.
To clear a plug in the shuttle tube, great care must be taken
as a dangerous condition will exist from pressure build-up
inside the shuttle tube. (With the shuttle valve, the concrete
can be pumped in reverse.) Use the following prodedures to
clear the shuttle tubes.
WARNING - SHUTTLE TUBES
DO NOT open any of the delivery system joint clamps.
E. Chip the concrete out of the reducer with the pry
bar.
F. Remove the reducer. From the discharge end, chip
the concrete out of the shuttle tube with the pry-bar.
If concrete cannot be loosened from the outlet of
the shuttle tube, remove the clean-out plug on the
bottom of the hopper to discharge the concrete.
G. Chip the blockage out with the pry-bar.
H. Flush the shuttle tube with water.
I. Before resuming operation of the pump, perform the
“Reverse” Pumping Procedure to relieve pressure
on the shuttle tubes.
“REVERSE” PUMPING PROCEDURE
A. Switch the pump into REVERSE. With pump speed
at a medium-slow (approx. 12 strokes per min.) try
to pull the “pack” back into the hopper with 5 or 6
reverse strokes.
B. Remix the concrete in the hopper.
C. Switch the pump into FORWARD. If it is still plugged,
repeat “Reversing” procedure three times.
If concrete still does not move, proceed to the Shuttle Tube
Inspection Procedure.
WARNING - ACCUMULATOR PRESSURE
Make sure the accumulator pressure gauge reads
ZERO psi. prior to performing any maintenance or
inspection.
SHUTTLE TUBE INSPECTION PROCEDURE
A. Stop the pump. Switch off the engine.
B The senior or most experienced operator must warn
all others to stand at least 20 feet away from the
machine and turn their heads to face away from the
pump.
C. The operator will position themself beside the
reducing elbow at the pump outlet. Wearing safety
glasses, slip the end of a pry bar (24" length of
reinforcing steel rod) under the latch of the hose
clamp and flip it up.
D. Carefully knock the end of the hose away from the
reducer.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 35
LS-60TD PUMP — OPERATING PROCEDURES
HOPPER REMIXER CONTROL
RADIO REMOTE CONTROL (OPTIONAL)
The Hopper Remixer Control lever is located to the left of
the Hydraulic Temperature gauge is (Figure 34).
The MAYCO LS-60TD Concrete Pump has a remote control
feature that allows the pump to be remotely controlled. If
desired, the pump can be operated via a receiver/transmitter
method (Figure 36) or a hardwire method, which utilizes a
25-ft. extension cable.
The manual remote cord (Figure 37) should be installed under
the main control box. Contact your MAYCO representative
for further information.
Figure 34. Hopper Remixer Control Lever
1. Push the Hopper Remixer Control lever DOWNWARD
(Figure 35) and observe that the blades (Figure 37) inside
the hopper are turning in a clockwise direction (forward).
Figure 36. Handheld Receiver/Transmitter
Figure 35. Hopper Remixer Blades (Rotation)
2. Push the Hopper Remixer Control lever UPWARD
(Figure 34) and observe that the blades (Figure 35) inside
the hopper are turning in a counter-clockwise direction
(REVERSE).
Figure 37. Handheld Remote Cable Unit
PAGE 36 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — TOWING SAFETY PRECAUTIONS
TOWING SAFETY PRECAUTIONS
CAUTION - LOCAL TOWING REGULATIONS
Check with your county or state safety towing
regulations department before towing your concrete
pump.
To reduce the possibility of an accident while transporting
the pump on public roads, always make sure that the trailer
and the towing vehicle are in good operating condition and
both units are mechanically sound.
The following list of suggestions should be used when towing
the pump:
■ Make sure that the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow the light tower's trailer with defective hitches,
couplings, chains etc.
■ CHECK the tire air pressure on both the towing vehicle
and the trailer. Also check the tire tread wear on both
vehicles.
■ ALWAYS make sure the trailer section of the pump is
equipped with a "Safety Chain".
■ ALWAYS attach trailer's safety chain to frame of towing
vehicle.
■ ALWAYS make sure that the vehicle and trailer directional,
backup, brake, and trailer lights are connected properly
and are working properly.
■ Remember in most cases the maximum speed unless
otherwise posted for highway towing is 55 MPH, however
before towing your pump, check your local state, and
county vehicle towing requirements. Recommended offroad towing is not to exceed 15 MPH or less depending
on type of terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Depending on soil conditions and location it may be
necessary to place support blocks underneath the trailer's
bumper to prevent tipping, while parked.
■ Inflate tires to correct pressure, inspect tires for cuts,
and excessive wear. See Table 5 (Tire Wear
Troubleshooting).
■ Check wheel mounting lug nuts with a torque wrench.
Torque wheel lug nuts as described in the "Lug Nut
Torque Requirements", Table 6.
■ Make sure brakes are synchronized and functioning
properly.
■ Check tightness of suspension hardware (nuts and bolts).
■ Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Retract wheel stand when transporting.
CAUTION - DAMAGED TRAILER COUPLER
If the trailer coupler is deformed replace entire coupler.
NEVER tow the pump with a defective trailer coupler.
There exist the possibility of the trailer separating from
the towing vehicle.
PUMP TRAILER VEHICLE CONNECTION
1. Check the vehicle hitch ball, and trailer coupler for signs
of wear or damage. Replace any parts that are worn or
damaged before towing.
2. Use only the 2-inch ball diameter with a towing capability
of 6,000 lbs. (2,720 kg) as indicated on the trailer's
coupler. Use of any other ball diameter will create an
extremely dangerous condition which can result in
separation of the coupler and ball or ball failure.
3. Be sure the coupler is secured to the hitch ball and the
lock lever is down (locked).
4. Attach safety chains as shown in Figure 40. Remember
to cross the safety chains.
5. After towing for about 50 miles recheck the entire towing
system for tightness.
RECOMMENDED MAINTENANCE
1. Smear ball socket and clamp face with chassis grease.
Periodically oil pivot points and wear surfaces of coupler
with SAE 30 W motor oil.
2. When parking or storing the concrete pump, keep the
coupler off the ground so dirt and other debris will not
build up in the ball socket.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 37
LS-60TD — TOWING INFORMATION
TOWING INFORMATION
CAUTION - TRAILER RELEASE LEVER
WARNING - LIFTING TRAILER TOUNGE
Use jack stand to lift tongue. DO NOT lift by hand as
back injury could result.
CAUTION - TRAILER BALL CAPACITY
The ball capacity must be greater than or equal to the
trailer GVWR. Do not use a worn hitch ball, it is unsafe
and must be replaced. USE 2" BALL ONLY
The release lever will close freely with finger pressure
when the ball is properly inserted into ball socket. If
the release lever does not close freely, do not tow the
pump. DO NOT force the release handle into the closed
position.
5. To make sure that the coupler is securely latched onto
the ball, extend the trailer tongue jack to the ground and
lift the truck and trailer combination 2" to 4". If the ball
does not disengage, the coupler is securely attached.
6. Insert a padlock or bolt through the lock hole for added
protection.
Take care not to damage the actuator when
backing up the towing vehicle for hook-up.
7. Connect the break-away cable solidly to the bumper or
frame of the tow vehicle as near to the center as possible.
The cable must hang clear of the trailer tongue and be
long enough to permit short radius turns without pulling
the breakaway cable forward.
1. Position actuator ball socket above 2" ball.
2. Hold the release lever in the open position (Figure 38).
3. Lower the trailer tongue until the ball rests in the ball
socket.
4. Close the release lever.
RELEASE LEVER
UNLOCK POSITION
(OPEN)
Check the location of the breakaway cable
periodically during each trip. The indicator
should rest against the rear stop. Accidental
application will cause the brakes to drag and
heat up, causing a failure.
Figure 38. Trailer Hitch Release Lever
PAGE 38 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD — TOWING INFORMATION
8. Test the brakes by pulling the emergency stop lever
(Figure 39) forward until it locks into its second notch
position. Attempt to rotate the wheels in a forward
direction.
If any wheels rotate, the brakes must be adjusted. Return
the emergecny stop lever to its release position to adjust
the wheel brakes. Repeat step 8 as needed until brakes
prevent all wheel movement.
EMERGENCY BRAKE LEVER
RELEASE POSITION
10. Retract the jack fully. Remove and store the caster, if
applicable.
11. Check for proper truck-trailer hook-up; the tow vehicle
and trailer should be level with a positive tongue load.
For further information, consult a dealer.
CAUTION - SHARP TURNS WHILE TOWING
Avoid sharp turns. This could bend, create extreme
stress or fracture either the actuator or trailer tongue.
Figure 39. Trailer Emergency Brake Lever
9. Cross the safety chains under the tongue and securely
attach them to the bumper or frame of the tow vehicle.
Check with local and state laws for proper compliance.
CAUTION - SAFETY CHAINS
Safety chains must ALWAYS be used.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 39
LS-60TD PUMP — TRAILER HITCH CONNECTIONS
Figure 40 shown below illustrates the typical towing
application that should be used when towing the pump.
Figure 40. Trailer Hitch Connections
PAGE 40 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MAINTENANCE (PUMP)
TABLE 5. MAINTENANCE CHECK SCHEDUAL
Daily
Engine Oil
Hourly Weekly Monthly
X
X
Engine Air Filter
X
Fuel Filter
X
Hydraulic Oil Level
erational
6-Months OpH
ours
500 hrs.
500 hrs.
X
Lubrication Box
X
Replace Hydraulic Oil
500 hrs.
Clean Hydraulic Filters
Axle Crank
X
2100 hrs.
X
Grease Hopper Discharge Outlet
X
2 hrs
Check System Pressure
X
40 hrs.
Check Hardware for Tightness
X
40 hrs.
Check Cutting Ware Ring
X
Check Trailer Brakes Function
X
Check Brake Lights
X
Check Tire Conditions
X
Inspect Saftey Devices / Decals
X
Check Wheel Bearings
X
Check Battery
X
Inspect Brake Lining
Visually Check for Oil Leaks
X
X
Main Hydraulic and Shuttle
Cylinders
DANGER - AMPUTATION RISK
You will be required to put your hand in the concrete
cylinders or near the shuttle tube. You are at
EXTREME RISK of injury or AMPUTATION if the
engine is running or if pressure is in the hydraulic
system.
Prior to performing any maintenance on the pump, stop
the engine by turning off the ignition switch and remove
the starter key. Place a “DO NOT OPERATE” tag
over the switch and disconnect the battery. The
pressure reading on the accumulator pressure gauge
MUST read ZERO. ALWAYS relieve the accumulator
circuit to zero pressure
prior to performing any
maintenance on the
pump.
X
CLEANING THE PUMP AND DELIVERY SYSTEM
Cleaning the pump is a very important operation as it
determines how the machine will pump the next time it is
used.
At the end of every pour, or because of long delays during a
pour, the pump and delivery system must be thoroughly
cleaned by removing all concrete material.
1. Following the Clearing Concrete Blockage operating
procedure, ensure that there is no blockage in the hose
and line or in the shuttle tube (using the Shuttle Tube
Inspection Procedure). If a blockage exists, clear it.
2. Pump concrete until the opening of the concrete cylinder
intake in the hopper is visible.
3. Stop the pump.
4. Carefully disconnect the first hose joint at the shuttle
tube discharge elbow.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 41
LS-60TD PUMP — MAINTENANCE (PUMP)
5. Add water to the hopper. Pump and flush clean the entire
hopper, shuttle tube and discharge elbow with water.
6. Scoop out 12 inches of concrete from the inboard end
of the delivery hose. “Cork screw” a 6" x 6" x 8" sponge
into the end of the first hose section. Reconnect the
hose to the discharge elbow.
7. Fill hopper with water. Pump until sponge and clean water
come out the discharge end of the hose and line system.
8. When the pump has been used to pump small aggregate
concrete (pea rock, ½" minus) or mixes with high fines
content (60% or more sand) there will be a tendency for
hardened concrete to build up on the inside surface of
the shuttle tube. Therefore, at the end of every such
pour, after the pump and system have been cleaned
and the engine shut off, remove the shuttle tube
inspection plate (follow the Shuttle Tube Inspection
Procedure) and remove all remaining concrete.
9. When the pump has been used to pump large aggregate
concrete (¾" to 1 ½") follow the instructions in step 8
once per week.
WARNING - ACID CLEANING
NEVER use muriatic acid to clean the pump. Acid will
dissolve the chrome finish on material cylinder bore and
main hydraulic cylinder rods.
Use only a 2½" diameter clean-out hook when
back-pumping into redi-mix truck. Use a
safety chain to secure the clean-out hook to
some solid part of the mixer truck to prevent
hook from jumping off of the drum. Run the
pump at 6 strokes per minute maximum
speed.
Deutz Model BF4L914 Diesel Engine
This pump is equipped with a Deutz BF4L914 turbo diesel
engine. For information concerning the procedure in checking,
removing, cleaning, etc. of the various engine parts or any other
information on the engine not contained herein, refer to the
engine manufacturer’s instruction manual.
