ꢀ LS60TDꢀandꢀLS600ꢀ(DeutzꢀEngine)
Control Box Replacement
The following instructions are intended to assist the user in the installation of the replacement control box on the
LS60TD and LS600 Concrete Pump. Please read all instructions before installing the control box and relay kit.
RequiReD TOOLS/COmpOnenTS
WORk SafeLY!
Only„a„qualified service technician„with„proper„training„
should„perform„this„installation.„Follow„all„shop„safety„rules„
when„performing„this„installation.
„„Crimping„Tool
„„Wire„Cutter„Tool
„„Wire„Stripper„Tool
pRepaRaTiOn
„„Two„12-10„AWG„Butt„Splice
„„One„14-16„AWG„Butt„Splice
„„One„12-10„AWG„Spade„Lug
1.„ Place„the„pump„in„an„area„free„of„dirt„and„debris.
2.„ Disconnect„negative„battery„cable„from„the„battery.
paRTS
3.„ Disconnect„the„4„plugs„from„the„receptacles„on„the„
rear„of„the„control„box„currently„installed„on„the„pump„
(see„Figure„2).„Mark„and„tag„the„plugs„for„reference„
when„new„control„box„is„installed.„Remove„the„fuse„
from„the„rear„of„the„control„box„and„keep„the„nut„and„
washers.„They„will„be„used„to„reinstall„the„fuse„on„the„
new„control„box.
Verify„that„parts„are„accounted„for.„See„Figure„1„and„Table„1.
2
5
3
4.„ Remove„the„existing„control„box„as„shown„in„Figure„2.„
Keep„the„hex„bolts,„flat„washers„and„lock„nuts.„They„
will„be„used„in„the„installation„of„the„new„control„box.
4
OPEN HATCH
PLUGS (4)
OLD
CONTROL
PANEL
FUSE
1
Figure 1. Required Parts
FLAT
WASHER (8)
Table 1. Required parts
item
no.
part no.
Description
qTY.
Remarks
1
EM517648A
EM515799
___
Digital„Control„Box
Relay„Kit
1
1
1
2
3
4
HEX BOLT (4)
LOCK NUT (4)
10/32"„Hex„Nut„
Not„Provided
Not„Provided
Not„Provided
___
___
#10„Lock„Washer
#10„Flat„Washer
1
1
SCREW (2)
5
Figure 2. Removing Existing Control Box
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 1
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BLACK 16 AWG
86
85
Butt Splice
30
87
Relay K1
REAR VIEW
STARTER
GROUND
POINT
Relay Connector
PURPLE 10 AWG
PURPLE 12 AWG
IN
+ 12V DC
Power
ORANGE 10 AWG
Butt Splice
OUT
Existing Fuse
RED 10 AWG
6
4
Spade Lug