HYDRAULIC OIL SYSTEM MAINTENANCE
The Mayco pump is equipped with an in-tank return hydraulic
filter with a 10 micron cleanable filter. The element has been
designed to remove all particles large enough to cause wear
and job break down. Under normal conditions, we recommend
replacement every 6 month.
The most important factor to keep in mind is the effect of
cold weather on the hydraulic oil. The viscosity (thickness)
of the hydraulic oil will be much heavier.
ALWAYS run machine until oil temperature reaches a
minimum of 50°F. before pumping. Damage to the main piston
pump will occur if the machine is cycled too fast before the
oil temperature reaches the minimum of 50°F. Cycle the
machine at 6-8 strokes per minute at approximately 1/3
throttle.
In areas where the weather normally remains under 50°F.,
use Shell Oil Tellus 46 (or the equivalent). The above steps
must be followed or severe damage to the main axial piston
pump can occur.
1. When changing the hydraulic oil or topping off the
reservoir, use only the following type.
(Reservoir capacity - 50 gal.)
Hydraulic oil: Shell Oil Tellius 68 or
Mobil DFE 26
Texaco Rand HDC
WARNING - HYDRAULIC OIL
DO NOT mix oil brands! This may impair quality.
2.
■
Lubrication: Grease daily/Hour
(Recommended after each Pour)
Main hydraulic cylinders
- 2 Place
■
■
■
Axle crank
Suttle cylinders
“S” tube outlet flange
Grease Type:
- 1 Place
- 2 Place
- 3 Place
Lithium Based EP
Texaco Multitak 20
Lubriplate ED-2
PAGE 42 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MAINTENANCE (PUMP)
BATTERY MAINTENANCE
CAUTION - BATTERY MAINTENANCE SAFETY
Wear safety glasses or face mask ,
protective clothes, and rubber gloves when
working with battery.
Mishandling of the battery shortens the service life of the
battery and adds to maintenance cost. When handling the
battery do the following:
 Be careful not to let the battery electrolyte come in
contact with your body or clothing.
 Always wear eye protection and rubber gloves, since
the battery contains sulfuric acid which burns skin and
eats through clothing.
 Always check the battery terminals periodically to
ensure that they are in good condition.
 Use wire brush or sand paper to clean the battery
terminals.
 Always check battery for cracks or any other damage.
If white pattern appears inside the battery or paste has
accumulated at the bottom, replace the battery.
 If the pump will not be in operation for a long period of
time, store in cool dry place and check the battery charge
level every month to maintain the performance of the
battery.
 Check the battery regularly and make sure that each
electrolyte level is to the bottom of the vent well
(Figure 41). If necessary add only distilled water in a
well-ventilated area.
BRAKE SYSTEM
The brake system should be periodically checked. Look for
fluid leaks worn or cracked hoses. Check the reservoir for
proper fluid levels. The Atwood surge brake should be
checked for damage. Make sure that all links and pivots are
kept lubricated. See Figure 16 for troubleshooting tips.
1. Keep all links and pivots lubricated to prevent rusting
and ensure ease of operation. Using SAE 30 oil, lubricate
inside the release handle and inside the actuator body.
This can be reached from the underside of the actuator.
Lubricate the hitch ball with conventional
automotive grease or a lubricant made for
hitch balls.
2. Check for any leaks in the brake system. Periodic checks
should be made on all hoses to guard against cuts and
worn hoses which may cause failure (leaks, rupturing
under pressure, and collapsing). Replace defective hoses.
CAUTION - MASTER BRAKE CYLINDER
DO NOT fill the master cylinder reservoir with used
brake fluid. DO NOT fill the reservoir beyond ½" from
top. DO NOT overfill; brake fluid will damage paint.
3. Check the brake fluid level in the master cylinder reservoir.
Keep it filled to within ½" from the top of the reservoir.
4. At the beginning of each year, inspect the brakes for
excessive wear, replace the linings if necessary.
Wheel bearings and seals should be inspected
and packed at this time.
Figure 41. Battery Electrolyte Levels
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 43
LS-60TD PUMP — MAINTENANCE (PUMP)
CYLINDER LUBRICATION BOX
ACCUMULATOR CIRCUIT
WARNING - FREEZING CONDITIONS
DANGER - ACCUMULATOR CHARGING
When using the pump during freezing conditions,
completely drain the water box and cover the hopper
after pumping. Frozen liquid will restrict the piston travel
and cause severe damage to the pump.
Improper accumulator charging can result in an
explosion causing serious injury or death! NEVER use
oxygen or compressed air to charge the accumulator!
Only qualified personal should perform this procedure.
Use only dry nitrogen to
charge the accumulator.
Contact your Mayco
service department or your
local Hydac representative
for proper charging
procedure.
CAUTION - SAFETY GUIDELINES
Before checking lubrication level, stop the engine and
remove the engine starter key.
1. The lubrication level should be checked everyday prior
to pumping and maintained at a height of 5 inches or
about ½ the concrete cylinder height. We recommend
using a SAE 30 weight motor oil.
2. As the rubber piston cups naturally wear, fine cement
particles will accumulate in the box. Once the concrete
paste reaches a height of about ½ inch from the bottom
of the box, drain and clean the lubrication box.
CLEANING THE LUBRICATION BOX
1. Remove the top cover and the drain plug (Figure 47)
located at the bottom of the box and fully drain the inside
of the box.
2. Once the box is drained, start the engine and stroke the
cylinder (keep hands out of box) ten to fifteen times.
3. While stroking, spray water inside of the box to
thoroughly clean out all contamination (Figure 42).
4. When the box is clean replace drain plug, add new
lubrication and install the top cover.
The accumulator circuit has two functions in the hydraulic system.
■
The accumulator circuit furnishes the hydraulic pressure
to cycle the shuttle tube.
■
The accumulator circuit also furnishes the pilot pressure
necessary to activate the hydraulic system.
The accumulator circuit is equipped with a
bladder type accumulator (Figure 43)
charged with 1100 PSI of dry nitrogen. The
accumulator stores one gallon of hydraulic
oil, which is, under 1750 PSI of pressure.
Figure 43. Accumulator
When the pump cycles, a part of the stored oil is released
to the shuttle cylinder. This pressure release assures the
shuttle tube has enough force to shear the cylinder of
concrete passing from the concrete cylinder to the concrete
delivery line during the cycle phase.
CHECKING ACCUMULATOR BLADDER PRESSURE
The normal accumulator charge pressure should be
approximately 1100 PSI. To check the accumulator pressure:
1. Start the engine and stroke the pump. The accumulator
pressure gauge (Figure 29) should read 1750 PSI.
Figure 42. Cleaning the Lubrication Box
2. To determine the actual accumulator PSI, stop the
engine and observe the pressure gauge. As the PSI
reading slowly decreases, it will reach a point where
there will be a sudden drop in the PSI. The PSI reading
should be taken just prior to this sudden drop. If you do
not read 1100 PSI, the accumulator may require charging
or bladder replacement.
PAGE 44 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MAINTENANCE (PUMP)
CHANGING THE CONCRETE CYLINDER PISTON CUPS
6.
The Rubber piston cups will occasionally require replacement
depending on the following factors.
■ The fluid level and cleanliness of the lubrication box.
7.
■ The size and type of aggregate.
■ The type of concrete being pumped.
It is time to replace the cups when increasingly large particles
of sand and cement pass into the lubrication box. Do not
allow the cups to become so worn that they begin to pass
lubrication into the material cylinders. If the liquid level of
the lubrication box becomes to low, the rubber cups will
severely deform due to excessive heat. Whenever
replacement is due, both cylinder cups should be replaced.
WARNING - AMPUTATION RISK
To prevent accidental cylcling of any pump
components, ALWAYS relieve the accumulator circuit
to ZERO pressure prior
to performing any
maintenance on the
pump.
8.
Remove the three 3/8 – 16 x 3” bolts from the piston.
Remove the front faceplate.
Install two the 3/8’ 16x3” bolts back into the piston –
do not tighten. Use the two bolts as leverage to remove
the rubber piston cup and rear components.
Obtain two 3/8 16x7” full thread studs (these studs will
be used to assist in assembly alignment) insert the
two studs into the piston adapter. Coat the concrete
cylinder with grease.
9.
The new “O” ring must now be modified. Using a sharp
knife cut four oil passage grooves into the ring. the
grooves should be placed at a distance of 90o apart.
The cut should be a v-shaped design, 0.059” deep and
0.157” wide at the top.
10. Install the “O” Ring around the oiler plate. Install the
plate into the concrete cylinder utilizing the studs for
alignment.
Felt ring must be saturated with 30 wt. oil
prior to installation.
CYLINDER CUP REPLACEMENT PROCEDURE
1.
Remove the two hydraulic hoses connected to the remix
motor. Plug the ports with fittings(not provided) to
prevent hydraulic hose leakage.
2.
Remove the hopper discharge nipple and loosen sleeve
seal. Inspect and replace if wear is excessive.
3.
Remove the two tie rod nuts and the four eyebolt nuts
securing the hopper to the pump frame.
4.
Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.
5.
Start the engine and turn on the pressure test switch.
Cycle pump in reverse until hydraulic system obtains
maximum pressure, then turn pump and engine
off.
Remove ignition key and disconnect battery. Think
safety! Check the hydraulic gauges on panel and make
sure accumulator pressure reads zero. One piston
should be in the fully discharged position at the end of
the concrete cylinder.
11. Install the felt holder over the oiler plate. Install felt ring
into felt holder. Install the bronze ring.
12. Using silicon sealant place a small bead of sealant
material on the front of the rubber piston cup and the
rear of the face plate. Install over alignment studs and
into concrete cylinders.
13. Insert one 3/8” 16x3” bolt into the open bolt hole, remove
the alignment studs one at a time and install the
remaining 3/8” 16x3” bolts.
Before installing 3/8” bolt, coat the back of
bolt heads with silicon sealant. Torque all three
bolts equal at 55 ft. lbs. each.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 45
LS-60TD PUMP — MAINTENANCE (PUMP)
CHANGING THE WEAR PLATE AND RING
Wear Plate Installation
Due to the swinging motion of the Nun-plate and the abrasive
nature of concrete, it is normal for the cutting ring to wear on
the side that shears through the concrete inside the hopper.
If the wear ring and wear plate do not fully seat against each
other the concrete slurry will pump into the hopper. This
condition can be easily observed by the sudden change of
the level of concrete inside the hopper during each stroke.
Wear Plate and Ring Replacement Procedure
1.
2.
1.
2.
3.
4.
5.
Remove the two hydraulic hoses connected to the remix
motor. Plug the ports with fittings(not provided) to
prevent hydraulic hose leakage.
Remove the hopper discharge nipple and loosen sleeve
seal. Inspect and replace if wear is excessive.
Remove the two tie rod nuts and the four eyebolt nuts
securing the hopper to the pump frame.
Install the two cylinder “O” rings.
Using silicon sealant, coat the circumference of the
concrete cylinders, the back of the wear plate and around
the five bolt holes. Next, install the wear plate and the
five bolts. The bolts must all be equally snugged and
tightened to 100 foot pounds each.
Wear Ring installation
1. Install the wear ring into the nun plate.
2. Install the steel insert ring inside of the rubber energizer
ring.
3. Install the energizer ring assembly into the nun-plate.
After installing the above mentioned components the
machine can be re-assembled by reversing steps 1 through
5 of the Wear Plate and Ring Replacement Procedure.
Using an approved lifting device, remove the hopper
using extreme care not to damage the hopper seal.
HEAT EXCHANGER COOLING FAN
Remove the four 1/2” 1-¼” bolts that hold the shuttle
tube to the nun-plate and remove shuttle tube.
This section is intended to make sure the fan is working
properly. Under normal conditions the fan should be running
any time the engine is turned on.
Using two small pry bars remove the rubber energizer
ring, steel insert ring and wear ring.
CAUTION - HYDRAULIC OIL TEMPERATURE
The energizer ring and wear ring will
normally have concrete contamination
holding them in position. It will be required
to chip some of the concrete loose to better
expose the energizer ring.
6.
7.
If the hydraulic oil temperature exceeds 170 degrees
fahrenheit, shut down the pump. DO NOT continue to
operate the pump. Failure to shut down the pump will
result in severe damage to the pump.
Clean out all concrete build up in and around the nunplate area with a wire brush.
Inspect the wear components for indications of wear.
The wear plate has two wear surfaces.
PAGE 46 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MAINTENANCE (PUMP)
WHEEL BEARINGS
EXTENDED STORAGE INSTRUCTIONS
After every 6 months of operation inspect the wheel bearings.
Once a year, or when required, disassemble the wheel hubs
remove the old grease and repack the bearings forcing grease
between rollers, cone and cage with a good grade of high
speed wheel bearing greases (never use grease heavier than
265 A.S.T.M. penetration “No. 2.”).
1. Fill the wheel hub with grease to the inside diameter of
the outer races and also fill the hub grease cap.
The following preventative maintenance is recommended
for extended periods of storage.
1. Check brake system for proper fluid level in master
cylinder and bleed all lines.
2. Lubricate all links and pivots to prevent any rusting.
2. Reassemble the hub and mount the wheel. Then tighten
the adjusting nut, at the same time turn the wheel in
both directions, until there is a slight bind to be sure all
the bearing surfaces are in contact.
3. Back off the adjusting nut 1/6 to 1/4 turn or to the nearest
locking hole or sufficiently to allow the wheel to rotate
freely within limits of .001” to .010” end play. Lock the
nut at this position.
4. Install the cotter pin and dust cap, and tighten all
hardware.
3. Remove wheel and drum assemblies and spray a good
anti-corrosion compound (CRC formula 5-56) under rubber
boot on forward end of brake wheel cylinder. Avoid
spraying drum and brake lining.
4. Grease all bearings and reinstall wheel and drum
assemblies.
5. Make sure breakaway cable is fully released.
6. After extended storage, refer to the Maintenance Steps
listed above to insure that the trailer is ready for towing.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 47
LS-60TD PUMP — MAINTENANCE (TRAILER)
TRAILER SAFETY PRECAUTIONS
CAUTION - TRAILER INSPECTION
ALWAYS make sure that the trailer is in good
operating condition. Check the tires for proper inflation
and wear. Also check the wheel lug nuts for proper
tightness.
This section is intended to provide the user with trailer
service and maintenance information. Remember periodic
inspection of the trailer will ensure safe towing of the
equipment and will prevent damage to the equipment and
personal injury.
It is the purpose of this section to cover the major
maintenance components of the trailer. The following trailer
components will be discussed in this section:
■ Tires
■ Lug Nut Torquing
■ Suspension
■ Electrical
The following list defines the major trailer components:
1. Frame Length – This measurement is from the ball hitch
to the rear bumper (reflector).
3. Frame Width – This measurement is from fender to
fender.
4. Jack Stand – Trailer support device with maximum
pound requirement from the tongue of the trailer.
5. Coupler – Type of hitch used on the trailer for towing.This
unit employes a 2" ball.
6. Tires Size – Indicates the diameter of the tire in inches
(10, 12, 13, 14, etc. ), and the width in millimeters (175,
185, 205 etc.). The tire diameter must match the
diameter of the tire rim. This unit employes 7.35" X 14"
tires.
8. Wheel Hub – The wheel hub is connected to the trailer's
axle.
9. Tire Rim – Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
10. Lug Nuts – Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug nuts.
See Table 7and Figure 38 for lug nut tightening and
sequence.
11. Axle – This trailer employes a torsion bar type suspension, which can support 6,000 lbs.
12. Electrical – Electrical connectors (looms) are provided
with the trailer so that brake lights and turn signal lights
can be connected to the towing vehicle. See Figure 40 for
proper wiring connections.
WARNING - SAFETY GLASSES
ALWAYS wear safety glasses
when removing or installing
force fitted parts. Failure to
comply may result in serious
injury.
SUSPENSION
The torsion bar suspension and associated hardware
(Figure 44) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
immediately.
7. Tires Ply – The tire ply (layers) number is rated in letters;
2-ply, 4-ply, 6-ply, 8-ply, 10-ply etc. This unit employes
6-ply tires.
Figure 44. Torsion Bar Suspension Components
PAGE 48 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MAINTENANCE (TRAILER)
TRAILER ACTUATOR
TIRES/WHEELS/LUG NUTS
The following maintenance steps should be performed
before towing the pump:
Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
1. Frequently check actuator brake fluid levels. (Fluids
must be approved, clean, and uncontaminated). Use
DOT 3 or 4 brake fluid.
2. Make sure actuator mounting bolts and coupler bolts
are secure.
3. Periodically check the brake system as descrubed in
the brakes owner’s manual. Consult certified brake
specialists to make necessary adjustments or repairs.
Failure to do so could result in loss of braking capabilities.
CAUTION - TRAILER WHEEL MAINTENANCE
DO NOT attempt to repair or modify a wheel. DO
NOT install an inter-tube to correct a leak through
the rim. If the rim is cracked, the air pressure in the
inter-tube may cause pieces of the rim to explode
(break-off) with great force and can cause serious
eye or bodily injury.
Servicing the Actuator Emergency Lever
If the actuator emergency lever is applied, disengage
using a screwdriver to lift upward on the front of the flat
emergency lever spring while pulling the lever forward until
it has been released.
Replace damaged parts as follows:
1. Remove the Master Cylinder and Push Rod Assembly.
Be careful not to get dirt into the master cylinder. A
new Master Cylinder Gasket should be used when reinstalling.
2. Remove the Cable S-hook from the Emergency Lever,
the Emergency Lever Guide, and the Flat Emergency
Lever Spring, then pull the lever out of the actuator
outer case through the cross-slot at the top of the
case.
3. Install a new emergency lever through the cross-slot
in the actuator casing. Attach a new emergency lever
spring and emergency lever guide.
4. Install a new master cylinder gasket to the master
cylinder. Put the push rod assembly and master
cylinder back into the outer case of the actuator.
5. Set the S-hook onto the emergency brake cable and
insert into the emergency lever. Squeeze the s-hook
shut to secure it to the lever.
TIRES WEAR/INFLATION
Tire inflation pressure is the most important factor in tire
life. Pressure should be checked cold before operation. DO
NOT bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 6 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
TABLE 6. TIRE WEAR TROUBLESHOOTING
CAUSE
WEAR PATTERN
SOLUTION
Center Wear
Over Inflation
Adjust pressure to
particular load per
tire manufacturer.
Edge Wear
Under Inflation
Adjust pressure to
particular load per
tire manufacturer.
Side Wear
Loss of chamber
or overloading.
Make sure load does
not exceed axle rating.
Align wheels.
Toe Wear
Incorrect toe-in
Align wheels.
Cupping
Out-of balance
Check bearing adjustment and balance tires.
Flat Spots
Wheel lockup &
tire skidding.
Avoid sudden stops
when possible and
adjust brakes.
6. Add adequate brake fluid to the master cylinder and
bleed the brake system.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 49
LS-60TD PUMP — MAINTENANCE (TRAILER)
LUG NUT TORQUE REQUIREMENTS
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 45. DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 7.
TABLE 7. LUG NUT TORQUE REQUIREMENTS
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
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
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
NEVER use an pneumatic air gun to tighten
wheel lug nuts.
Figure 45. Wheel Lug Nuts Tightening Sequence
PAGE 50 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — WIRING DIAGRAM (TAIL LIGHTS)
Figure 46. Trailer Tail Lights Wiring Diagram
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 51
LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)
Figure 47. Control Box Wiring Diagram
PAGE 52 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)
Figure 47. Control Box Wiring Diagram
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 53
LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)
Figure 48. Control Box Wiring Diagram
PAGE 54 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — WIRING DIAGRAM (CONTROL BOX)
Figure 48. Control Box Wiring Diagram
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 55
LS SERIES PUMP — WIRING DIAGRAM (TERMINAL BLOCKS TO COMP.)
Figure 49. Terminal Blocks to
Computer Wiring Diagram
PAGE 56 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS SERIES PUMP — WIRING DIAGRAM (OPTIONAL HOPPER VIBRATOR)
Figure 50. Hopper Vibrator
Wiring Diagram (Optional)
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 57
LS-60TD PUMP — WIRING DIAGRAM (START/SHUTDOWN SOLENOID RELAY)
Interior of Control Box
Figure 51. Start/Shutdown Solenoid Relay Diagram
PAGE 58 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HYDRAULIC SYSTEM DIAGRAM
Figure 52. Hydraulic System Diagram
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 59
LS-60TD PUMP — MANIFOLD BLOCK PORTS
MANIFOLD BLOCK PORTS
ACC
Connect to Accumulator Tank, Hose A
A1
Connect to Shuttle Cylinder, Hose T
A2
Connect to Hydraulic Cylinder, Hose I
B1
Connect to Shuttle Cylinder, Hose U
B2
Connect to Hydraulic Cylinder, Hose J
GA
Connect to Accumulator Gauge, Hose D
P1
Connect to Secondary Hyd. Pump, Hose E
P2
Connect to Flow Control Valve, Hose K
T1
Connect to Hydraulic Tank, Hose G
T2
Connect to Heat Exchanger, Hose L
T3
Connect to Tank, Relief Heat Exchanger, Hose H
Figure 53. Manifold Block Ports
PAGE 60 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
APPENDIX — CONCRETE MIX INFORMATION
The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to
help create a better understanding of the importance of uniform gradation and proportioning of materials which affect
pumpability of concrete mixes. These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock
ratio can be adjusted (65% sand 35% rock) and pumpability should be excellent.
EXAMPLE #1 (A California Test Lab. Report)
JOB: Building Foundations (Water Project)
Sacks per cu./yd.
Gallons per sack
Washed Sand-#200 wash
6.5 designed for 2,500 lbs. in 28 days
7.1
1.3
Organic matter-OK
Specific gravity (SSD)
Sand-2.58; Pea Gravel-2.60
Sieve analysis-percent passing
Material
W.C. Sand
1.5”
1”
3/4”
Pea Gravel
% Comb.
3/8”
100
#4
99.7
#8
79.1
#16
60.4
#30
36.5
#50
14.3
#100
4.0
#200
1.1
100
100
3.0
66
51
39
23
9
3
1.0
DESIGN FOR ONE YARD OF CONCRETE (SATURATED & SURFACE DRY):
Absolute volume of aggregate in one cu. yard:
Specific gravity of aggregates in one cu. yard:
17.78 cu. ft.
2.58
Weight of aggregates in one cu. yard batch:
2850 lbs.
W.C. Sand
PEA GRAVEL
WATER 46 gal.
%
65
BATCH
1800
SPEC. GRAVITY
2.58
ABS. VOL.
11.56
35
1000
1
2.60
6.22
CEMENT 6.5 sk.
TOTAL
ADMIXTURE:
611
None
SLUMP
REMARKS
4”
This mix designed for pumping
NOTE:
Due to the availability of well-graded sand as shown in the above sieve analysis,
this mix pumped very successfully.
27.00
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 61
APPENDIX — CONCRETE MIX INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
PAGE 62 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
APPENDIX — SLUMP TEST PROCEDURE
1. To obtain a representative sample (concrete), take
several samples at three or more regular intervals
throughout the discharge of the mixer or truck. DO
NOT take samples at the beginning or end of the
discharge.
2. Dampen the inside of the cone and place it on a
smooth, moist, nonabsorbent, level surface large
enough to accommodate both the slumped concrete
and the slump cone. Stand on the “foot pieces”
throughout the test procedure to hold the cone firmly
in place.
3. Fill the cone 1/3 full by volume (Figure 54-A) and rod
25 times with a 1/2” dia x 24” lg. bullet-pointed steel
rod. (This is a specific requirement which will produce
non-standard results unless followed exactly.) Distribute rodding evenly over the entire cross section of
the sample.
5. Fill cone to overflowing
(Figure 54-C). Rod this layer 25
times with rod penetrating into
but not through, the second
layer. Distribute rodding evenly
over the entire cross section of
this layer.
FULL
(OVERFLOW)
Figure 54-C. Slump Test
(Full-Overflow)
6. Remove the excess concrete
(Figure 54-D) from the top of
the cone, using the tamping
rod as a screed.
Figure 54-D. Slump Test
(Removing Excess Concrete)
BULLET POINTED
STEEL ROD
1/3 FULL
1/2 DIAMETER
24 INCHES LONG
FOOT
PIECE
Figure 54-A. Slump Test (1/3 Full)
4. Fill cone another 1/3 (Figure 54-B) which will make the
cone 2/3 full by volume. Rod this second layer 25 times
with the rod penetrating into, but not through, the first
layer. Distribute rodding evenly over the entire cross
section of the layer.
2/3 FULL
7. Lift the cone vertically
(Figure 54-E) with a slow even
motion. DO NOT jar the concrete or tilt the cone during this
process. ( Invert the withdrawn
cone, and place it next to, but
not touching the slumped concrete.
Figure 54-E. Slump Test
(Cone Invert)
8. Lay a straight edge (Figure 54-F) across the top of the
slumped cone. Measure the amount of slump in inches
from the bottom of the straight
edge to the top of the slumped
concrete at a point over the
original center of the base . The
slump operation must be complete in a maximum elapsed
time of 1-½ minutes. Discard
the concrete. DO NOT use it in
another tests.
Figure 54-B. Slump Test (2/3 Full)
Figure 54-F. Slump Test (Measurement)
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 63
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
Figure 55. Recommended Shotcrete System
PAGE 64 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
NO.
1
2
PART NO.
EM28906
EM25837
PART NAME
COUPLING, 5” H-D “CF”
ELBOW, 5"x4”x90°
3
4
5
EM28905
EM402552
EM28061
COUPLING, 4” H-D w/GASKET & PIN
REDUCER, 4”x2.5”x53” H-D ENDS
PIPE, 2.5”x120w x 10’ H-D
6
7
EM289035
EM28001DD
COUPLING, 2.5” H-D w/GASKET & PIN
REDUCER, 2.5”x2”x36” H-D
8
9
10
EM23815D
EM28902
EMDC400
REDUCER, 2.5”x2” w/AIR VIBRATOR
COUPLING, 2” H-D w/GASKET & PIN
AIR VIBRATOR ASSY.
11
EM28131D
2”x2” ELBOW 90º
12
EM24841
HOSE, 2”x25’ H-D w/ENDS
13
14
EM23808D
EM23806
NOZZLE ASSEMBLY, 2” H-D
NOZZLE TIP, RUBBER 1-3/8”
15
EM23807
NOZZLE TIP, RUBBER 1.25”
QTY.
REMARKS
GENERAL RECOMMENDATIONS
■ If the site will permit, use steel pipe from the pump to
the pool perimeter. It will reduce line pressures which is
highly recommended.
■ The vibrator on the reducer by the pool improves
pumpability.
■ Turn both air vibrators off whenever the pump is stopped
to prevent separation of mix.
■ The air vibrators are low consumption (4.2 scfm).
■ Leave the air on at the nozzle when the pump is stopped
to prevent clogging of air the hoses in the air insert.
■ Use item #11 (steel elbow) at the edge of the pool to
prevent collapse of the rubber hose, which can cause
blockage.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 65
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
Figure 56. Shotcrete System Accessories
Use a 1-3/8" rubber nozzle tip for a wide spray pattern. Use a 1-1/4" rubber nozzle tip for a narrow spray
pattern. DO NOT INSTALL THE NOZZLE AT THE END OF THE HOSE UNTIL THE FIRST MATERIAL
HAS PASSED THROUGH THE ENTIRE HOSE LENGTH.
Disassemble and clean the nozzle assembly thoroughly after each job. Grease all threads before reassembly. DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air
passages clean.
PAGE 66 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
NO.
1
2
3
4
5
6
7
8
9
10
11
11
11
12
*
13
*
14
*
15
*
16
*
17
*
18
*
19
*
20
21
PART NO.
EM26107
EM23101
EM132
EM23407
EM23408
EM23411
EM912073
EM23409
EM923346
EM406
EM23818
EM24841
EM23845
EM23802
EM23803
EM20816
EM23804
EM23805
EM23806
EM23807
EM911076
EM23808
PART NAME
QTY.
REMARKS
HOPPER SCREEN ......................... 1 .......... W/AIR VIBRATOR MOUNTING
AIR VIBRATOR
1
BOLT, 1/2-13X2
2
AIR HOSE
1
BUSHING
1
VALVE
1
NIPPLE
2
COUPLING
1
WASHER, 1/2 LOCK
2
NUT, HEX 1/2-13
2
2"X25' GROOVED HOSE
2"X25' RAISED HOSE
2"X50' GROOVED HOSE
VIC ADAPTER / EM23802D H.D 1
GUN BODY
1
“O” RING
1
AIR INSERT
1
NOZZLE CLAMP
1
NOZZLE TIP, 1-3/8", SHORT
1
NOZZLE TIP, 1-1/4", LONG
1
STREET ELBOW
1
AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO
NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES ITEMS W/
*
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 67
LS-60TD PUMP — TROUBLESHOOTING (PUMP)
The hydraulic troubleshooting procedures listed below are
intended for use by individuals equipped with the proper tools
and equipment and are familiar with hydraulic systems and
safe shop practices. Use the Pump Troubleshooting Table
(Table 8) to identify possible causes for the pump’s
malfunction. Contact the Multiquip Service department for
the proper repair procedure.
WARNING - HYDRAULIC SYTEM HAZARD
DO NOT open hydraulic lines or loosen hydraulic fittings
while the engine is running! Hydraulic fluid under pressure
can penetrate the skin, blind, cause burns or create other
potentially dangerous hazards.
TABLE 8. PUMP TROUBLESHOOTING
Problem
Possible Problem
Incorrect System Operating
Pressure
Check the pump pressure gage. Verify
it is approx. 3200 PSI.
Incorrect Engine RPM setting
Verify the engine's high RPM speed is
set to 2550.
Contaminated Main Relief Valve
Check the manifold for a contaminated
Relief Valve.
Obstructed Material Cylinders
Check for obstructions (dried material)
inside the cylinders.
Main Hydraulic Cylinder will
Malfunctioning Proximity Switch
not cycle
Main Hydraulic Cylinders
shor t stroke
To Troubleshoot
Manually cycle the pump using the
manual cylinder jogging switch.
Malfunctioning Computer or Poor
Ground
Check for computer active voltage.
Malfunctioning Pilot Cycling Valve
Manually cycle the pump using the
manual pilot valve push pins.
Defective Proximity Switch or
Switch Clearance too Large
Replace or adjust clearance.
Dir ty or Contaminated Proximity
Switch Connectors
Clean or replace.
Cylinder Check Valves
Contaminated or Broken. Piston
Seals May Be Cut.
Clean or replace springs. Replace
piston seals.
Proximity Switch out of
Adjustment
Adjust proximity switch cylinder travel.
Incorrect Directional Control
Operating Pressure
Verify the Directional Control operating
pressure is approx. 1000 PSI.
Contaminated Relief Valve
Check the manifold for a contaminated
Relief Valve.
Broken Shaft Coupler Key
Check the Hopper Remixer shaft
coupler for a broken key.
Loose Shaft Retaining Set Collar
Check the Shaft Retaining Set Collar
for tightness.
Hopper Remix Paddles will
not rotate
PAGE 68 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — TROUBLESHOOTING (PUMP)
TABLE 8. PUMP TROUBLESHOOTING (CONTINUED)
Shuttle Cylinder does
not stroke
Shuttle Cylinder slow to
complete stroke
Pump Engine will idle
but not increase to full
operating speed
Battery Indicator Light
will not illuminate and
the engine will not star t.
Incorrect Accumulator
SystemPressure
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 out solenoid and
12V signal voltage
Swing Valve not functioning properly
Manually cycle the pump using the
manual cylinder jogging switch
Improper Flow Control setting
Fully open Flow Control Vave
Incorrect Engine RPM setting
Verify the engine's high RPM speed is
set to 2550
Incorrect Main Hydraulic
System Operating Pressure
Check the pump pressure gage. Verify
it is approx. 3200 PSI
Contaiminated Swing Relief
Car tridge
Check the manifold for contaminated
Swing Relief Car tridge
Low Accumulator System Pressure
Check the accumulator pressure
reading. Verify it is approx. 1750 PSI
Hopper Discharge Nipple Seal
improperly lubricated
Check the Hopper Discharge Nipple
Seal for siezing and lack of lubricant
Throttle Control Block Solenoid
not engergizing
Check for burned out solenoid and
computer ground activation voltage.
Blown out Fuse
Check the fuse
Dead battery
Check the charge on the battery
Wiring connection inside Control Box
Check the wiring connections and
verify power is reaching ignition switch
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 69
LS-60TD PUMP — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Engine Troubleshooting (Table 9) information
shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult
our company's business office or service plant.
TABLE 9. ENGINE TROUBLESHOOTING
SYMPTOM
Engine will not star t or star t is
delayed, although engine can be
turned over.
At low temperatures engine
will not star t.
Engine fires but stops soon as
star ter is switched off.
Engine stops by itself during
normal operation.
Low engine power, output and
speed.
Low engine power output and low
speed, black exhaust smoke.
POSSIBLE PROBLEM
SOLUTION
Speed control lever is in "STOP" position
Set speed control lever to "START" position.
No fuel reaching injection pump
Add fuel. Check entire fuel system.
Defective fuel pump
Replace fuel pump.
Fuel filter clogged
Replace fuel filter and clean tank.
Faulty fuel supply line
Replace or repair fuel line.
Compression too low
Check piston, cylinder and valves. Adjust or
repair per engine repair manual.
Fuel injector not working correctly
Repair or replace injector in accordance with
engine repair manual.
Oil pressure too low
Check engine oil pressure.
Low star ting temperature limit exceeded
Comply with cold star ting instructions and
proper oil viscosity.
Fuel separates has inadequate resistance to
low temperatures
Check whether clear (not turbid) fuel emerges
from the fuel line (detach from injection
pump). If the fuel is turbid or separated, warm
up the engine or drain the complete fuel
supply system. Refuel with winter grade diesel
fuel.
Engine oil too thick
Refill engine crankcase with correct type of oil
for winter environment.
Throttle lever in STOP position
Reposition throttle lever to RUN position.
Fuel filter blocked
Replace fuel filter.
Fuel supply blocked
Check the entire fuel system.
Fuel tank empty
A d d f u e l.
Fuel filter blocked
Replace fuel filter.
Fuel tank empty
Replace fuel filter.
Fuel filter clogged
Replace fuel filter.
Fuel tank venting is inadequate
Ensure that tank is adequately vented.
Speed control lever does not remain in
selected position
See engine manual for corrective action.
Engine oil level too full
Correct engine oil level?
Air filter blocked
Clean or replace air filter.
Incorrect valve clearances
Adjust valves per engine specification.
Malfunction at injector
See engine manual.
PAGE 70 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — TROUBLESHOOTING (BRAKE SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Brake System Troubleshooting
(Table 10) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 10. BRAKE SYSTEM TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Overheated wheel bearing
Replace wheel bearing and pack with grease.
Low brake fluid
Fill and bleed brake system.
Siezed acutator master cylinder
Replace/Rebuild master cylinder.
Brake shoe noise
Inspect drums. Adjust shoes or replace if necessary.
Leaking wheel cylinder
Check and replace wheel cylinder and bleed brake system.
Low brake fluid level
Fill with dot approved brake fluid and bleed brake system.
Brake actuator frame damage
Replace complete actuator unit.
Brake line being pinched
Replace brake line.
Seized actuator
Replace or rebuild actuator.
Broken return spring
Replace spring.
Brakes improperly adjusted
Check adjustment.
Break-away cable system
par tially activated
Break-away cable might be pulled. Determine cause and correct. Pry
up on cable until indicator bead touches or rests against cable spring
stop. This will fully release the frame brakes and prevent drag.
Brakes squeak, chatter or chuck.
Brakes overheah, fail to operate,
pull to the side, or function poorly
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 71
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.
SAMPLE PARTS LIST
NO.
1
2%
2%
3
4
PART NO. PART NAME
QTY. REMARKS
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
12347
WASHER, 3/8 IN....1 .....MQ-45T ONLY
12348
HOSE ..................A/R ...MAKE LOCALLY
12349
BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
QTY. Column
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Unique Symbols — All items with same unique
symbol
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
PAGE 72 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — SUGGESTED SPARE PARTS
LS-60TD
STRUCTURAL CONCRETE PUMP
1 Unit
Qty.
P/N
Description
1 .......... EM16462 .............. FELT HOLDER
4 .......... EM98050 .............. PISTON CUP, ORANGE
4 .......... EM16493 .............. FELT RING
1 .......... EM98033 .............. OIL PLATE
2 .......... EM14408 .............. BRONZE RING
2 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE )
1 .......... EM98021 .............. WEAR PLATE
2 .......... EM168161A .......... ENERGIZER RING
1 .......... EM16816-2 ........... INSERT RING
2 .......... EM98065 .............. SLEEVE SEAL
1 .......... EM98022 .............. WEAR RING
1 .......... EM98065 .............. RUBBER RING
2 .......... EM14407 .............. O-RING
1 .......... 34507 ................... CAP, FUEL
2 .......... EM20763 .............. FILTER, FUEL (IN LINE)
1 .......... P53712 ................. CARTRIDGE, WATER SEPERATOR
3 .......... 01174416 ............. FILTER, OIL (ENGINE)
3 .......... 01174696 ............. FILTER, FUEL (ENGINE)
2 .......... EM98093P ............ ELEMENT, PRIMARY
2 .......... EM98093S ............ ELEMENT, SECONDARY
1 .......... EM98163 .............. SWITCH, PROXIMITY
1 .......... EM981121 ............ ELEMENT, RETURN OIL
LS-60TD
STRUCTURAL CONCRETE PUMP
3 Units
Qty.
P/N
Description
1 .......... EM16459 .............. PIN
2 .......... EM25801 .............. CONCRETE CYLINDER
4 .......... EM16462 .............. FELT HOLDER
6 .......... EM98050 .............. PISTON CUP, ORANGE
8 .......... EM16493 .............. FELT RING
4 .......... EN98033 .............. OIL PLATE
4 .......... EM14408 .............. BRONZE RING
4 .......... EM16145A ............ BUSHING, SWING AXLE (BRONZE )
3 .......... EM98021A ............ WEAR PLATE
4 .......... EM168161A .......... ENERGIZER RING
2 .......... EM16816-2 ........... INSERT RING
4 .......... EM98065 .............. SLEEVE SEAL
6 .......... EM98022 .............. WEAR RING
3 .......... EM98065 .............. RUBBER RING
6 .......... EM14407 .............. O-RING
2 .......... EM16174 .............. O-RING
2 .......... EM98163 .............. SWITCH, PROXIMITY
6 .......... 510265 ................. BOLT, HEX HEAD 3/8 NC x 3-1/4 IN. G8
1 .......... 34507 ................... CAP, FUEL
6 .......... EM20763 .............. FILTER, FUEL
3 .......... P53712 ................. CARTRIDGE, WATER SEPERATOR
9 .......... 01174416 ............. FILTER, OIL (ENGINE)
9 .......... 01174696 ............. FILTER, FUEL (ENGINE)
6 .......... EM98093P ............ ELEMENT, PRIMARY
6 .......... EM98093S ............ ELEMENT, SECONDARY
2 .......... EM981121 ............ ELEMENT, RETURN OIL
Part numbers on this Suggested Spare Parts
List may supercede or replace the P/N shown
in the text pages of this book.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 73
LS-60TD PUMP — NAMEPLATE AND DECALS
PAGE 74 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — NAMEPLATE AND DECALS
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
PART NO.
EM514238
DCL302
EM511709
EM97072
EM98000
DCL301
EM970
EM511091
EM985
DCL304
EM97083
EM955
EM97070
EM97070
35137
EM97084
DCL300
EM965
EM965
513580
EM995
34536
DCL305
EM696
514666
PART NAME
QTY.
REMARKS
DECAL, LS-60 SMALL
1
SERIAL PLATE ...................................................... 1 .......... CONTACT PARTS DEPT.
DECAL, WARNING BURN HAZARD
1
DECAL, 800-30-MAYCO
1
DECAL, CAUTION - OP. INSTRUCTIONS
2
DECAL, CAUTION - GREASE 2 HOURS
4
DECAL, SHUTTLE TUBE DANGER
2
DECAL, HOPPER REX MIXER
1
DECAL, MINIMUM OIL LEVEL
1
DECAL, HYDRAULIC OIL ONLY
1
DECAL, DANGER IMPROPER CHARGING
1
DECAL, WARNING - ACCUM. SAFETY
1
DECAL, DANGER CHARGING ACCUM.
1
DECAL, ACCUMULATOR PRESSURE
1
DECAL, PUMPING PRESSURE DECAL
1
DECAL, CAUTION READ MANUAL
1
DECAL, MAINTENANCE
1
DECAL, DANGER LUBRICATION BOX
1
DECAL, VOLUME CONTROL
1
DECAL, THROTTLE
1
DECAL, ENGINE RPM SETTING
1
DECAL, CAUTION DIESEL FUEL
1
DECAL, OWNERS MANUAL
1
DECAL, WARNING REAR STABILIZERS
1
DECAL, CAUTION - TOWING DECAL
1
DECAL, LS-60 LARGE
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 75
LS-60TD PUMP — FRAME ASSY.
PAGE 76 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — FRAME ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO.
EM514355
TBD
EM25610
EM70186
EM491686
EM491076
EM490236
EM744
EM491686
EM491744
509562
0166 A
503112
3019092
EM969013
PART NAME
QTY.
REMARKS
FRAME, MAIN
1
CHAIN, TRAILER HITCH, 3/8 X 40", GRADE 40
2
JACK STAND, FRONT
1
SUPPORT STAND
2
PIN
2
PIN RING 3/4"
2
CHAIN 15 3.5 GALV.
2
PIN
2
PIN, COTTER
2
RIVET, POP AM-44
2
BOLT, 3/8" NC X 5/8" G5
2
LOCK, WASHER 3/8" ................................................. 2 ............. REPLACES 492624
BOLT 3/8" X 2-3/4"
1
WASHER 3/8" ............................................................ 2 ............. REPLACES 492598
NUT 3/8" .................................................................... 1 ............. REPLACES 492583
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 77
LS-60TD PUMP — AXLE ASSY. (RIGHT/LEFT)
PAGE 78 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — AXLE ASSY. (RIGHT/LEFT)
NO.
1
2
2
PART NO.
EM98116
EM092305
EM092306
3
4
5
6#%
7
8
9
10
11
12
13
14
15
16
17
18
363198
363196
383911
363909
363239
363916
363420
568326
363257
363258
EM514813
363203
363199
EM104
0401450160
EM969023
PART NAME
QTY.
REMARKS
AXLE, TORSION BAR ASSY.
1
BRAKE ASSY COMPLETE, RIGHT ................ 1 .............. INCLUDES ITEMS W/#
BRAKE ASSY COMPLETE, LEFT .................. 1 .............. INCLUDES ITEMS W/%
.......................................................................................... SEE NOTE BELOW
OIL SEAL
1
INNER BEARING CONE 2 IN.
1
INNER BEARING CUP 2 IN.
1
WHEEL STUD 1/2 IN. - 20 UNF PRESS IN 8
HUB AND DRUM ASSY.
2
OUTER BEARING CONE
1
OUTER BEARING CUP
1
LOAD WASHER 1 IN. T5 HP
1
SLOTTED NUT, 1 IN. UNF
2
COTTER PIN 3/16 IN. X 1-1/2
2
RIM AND TIRE
2
WHEEL LUG NUTS 1/2 UNF 60 CON
8
GREASE CAP
2
BOLT, HEX HEAD 5/8 IN. NC X 2 IN. G5 ......... 4 .............. REPLACES 503982
WASHER, FLAT 5/8 IN. ................................... 8 .............. REPLACES 492602
NUT, LOCK 5/8 IN. ........................................... 4 .............. REPLACES 492586
RIGHT AND LEFT SIDE AXLE
ASSEMBLIES ARE IDENTICAL WITH THE
EXCEPTION OF THE BRAKE ASSEMBLY.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 79
LS-60TD PUMP — BRAKE LINE ASSY.
PAGE 80 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — BRAKE LINE ASSY.
NO.
1
2
3
4
PART NO.
34566
EM512877
EM512876
34565
PART NAME
KIT, MAIN BRAKE LINE
ADAPTOR, STRAIGHT
ADAPTOR, ELBOW
KIT, WHEEL BRAKE LINE
QTY.
1
2
2
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 81
LS-60TD PUMP — BRAKE LIGHT ASSY.
PAGE 82 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — BRAKE LIGHT ASSY.
NO.
1
2
PART NO.
EM26536
29207
PART NAME
QTY.
REMARKS
BRAKE LIGHT ASSY.
2
HARNESS ASSY. W/RECEPTACLES ................ 1 ............. REPLACES V5425Y
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 83
LS-60TD PUMP — TRAILER HITCH ASSY.
PAGE 84 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — TRAILER HITCH ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
29228
19067
503111
492600
492584
EM507658
492586
29369
PART NAME
QTY.
REMARKS
COUPLING, TRAILER 2 IN.BALL, 6000 LBS. 1
ACTUATOR, BRAKE
1
BOLT, HEX HEAD 1/2 NC X 4-1/2 IN.
3
WASHER, FLAT 1/2 IN.
3
NUT, LOCK 1/2 IN.
3
2
BOLT, HEX HEAD 5/8 NC X 4-1/2 IN. G5
NUT, LOCK 5/8 IN.
2
TOW RING, 3 IN. LUNETTE EYE ....................... 1 .......... REPLACES 16137
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 85
LS-60TD PUMP — BATTERY ASSY.
PAGE 86 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — BATTERY ASSY.
NO.
1
2
3
4
PART NO.
34506
16738
514856
513577
PART NAME
BATTERY BOX W/ BELT
BATTERY 12V 125A
BATTERY CABLE POSITIVE
BATTERY CABLE NEGATIVE
QTY.
1
1
1
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 87
LS-60TD PUMP — HOPPER ASSY.
PAGE 88 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HOPPER ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
29
30
31
32
33
34
35
36
37
39
40
41
42
43
44
45
PART NO.
EM514354
EM16184
EM516779
EM200303
EM200301
EM516820
EM514339
510717
EM514338
EM514706
EM902153
EM200018
EM703
500264
EM511428
EM516780
EM98108
505989
6109180
EM25508
EM70860-1
EM50417
EM508830
492378
0166 A
EM514031
EM514032
EM514033
513454
6109180
492589
EM25483
EM70860
EM515460
516799
EM702
EM703
516787
EM500264
516776
516775
PART NAME
QTY.
REMARKS
HOPPER ASSY
1
HOPPER SEAL
1
REMIXER SHAFT
1
FOLLOWER RING
2
GRAPHITE SEAL
6
COMPRESSION SPRING
2
HOPPER SPRING SEAT
2
BOLT 1/2 X 1-3/4 IN.
4
SUPPORT, LEFT
1
END CAP, SHAFT SUPPORT
1
BEARING
2
SET COLLAR
1
SET SCREW ............................................ 2 ................ REPLACES 492470
KEY 3/8 IN.
1
BOLT 1/2 X 3-1/2 IN.
4
HOUSING
1
MOTOR, REMIX
1
BOLT 1/2 X 1-1/4 IN.
2
WASHER, LOCK 1/2 IN. ........................... 2 ................ REPLACES 492626
ADAPTER, FITTING
2
PISTON CUP HOLDER
1
PISTON CUP
1
HANDLE
1
BOLT 3/8 X 1-3/4 IN.
4
WASHER, LOCK 3/8 IN. ........................... 4 ................ REPLACES 492624
PADDLE ARM, END
2
PADDLE ARM, MOTOR END
2
PADDLE ARM, CENTER
2
BOLT 1/2 X 3-1/4 IN.
6
WASHER, LOCK 1/2 IN. ........................... 6 ................ REPLACES 492626
HEX NUT 1/2 IN. ...................................... 6 ................ REPLACES 507661
HOSE ........................................................ 2 ................ CONNECT TO REMIX VALVE
HANDLE ASSY.
1
RETAINING RING
1
SPACER 6MM
1
DOG POINT SET SCREW 3/8"
1
SET SCREW 3/8"
3
REMIX SHAFT COUPLER
1
SQUARE KEY 3/8"
1
DRIVE MEMBER COUPLER
1
MOTOR SHAFT COUPLER
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 89
LS-60TD PUMP — HOPPER ATTACHMENT ASSY.
PAGE 90 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HOPPER ATTACHMENT ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
PART NO.
EM514204
EM514620
EM491686
EM70134-2
EM505723
EM16166
505728
EM14165
EM619
EM968446
505121
EM968446
505123
492491
6109160
492379
3019092
515395
492584
EM969013
PART NAME
QTY.
REMARKS
SPLASH PLATE
1
HINGE PIN
1
COTTER PIN 1/8 X 1-1/2 IN.
1
PIN, SPLASH PLATE
1
COTTER PIN 5/32 X 1-1/2 IN.
1
TIE ROD
1
NUT, HEX 1 IN. NC
6
EYE BOLT 3/4 IN.
4
O-RING 3/4 IN.
4
NUT, HEX 3/4 IN.
4
BOLT 3/4 IN. X 3 IN.
4
HEX NUT 3/4 IN.
4
HEX BOLT 1/2 X 2-1/2 IN.
2
HEX BOLT 1/2 X 1-1/2 IN.
1
HEX NUT 1/2 IN. ................................................ 3 .............REPLACES 492556
SCREW CAP 3/8"
2
WASHER FLAT 3/8"
4
BOLT 7/16 NC X 4" G5
2
NUT LOCK 1/2"
2
NUT NYLOC
2
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 91
LS-60TD PUMP — HOPPER INTERIOR ASSY.
2
4
1
3
5
6
6A
7
18
25
27
32
30
9
10
29
8
26
12
14
28
19
11
16
20
31
17
21
13
15
PAGE 92 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HOPPER INTERIOR ASSY.
NO.
1
2
3
4
5
6
6A
7
8
9
10
11
12
13
14
15
17
18
19
20
21
25
26
27
28
29
30
31
32
PART NO.
EM16145A
EM284
EM16175
EM16170
EM16176
EM98022
EM16816-1A
EM16816-2
EM16804
EM104
EM923348
EM25803
EM98065
EM512212
491701
EM210
EM16811
EM25843
EM104
491719
EM923348
EM514357
EM98021
EM969023
EM265
EM492628
EM151
EM264
EM517700
PART NAME
QTY.
REMARKS
SWING AXLE BUSHING
2
STUD 1 IN. - 14 UNF
1
O-RING
1
RING SEAL, SHUTTLE AXLE
1
O-RING
1
WEAR RING HF
1
RING, ENERGIZER RUBBER
1
RING, INSERT STEEL
1
SLEEVE 5 IN.
1
BOLT 5/8 X 2 IN. ....................................... 4 ............... REPLACES 503982
WASHER, LOCK 5/8 IN. ............................ 4 ............... REPLACES 492627
DISCHARGE PLATE BEARING
1
SEAL, RUBBER
1
DISCHARGE NIPPLE
1
GREASE FITTING
3
BOLT 5/8 X 2 IN.
6
SHUTTLE CYLINDER
1
NUN PLATE
1
BOLT, HEX HEAD 5/8 X 2 IN..................... 4 ............... REPLACES 503982
PIN
1
WASHER, LOCK 5/8 IN.
4
HOPPER SCREEN
1
PLATE, WEAR HF
1
NUT, HEX 5/8 IN. NC INS. ......................... 2 ............... REPLACES 492586
BOLT, COUNTER SUNK 5/8-11 x 3 IN.
2
WASHER, LOCK 3/4 IN.
2
BOLT, HEX HEAD 3/4-10 X 2 IN.
2
BOLT, COUNTER SUNK 1/2-13 x 3 IN.
2
O-RING
2
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 93
LS-60TD PUMP — SHUTTLE CYLINDER ASSY.
PAGE 94 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — SHUTTLE CYLINDER ASSY.
NO.
1
2
3
4
5
6
7
7A
8
9
10
*
11
12
13
14
15
*
16
*
18
*
19
*
20
21
PART NO.
EM16145
EM510684
EM16169
EM25236
EM505490
EM16814
EM424
EM924006
EM417
EM98106
EM254549
492397
EM621
6109180
492584
0820270000
0820270000
515249
EM254541
3322
EM514590
22
EM514591
23
24
25
26
27
*
28
EM515628
0202
EM923023
2105164
EM26126
EM717
*
PART NAME
QTY.
REMARKS
SWING AXLE BUSHING
2
GREASE FITTING
1
THRUST WASHER
1
SHUTTLE CRANK, SPLINED SHAFT
1
GREASE FITTING
2
TENSIONER
1
HEX NUT 1 IN. 14NF .................................... 1 ............ REPLACES 491690
COTTER PIN 5/32 X 2 IN.
1
NUT 1 IN. 14NF
1
SHUTTLE CYLINDER ASSY. ....................... 1 ............ INCLUDES ITEMS W/
*
BRACKET, PIVOT
1
BOLT 1/2 X 2-1/2 IN.
4
WASHER 1/2 IN.
4
WASHER, LOCK 1/2 IN. ............................... 4 ............ REPLACES 492626
NUT 1/2 IN.
4
CLEVIS PIN 3/4 IN.
1
COTTER PIN
2
NUT JAM 1"-14
1
FEMALE CLEVIS
1
FITTING, ELBOW
2
HOSE ............................................................ 1 ............ CONNECT TO
...................................................................................... MANIFOLD PORT “A1”
HOSE ............................................................ 1 ............ CONNECT TO
...................................................................................... MANIFOLD PORT “B1”
COVER, SHUTTLE CYLINDER
1
SCREW, HHC 5/16-18 X 1 ZINC ................... 3 ............ REPLACES 492364
WASHER, FLAT ............................................ 3 ............ REPLACES 492597
NUT, HEX ...................................................... 3 ............ REPLACES 492582
CLEVIS PIN
1
COTTER PIN
2
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 95
LS-60TD PUMP — LUBRICATION PISTONS ASSY.
PAGE 96 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — LUBRICATION PISTONS ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
PART NO.
EM963064
EM16464
EM16465
EM98050
EM14408
EM16493
EM16462
EM16461
EM14407
EM25801
EM25110
EM963610
0166 A
3019092
514197
EM507895
515796
EM514610
EM491754
492378
0166 A
EM274351
EM50425
EM492451
EM50443
EM514208
EM98163
EM98135
EM98134
EM98138
EM514611
EM504505
PART NAME
QTY.
REMARKS
BOLT, HEX HEAD 3/8 NC X 3-1/2 IN., BLACK OXIDE G8
6
FACE PLATE
2
PISTON CUP SPACER
6
CUP, PISTON- ORANGE
2
RING, BRONZE
2
RING, FELT
2
FELT HOLDER
2
OILER PLATE
2
O- RING, OILER PLATE
2
CYLINDER, CONCRETE
2
RETAINER, CYLINDER
4
BOLT, 3/8 NC X 1.3/4 IN. G5 ................................................... 8 ........... REPLACES 492375
WASHER LOCK 3/8 IN. .......................................................... 8 ........... REPLACES 492624
WASHER, FLAT 3/8 IN. ..........................................................22 .......... REPLACES 492598
LUBRICATION BOX
1
PLUG
1
COVER, LUBRICATION BOX
1
LATCH, COVER
1
RIVET, AM-66
2
BOLT, 3/8 NC X 1.3/4 IN. G5
6
WASHER, LOCK 3/8” .............................................................. 6 ........... REPLACES 492624
SEAL LUBE BOX
2
FLANGE, RING
2
BOLT 3/8 - 24 X 1 IN. HEX HEAD
8
SEAL, OIL BOX
8
BAR,PROXIMITY SWITCH SUPPORT
1
SWITCH, PROXIMITY W/CABLE
2
CABLE HOUSING, FEMALE
2
SEAL, CONNECTOR HOUSING
6
TERMINAL PIN, FEMALE
6
GROMMMET
2
WRAP TIE
8
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 97
LS-60TD PUMP — LUBRICATION PISTONS ASSY.
PAGE 98 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — LUBRICATION PISTONS ASSY.
NO.
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
PART NO.
492366
EM492623
EM514216
EM492556
EM514207
EM492597
EM492582
EM98211
EM514920
EM514202
EM185
EM25497
EM25474
EM16459
EM505723
EM491701
EM517126
EM513352
PART NAME
QTY.
BOLT, HEX HEAD 5/16 NC X 1 IN. G5
6
WASHER, LOCK 5/16 IN.
4
ADJUSTMENT ROD, PROXIMITY SWITCH
2
NUT, HEX 1/2 IN.
4
BRACKET, ADJUSTMENT ROD
2
WASHER, FLAT 5/16 IN.
6
NUT, HEX HEAD 5/16 IN
2
CYLINDER, MAIN
2
HOSE, MAIN HYD. CYLINDER
2
EXTENSION, SPACER
2
BOLT, SOCKET HEAD 3/8 NC X 3 IN., BLACK OXIDE G8 6
FITTING, 90°
4
HOSE, HYDRAULIC SLAVE
1
PIN, WRIST
2
PIN, COTTER
4
FITTING, GREASE
2
LOCK WASHER INTERNAL
6
SEAL, SQUARE
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 99
LS-60TD PUMP — FUEL TANK ASSY.
PAGE 100 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — FUEL TANK ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
PART NO.
EM514084
514080
492362
EM923343
34507
EM514559
506208
EM514536
EM20426
EM514536
EM20763
PART NAME
QTY.
REMARKS
COVER, DIESEL TANK
4
GASKET
4
BOLT 5/16 X 5/8 IN.
28
WASHER, LOCK 5/16 IN. .................................. 28 ......... REPLACES 492623
CAP, FUEL W\GAUGE
1
ADAPTOR
1
CLAMP
5
HOSE, FUEL RETURN 5/16 IN.
A/R
ADAPTER
1
HOSE, FUEL FILTER 5/16 IN.
A/R
FILTER, FUEL
2
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 101
LS-60TD PUMP — HEAT EXCHANGER ASSY.
PAGE 102 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HEAT EXCHANGER ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART NO.
EM98118
EM514175
EM963610
3019092
0166 A
0202
EM923023
2105164
EM25497
EM514607
EM25566
EM509345
EM514606
EM509401
EM514604
EM98264
PART NAME
QTY.
REMARKS
HEAT EXCHANGER
1
COVER, HEAT EXCHANGER
1
BOLT 3/8 IN. X 1 IN. ........................... 4 .............. REPLACES 492375
O-RING 3/8 IN. ................................... 4 .............. REPLACES 492598
WASHER, LOCK 3/8 IN. ..................... 4 .............. REPLACES 492624
BOLT 5/16 X 1 IN. .............................. 4 .............. REPLACES 492364
WASHER, FLAT 5/16 IN. .................... 8 .............. REPLACES 492597
NUT 5/16 IN. ....................................... 4 .............. REPLACES 492582
ADAPTER
1
HOSE 4000 PSI
1
ADAPTER
1
ADAPTER
1
HOSE 2000 PSI
1
ADAPTER
1
HOSE, 2000 PSI
1
MOTOR AND FAN ASSY
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 103
LS-60TD PUMP — ACCUMULATOR ASSY.
PAGE 104 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — ACCUMULATOR ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
PART NO.
EM97015
EM97016
EM9603055
3019092
0166A
EM509425
EM509353
EM514603
EM98009
EM98052
PART NAME
ACCUMULATOR 1 GAL.
BRACKET, ACCUMULATOR
BOLT, HHCS 3/8 IN. DIA.
WASHER, FLAT 3/8 IN.
WASHER, LOCK 3/8 IN. DIA.
FITTING, STRAIGHT
FITTING, 90° ELBOW
HOSE, ACCUMULATOR
ACCUMULATOR REPAIR KIT
ACCUMULATOR TEST/CHARGE KIT
QTY.
1
1
2
2
2
1
1
1
1
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 105
LS-60TD PUMP — REMIXER CONTROL ASSY.
PAGE 106 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — REMIXER CONTROL ASSY.
NO.
1
2
3
4
5
6
7
8
9
PART NO.
EM25495
515384
506195
EM25509
EM218
EM923343
2105164
EM98015
EM98014
PART NAME
QTY.
REMARKS
VALVE REMIXER W/ LEVER
1
ADAPTER FITTING, T
1
ADAPTER FITTING, 90° ELBOW
1
ADAPTER FITTING, STRAIGHT
2
BOLT 5/16 X 2-1/2 IN.
2
WASHER, LOCK 5/16 IN. .............................. 2 .................REPLACES 492623
NUT, HEX 5/16 IN. ......................................... 2 .................REPLACES 492553
COUPLING
1
TEST PORT
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 107
LS-60TD PUMP — LUBRICATION PANEL
Grease daily, two or three hots of #2 multipurpose automotive grease. Over greasing
any bearing will not damage the machine.
ALWAYS grease before and after pump
operation.
POSITION
LOCATION
LENGTH OF LINES
A ................................................. CLEVIS GREASE POINT ................................................ 34 in. (1.1 m)
B ................................................. SWING AXLE BUSHING GREASE POINT ...................... 26 in. (.85 m)
C................................................. PIVOT BRACKET GREASE POINT ................................. 41 in. (1.5 m)
PAGE 108 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — LUBRICATION PANEL
NO.
1
2
3
4
5
PART NO.
EM491701
EM508812
EM510684
EM505516
EM505516
PART NAME
GREASE FITTING
CONNECTOR
CONNECTOR
HOSE, PLASTIC
HOSE, STEEL
QTY.
3
2
3
A/R
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 109
LS-60TD PUMP — ENGINE COVER ASSY.
PAGE 110 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — ENGINE COVER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM515132
EM492356
EM492622
EM492596
EM514889
EM510271
EM492581
29057
PART NAME
COVER, TOP
BOLT, HEX 1/4 X 3/4 IN.
WASHER, LOCK 1/4 IN.
WASHER, FLAT 1/4 IN.
PLATE, SIDE COVER
COVER, FRONT ENGINE
NUT, HEX 1/4 IN. NC
DOCUMENT BOX
QTY.
1
18
18
18
1
1
4
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 111
LS-60TD PUMP — HYD. TANK ASSY. (OLD STYLE)
PAGE 112 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HYD. TANK ASSY. (OLD STYLE)
NO.
1
3
4%
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NO.
514040
0166 A
517295
EM251191
EM25184
492362
EM923343
EM98263
492267
16433
EM491189
EM18436
EM514605
EM514622
EM514597
EM491164
EM491375
EM514598
EM509369
491237
506094
EM98188
EM97066
EM97067
EM25523
EM509517
EM514602
EM16517
EM98112
33
34
35
41%
42%
43%
44
EM16513
492376
492598
TBD
TBD
TBD
EM508659
PART NAME
QTY.
REMARKS
HYDRAULIC TANK, LS-S
1
LOCK, WASHER 3/8 IN. .......................................4 ........... REPLACES 492624
HANDLE
1
TANK COVER PLATE
1
RESERVOIR GASKET
1
BOLT 5/16 X 5/8 IN.
20
WASHER, LOCK 5/16 IN. .................................... 20 ..........REPLACES 492623
CAP ASSEMBLY, OIL FILL
1
BOLT 3/16 X 5/8 IN.
6
TUBE
1
FITTING
1
90° MALE ADAPTER 2103-16-16
3
HOSE
1
FITTING 1 IN.
1
HOSE
1
ELBOW, 3/4 IN.
1
ADAPTER 2103-12-08
1
HOSE (2000 PSI)
1
STRAIGHT MALE ADAPTOR , 0101-08-08
1
VALVE 1/2 IN.
1
CAP 1/2 IN.
1
GAUGE, LEVEL & TEMP. .....................................1 ........... REPLACES EM16478
GAUGE 3000PSI, ACCUMULATOR
1
GAUGE 5000 PSI, MAIN
1
ADAPTER
2
HOSE, 4000 PSI MAIN GAUGE
1
HOSE, 4000 PSI ACCUMULATOR GAUGE
1
STRAIGHT MALE ADAPTER 0102-24-16
1
FILTER RETURN ASSY.
1
ELBOW 1-1/2, 11-1/2 IN. NPT ..............................1 ........... DISCONTINUED. SEE HYD.
............................................................................................ TANK ASSY. (NEW STYLE)
............................................................................................ ITEMS 31 AND 48.
DIFFUSER
1
BOLT 3/8 X 1-1/4 IN.
4
WASHER, FLAT 3/8 IN.
4
BOLT
2
WASHER
2
NUT
2
HANDLE ASSY. ....................................................1 ........... INCLUDES ITEMS W/%
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 113
LS-60TD PUMP — HYD. TANK ASSY. (NEW STYLE)
PAGE 114 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HYD. TANK ASSY. (NEW STYLE)
NO.
1
3
4%
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
41%
42%
43%
44
45
46
47
48
49
50
51
52
PART NO.
514040
0166 A
517295
EM251191
EM25184
492362
EM923343
EM98263
492267
16433
EM491189
EM18436
EM514605
EM514622
EM514597
EM491164
509784
517002
EM509369
491237
506094
EM98188
EM97066
EM97067
EM25523
EM509517
EM514602
EM16517
EM98112
516814
EM16513
492376
492598
509343
EM517129
EM517130
EM517131
EM508659
516813
409401
EM16414
16516
509344
514604
514604
517029
PART NAME
QTY.
REMARKS
HYDRAULIC TANK, LS-S
1
LOCK, WASHER 3/8 IN. .......................................4 ........... REPLACES 492624
HANDLE
1
TANK COVER PLATE
1
RESERVOIR GASKET
1
BOLT 5/16 X 5/8 IN.
20
WASHER, LOCK 5/16 IN. .................................... 20 ..........REPLACES 492623
CAP ASSEMBLY
1
BOLT 3/16 X 5/8 IN.
6
TUBE
1
FITTING
1
90° MALE ADAPTER 2103-16-16
1
HOSE
1
FITTING 1 IN.
1
HOSE
1
ELBOW, 3/4 IN.
1
ADAPTER
1
HOSE .................................................................... 1 ........... MAY 2006 AND ABOVE
STRAIGHT MALE ADAPTOR , 0101-08-08
1
VALVE 1/2 IN.
1
CAP 1/2 IN.
1
GAUGE, LEVEL & TEMP. ..................................... 1 ........... REPLACES EM16478
GAUGE 3000PSI, ACCUMULATOR
1
GAUGE 5000 PSI, MAIN
1
ADAPTER
2
HOSE, 4000 PSI MAIN GAUGE
1
HOSE, 4000 PSI ACCUMULATOR GAUGE
1
STRAIGHT MALE ADAPTER 0102-24-16
1
FILTER RETURN ASSY.
1
90° FITTING ..........................................................1 ........... MAY 2006 AND ABOVE
DIFFUSER
1
BOLT 3/8 X 1-1/4 IN.
4
WASHER, FLAT 3/8 IN.
4
TEE FITTING ........................................................1 ........... MAY 2006 AND ABOVE
BOLT
2
WASHER
2
NUT
2
HANDLE ASSY. ....................................................1 ........... INCLUDES ITEMS W/%
BUSHING ..............................................................1 ........... MAY 2006 AND ABOVE
ADAPTOR 3903-16-16 ...........................................1 ........... MAY 2006 AND ABOVE
VALVE NEEDLE ................................................... 1 ........... MAY 2006 AND ABOVE
NUT, JAM 1-5/6 NPT X16 .....................................1 ........... MAY 2006 AND ABOVE
ADAPTOR 063T-16-16 ...........................................1 ........... MAY 2006 AND ABOVE
HOSE .................................................................... 1 ........... MAY 2006 AND ABOVE
HOSE .................................................................... 1 ........... MAY 2006 AND ABOVE
FITTING, STRAIGHT ............................................ 1 ........... MAY 2006 AND ABOVE
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 115
LS-60TD PUMP — LS-60TD ENGINE ASSY.
PAGE 116 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — LS-60TD ENGINE ASSY.
NO.
1
2
3
4
5
6
7
12
13
14
15
16
17
18
19
20
21
22
23
24
PART NO.
EM98197
492401
6109170
6109180
01174416
01174696
EM513776
EM514633
492371
EM923023
EM514714
EM923343
2105164
EM510897
0202
EM923023
2105164
EM506886
EM923343
EM516435
PART NAME
QTY.
REMARKS
ENGINE, DEUTZ TURBO 110 HP BF4L914
1
4
BOLT1/2 IN.X 4 FT.
WASHER, FLAT 1/2 IN. ........................................... 4............ REPLACES 492600
WASHER, LOCK 1/2 IN. ......................................... 4............ REPLACES 492626
FILTER, OIL (ENGINE)
1
FILTER, FUEL (ENGINE)
1
DEFLECTOR
1
REDUCTION TUBE, EXHAUST
1
BOLT 5/16 NC X 3 IN. G5
2
WASHER, FLAT 5/16 IN. ......................................... 4............ REPLACES 492597
SPACER, EXHAUST
2
WASHER, LOCK 5/16 IN. ........................................ 2............ REPLACES 492623
HEX NUT 5/16 IN. G5 .............................................. 2............ REPLACES 492553
1
CAP, EXHAUST 2-1/2 IN.
BOLT 5/16 X 1 IN. ................................................... 2............ REPLACES 492364
WASHER, FLAT 5/16 IN. ........................................ 7............ REPLACES 492597
NUT, HEX 5/16 IN. .................................................. 3............ REPLACES 492582
BOLT M8 X 20 X 1-1/4 IN.
3
WASHER, LOCK 5/16 IN. ........................................ 4............ REPLACES 492623
PIPE, EXHAUST
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 117
LS-60TD PUMP — LS-60TD ENGINE AIR FILTER ASSY.
PAGE 118 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — LS-60TD ENGINE AIR FILTER ASSY.
NO.
1
2
3
4
5
*
6
*
7
*
8
*
9
*
10
*
11
*
12
*
13
*
14
*
15
*
16
*
PART NO.
EM493108
513227
EM514367
EM98093
EM98207
EM98093P
EM98093S
492357
EM923057
TBD
492581
PART NAME
QTY.
REMARKS
CLAMP
3
AIR FILTER HOSE 3-1/2 IN.
.5
TUBE AIR FILTER UNION
1
AIR CLEANER ASSY. ............................................. 1............ INCLUDES ITEMS W/
*
FILTER, AIR ............................................................ 1............ NOT SOLD SEPARATELY
CAP, RAIN
1
ELEMENT, PRIMARY
1
ELEMENT, SECONDARY
1
HOOD, AIR CLEANER ............................................ 1............ NOT SOLD SEPARATELY
DUST EJECTOR ..................................................... 1............ NOT SOLD SEPARATELY
ADJUSTABLE SUPPORT, AIR FILTER ................... 1............ NOT SOLD SEPARATELY
SUPPORT, AIR FILTER .......................................... 1............ NOT SOLD SEPARATELY
BOLT, HEX HEAD 1/4 X 1 IN.
4
WASHER, FLAT 1/4 IN. ........................................... 8............ REPLACES 492596
WASHER, LOCK 1/4 IN.
4
NUT, HEX 1/4 IN.
4
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 119
LS-60TD PUMP — THROTTLE ASSY.
PAGE 120 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — THROTTLE ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
*
11
*
12
13
14
15
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NO.
EM512837
EM492358
2101402
EM923057
512185
492581
EM506599
492622
EM98168
EM98167
EM98166
EM25429
EM509937
EM25577
EM50449
EM509366
EM50449
EMCC700
492357
492581
515822
513213
2101428
510229
EM491089
EM501102
EM98228
EM98232
PART NAME
QTY.
REMARKS
SUPPORT BASE, ACCELERATOR
1
BOLT 1/4 X 1-1/4
2
WASHER 1/4 IN. ............................................... 2 .............. REPLACES 492622
LOCK WASHER 1/4 IN. ..................................... 2 .............. REPLACES 492596
BOLT 1/4 X 1-3/4 IN.
1
HEX NUT 1/4 IN.
2
BOLT M6 X 15
2
WASHER, FLAT 1/4 IN.
4
THROTTLE BLOCK COUPLING ....................... 1 .............. INCLUDES ITEMS W/
*
SEAL CONNECTOR
1
CONNECTOR, DIN PG9
1
ELBOW ADAPTER 90° MALE
4
HOSE, HYDRAULIC COMPENSATOR
1
ELBOW ADAPTER IN.T IN.
1
ELBOW ADAPTER 90 DEG. MALE
2
HOSE 13.75 IN. LONG
2
ELBOW ADAPTER 90° MALE
2
HYDRAULIC CYLINDER
1
BOLT 1/4 IN. X 1 IN.
1
NUT 1/4 IN.
1
BRACKET, ACCELERATOR
1
THROTTLE CABLE GUIDE
1
HEX NUT 1/4-20 IN.
1
CABLE CONTROL ACCELERATOR
1
BOLT 8 X 1/4 IN.
1
SLEEVE, ACCELERATOR
1
COIL, 12V
1
CARTRIDGE VAL VE
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 121
LS-60TD PUMP — WATER SEPARATOR ASSY.
PAGE 122 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — WATER SEPARATOR ASSY.
NO.
1
2
3
3A
4
5
6
7
8
PART NO.
EM509449
EM492356
EM16747
EM167472
EM492356
2105164
C514559
EM506208
EM514536
PART NAME
QTY.
REMARKS
BRACKET, WATER SEPERATOR
1
BOLT
2
WATER SEPERATOR ASSEMBLY
1
CARTRIDGE, WATER SEPERATOR ................. 1 .............. REPLACES P53712
BOLT 5/16 X 1 IN.
3
HEX NUT 5/16 IN. ............................................. 3 .............. REPLACES 492582
ELBOW ADAPTER 90° MALE
2
CLAMP, HOSE
2
HOSE 5/16 IN.
TBD
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 123
LS-60TD PUMP — HYDRAULIC PUMP ASSY. (OLD STYLE)
PAGE 124 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HYDRAULIC PUMP ASSY. (OLD STYLE)
NO.
1
*
2
3
4
5
6
7
8
9
10
11
12%
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
37
38
39
PART NO.
EM514614
EM514608
PART NAME
QTY.
REMARKS
O-RING
1
FLANGE, SUCTION PIPE ................................... 2 .......... INCLUDES ITEMS W/
*
BOLT 1/2 X 1-1/2 IN. ............................................ 4 .......... MAY 2007 AND BELOW
WASHER, LOCK 1/2 IN. ...................................... 8 .......... REPLACES 492626
SUCTION PIPE ADAPTER, 40 SPECIAL
1
CLAMP TYPE 'J' 3 IN. ......................................... 4 .......... MAY 2007 AND BELOW
HOSE, SUCTION 2 IN.
1
ADAPTER, SUCTION PIPE 32
1
FLANGE, SUCTION PIPE ................................... 1 .......... INCLUDES ITEMS W/%
BOLT 1/2 X 1-1/2 IN.
4
WASHER, LOCK 1/2 IN. ...................................... 4 .......... REPLACES 492626
O-RING
1
COUPLER, ENGINE ASSY.
1
MAY 2007 AND BELOW
BOLT 1/2 X 1-1/2 IN.
4
PUMP, MAIN 100CC, PARKER P2-100 SERIES 1
VALVE, CARTRIDGE
1
BOLT 7/16 X 3 IN.
4
GASKET
1
PUMP, SECONDARY
1
BOLT 3/8 X 1 IN. .................................................. 2 .......... REPLACES 492375
WASHER, LOCK 3/8 IN. ...................................... 2 .......... REPLACES 492624
STRAIGHT ADAPTER ......................................... 1 .......... MAY 2007 AND BELOW
ADAPTER............................................................. 1 .......... MAY 2007 AND BELOW
HOSE 4000 PSI, SENSOR .................................. 1 .......... MAY 2007 AND BELOW
ELBOW ADAPTER ............................................... 1 .......... MAY 2007 AND BELOW
STRAIGHT ADAPTER ......................................... 1 .......... MAY 2007 AND BELOW
STRAIGHT ADAPTER ......................................... 1 .......... MAY 2007 AND BELOW
STRAIGHT ADAPTER
1
ELBOW ADAPTER 90° MALE
2
ELBOW ADAPTER 90° FEMALE ......................... 1 .......... MAY 2007 AND BELOW
HOSE 2000 PSI, REMIX VALVE
1
FLOW CONTROL ASSY. ...................................... 1 .......... SEE HYD. PUMP ASSY.
........................................................................................... (NEW STYLE) ITEM 33
HOSE, MAIN MANIFOLD ..................................... 1 .......... MAY 2007 AND BELOW
HOSE
1
54812
EM506611
SCREW ALLEN HEAD CAP ...................................... 10 ........... REPLACES EM162
BOLT
8
EM514719
EM492455
6109180
EM514718
EM26473
EM514623
EM514627
EM514628
EM510902
6109180
EM98176
EM510902
EM98154
EM98209
EM506953
EM16190
EM98107
EM963610
0166 A
EM25462
EM25511
EM514599
EM25506
EM16525
TBD
EM25498
EM16524
506195
EM514601
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 125
LS-60TD PUMP — HYDRAULIC PUMP ASSY. (NEW STYLE)
PAGE 126 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — HYDRAULIC PUMP ASSY. (NEW STYLE)
NO.
1
2
3
4
5
6
7
8
9
10
11
12%
13
14
16
17
18$
19
20
21
22
23
24
25
26
29
30
31
32
33
EM516777
EM510902
EM98257
TBD
511428
EM16190
EM98107
EM963610
0166 A
EM509796
EM25429
516875
EM25429
EM25498
EM16524
506200
EM514601
EM98165A
34
35
36$
37
39
40
41
42
43
EM517032
EM25459
TBD
EM514608
EM25459
EM25429
54812
EM506611
EM517149
*
PART NO.
TBD
EM514719
EM492444
6109180
EM514718
EM515207
EM514623
EM514627
EM514628
EM510902
6109180
PART NAME
QTY.
REMARKS
O-RING
1
FLANGE, SUCTION PIPE .......................................... 2 ............ INCLUDES ITEMS W/
BOLT 1/2 X 1-1/4 IN. ................................................... 4 ............ JUNE 2007 AND ABOVE
WASHER, LOCK 1/2 IN. .............................................. 6 ............ REPLACES 492626
SUCTION PIPE ADAPTER, 40 SPECIAL
1
CLAMP 2 IN. ................................................................ 2 ............ JUNE 2007 AND ABOVE
HOSE, SUCTION 2 IN.
1
ADAPTER, SUCTION PIPE 32
1
FLANGE, SUCTION PIPE .......................................... 1 ............ INCLUDES ITEMS W/%
BOLT 1/2 X 1-1/2 IN.
4
WASHER, LOCK 1/2 IN. .............................................. 4 ............ REPLACES 492626
O-RING
1
COUPLER, ENGINE ASSY.
1
JUNE 2007 AND ABOVE
BOLT 1/2 X 1-1/2 IN.
2
PUMP, MAIN 100CC, PARKER P1-100 SERIES ........ 1 ............ JUNE 2007 AND ABOVE
VALVE, CARTRIDGE
1
SCREW ALLEN HEAD 1/2-13X3
4
GASKET
1
PUMP, SECONDARY
1
BOLT 3/8 X 1 IN. .......................................................... 2 ............ REPLACES 492375
WASHER, LOCK 3/8 IN. .............................................. 2 ............ REPLACES 492624
STRAIGHT ADAPTER ................................................ 1 ............ JUNE 2007 AND ABOVE
ELBOW ADAPTER ..................................................... 1 ............ JUNE 2007 AND ABOVE
HOSE, 4000 PSI SENSOR ......................................... 1 ............ JUNE 2007 AND ABOVE
ELBOW ADAPTER ..................................................... 1 ............ JUNE 2007 AND ABOVE
STRAIGHT ADAPTER
1
ELBOW ADAPTER 90° MALE
2
ELBOW ADAPTER ..................................................... 1 ............ JUNE 2007 AND ABOVE
HOSE 2000 PSI, REMIX VALVE
1
FLOW CONTROL MANIFOLD ASSY.
1
W/ PARKER P1-100 AND P2-100 PUMP ................................... INCLUDES ITEMS W/$
..................................................................................................... JUNE 2007 AND ABOVE
HOSE, MAIN MANIFOLD ............................................ 1 ............ JUNE 2007 AND ABOVE
ELBOW ........................................................................ 1 ............ JUNE 2007 AND ABOVE
VALVE, MAIN RELIEF ................................................. 1 ............ JUNE 2007 AND ABOVE
HOSE
1
ELBOW ........................................................................ 1 ............ JUNE 2007 AND ABOVE
ELBOW ADAPTER ..................................................... 1 ............ JUNE 2007 AND ABOVE
SCREW ALLEN HEAD CAP ...................................... 10 ........... REPLACES EM162
BOLT
8
FITTING 90° ................................................................ 1 ............ JUNE 2007 AND ABOVE
*
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 127
LS-60TD PUMP — MANIFOLD ASSY.
7
4
6
2
FRONT OF
MACHINE
5
1
3
10
8
A1
B1
9
16
T1
11
15
13
18
19
19
12 12A
14
A2
B2
16
T3
17
23
18
14
T2
P2
14
AAC
P1
20
GA
21
24
25
22
23
22
23
PAGE 128 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — MANIFOLD ASSY.
NO.
1
2
3
4%
5%#
6%#
7%#
8%
9%&
10%
11%
12%
12A%
13
14
15
16
17
18
19
19
20
21
22
23
24
25
PART NO.
EM963102
6109180
EM98261
EM98220
EMBK227
EM98223
EMK2097
EM98221
EM98222
TBD
EM98224
EM98228
EM98229
EM25498
EM509401
EM514488
EM25459
EM98226
EM514231
EM14489
EM514489
EM509796
506193
EM25462
EM509353
EM25429
TBD
PART NAME
QTY.
REMARKS
BOLT 1/2 X 1-1/4 IN. ................................................ 4 .......... REPLACES 492393
WASHER, LOCK 1/2 IN. ........................................... 4 .......... REPLACES 492626
MANIFOLD ASSY COMPLETE ............................... 1 .......... REPLACES EM98109
CYCLING VALVE ASSY, SWING ............................. 1 .......... INCLUDES ITEMS W/ #
BOLT, ALLEN HEAD, 1/2 X 2 1/4" SHCS
12
PILOT VALVE, SHUTTLE
1
BOLT, ALLEN HEAD, 1/2 X 1 1/4" SHCS
8
CYCLING VALVE ASSY, MAIN ................................ 1 .......... INCLUDES ITEM W/ &
PILOT VALVE, MAIN CYLINDER
1
CHECK VALVE
1
MAIN RELIEF VALVE ............................................... 1 .......... DISCONTINUED MAY 2007
COIL, 12VDC ACCUMULATOR
1
ACCUMULATOR UNLOADER CARTRIDGE ASSY 1
ADAPTER
1
ADAPTER
3
ADAPTER
1
ADAPTER
2
UNLOADING RELIEF VALVE, SHUTTLE
1
ADAPTER
2
ADAPTER ................................................................. 3 .......... MAY 2007 AND BELOW
ADAPTER ................................................................. 2 .......... JUNE 2007 AND ABOVE
ADAPTER
1
ADAPTER
1
ADAPTER
2
ADAPTER
3
ADAPTER
1
CHECK VALVE
1
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 129
LS-60TD PUMP — CONTROL BOX ASSY.
PAGE 130 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART NO.
EM9812560
492364
492597
492582
EM98171
EM98206
EM98206K
EM98208
01180384
51908
01180382
EM98120
EM98119
EM98121
EM98122
EM97062
EM98124
EM97068
PART NAME
CONTROL BOX ASSY
BOLT 5/16 X 1 IN.
WASHER, FLAT 5/16 IN.
NUT 5/16 IN.
OVERLAY, CONTROL PANEL
IGNITION SWITCH ASSY.
KEY, IGNITION
EMERGENCY STOP SWITCH ASSY.
BATTERY LIGHT ASSY.
BULB, LIGHT
OIL LIGHT ASSY.
FLOW DIRECTION SWITCH ASSY.
MAIN CONTROL SWITCH ASSY.
AUTO/JOG SWITCH ASSY.
JOG A/B SWITCH ASSY.
HOUR METER ASSY.
TACHOMETER ASSY.
RECEPTACLE, REMOTE
QTY.
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
2
1
1
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 131
LS-60TD PUMP — CONTROL BOX HARNESSES ASSY.
PAGE 132 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — CONTROL BOX HARNESSES ASSY.
NO.
1
2
4
5
6
7
PART NO.
EM514639
344102000
EM514637
EM514638
509588
16716
PART NAME
WIRE HARNESS 1
FUSE, 30 AMP
WIRE HARNESS 3
WIRE HARNESS 4
POLY FLEX TUBE 1/2 IN. BLACK
CONDUCTIVE DIVIDER 3/8 IN.
QTY.
1
1
1
1
AR
AR
REMARKS
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 133
LS-60TD PUMP — REMOTE CONTROL CABLE ASSY.
PAGE 134 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
LS-60TD PUMP — REMOTE CONTROL CABLE ASSY.
NO.
1
*
2
*
2A
3
*
4
*
5
*
6
*
7
8
9
PART NO.
EM16753
EM16754
EM97075
EM491897
EM16756
EM26791
EM26790
EM26793
EM97065
EM97099
PART NAME
QTY.
REMARKS
JUNCTION BOX
1
SWITCH
1
SWITCH
1
CONNECTOR, RING 3/16 IN.
4
GUARD SWITCH - ALUMINUM
2
SEAL, GRIP CORD
1
CORD, MX P/E 25 FT.
1
ADAPTER, CORD GRIP 1/2 IN.
1
ADAPTER, CORD 100 FT.
1
COMPLETE CORD ASSY 25 FT .............. 1 ................ INCLUDES ITEMS W/
*
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 135
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5.
Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
6.
The following items are not returnable:
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
a.
SPECIAL EXPEDITING SERVICE
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
b.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
1.
2.
A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
c.
Any line item with an extended
dealer net price of less than
$5.00.
d.
Special order items.
e.
Electrical components.
f.
Paint, chemicals, and lubricants.
g.
Decals and paper products.
h.
Items purchased in kits.
7.
The sender will be notified of any material
received that is not acceptable.
To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
8.
Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
a.
The parts numbers and descriptions
must match the current parts price
list.
9.
b.
The list must be typed or computer
generated.
Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
c.
The list must state the reason(s)
for the return.
d.
The list must reference the sales
order(s) or invoice (s) under
which the items were originally
purchased.
e.
The list must include the name
and phone number of the person
requesting the RMA.
3.
A copy of the Return Material Authorization
must accompany the return shipment.
4.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
Effective: February 22, 2006
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
PAGE 136 — MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11)
MAYCO PUMP WARRANTY
Mechanical Drive Models
MAYCO PUMP, hereinafter referred to as “Manufacturer’,
warrants each new Mayco Pump sold by the manufacturer
to be free from defects in material and workmanship, under
normal use and service, for a period of one year after the
date of delivery to the original retail purchaser. Manufacturer
will, at its option, replace or repair at a point designated by
the Manufacturer any part or parts which shall appear to
the satisfaction of the Manufacturer upon inspection at such
point to have been defective in material or workmanship.
This warranty does not obligate the Manufacturer to bear
any transportation charges or labor charges in connection
with the replacement or repair the of the defective parts.
This warranty does not apply to any pump if attempts have
been made to pump concrete materials which have
separated, to any pump which has been repaired with other
than Genuine Mayco Parts, nor to any pump which has
been altered, repaired or used in such manner as to adversely
affect its performance, nor to normal service or maintenance
or where blockages have developed within the pump manifold
or placing line or which has been operated in any other
manner not recommended by the Manufacturer. Due to the
abrasive nature of concrete, Mayco does not cover natural
component wear.
THIS WARRANTY AND MANUFACTURER’S OBLIGATION
HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER
OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR
CONSEQUENTIAL DAMAGES OR CONTINGENT
LIABILITIES ARISING OUT OF THE FAILURE OF ANY
PUMP OR PART TO OPERATE PROPERLY, INCLUDING
ANY WARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE.
Hydraulic Drive Models
MAYCO PUMP, hereinafter referred to as “Manufacturer”,
warrants each new Mayco Pump sold by the manufacturer
to be free from defects in material and workmanship, under
normal use and service, for a period of one year or 2000
hours after the date of delivery to the original retail purchaser.
The Manufacturer will, at its option, replace or repair at a
point designated by Manufacturer any part or parts which
shall appear to the satisfaction of Manufacturer upon
inspection at such point to have been defective in material
or workmanship. This warranty does not obligate
Manufacturer to bear any transportation charges or labor
charges in connection with the replacement or repair of the
defective parts.
This warranty does not apply to any pump if attempts have
been made to pump concrete materials which have
separated, to any pump which has been repaired with other
than Genuine Mayco Parts, nor to any pump which has
been altered, repaired or used in such manner as to adversely
affect it’s performance, nor to normal service or maintenance
or where blockages have developed within the pump manifold
or placing line or which has been operated in any other
manner not recommended by the Manufacturer. Due to the
abrasive nature of concrete, Mayco does not cover natural
component wear.
THIS WARRANTY AND MANUFACTURER’S OBLIGATION
HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER
OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR
CONSEQUENTIAL DAMAGES OR CONTINGENT
LIABILITIES ARISING OUT OF THE FAILURE OF ANY
PUMP OR PART TO OPERATE PROPERLY, INCLUDING
ANY WARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE.
MAYCO LS-60TD PUMP — OPERATION AND PARTS MANUAL — REV. #4 (09/15/11) — PAGE 137
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
MQ Parts Department
Tel. (800) 421-1244
Fax (800) 537-3927
Service Department
800-421-1244
310-537-3700
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
Fax: 310-537-4259
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
Fax: 310-943-2238
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, MULTIQUIP INC.
Multiquip Inc, the MQ logo and the Mayco logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks
are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
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 manual 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
in this publication at any time without notice and without incurring any obligations.
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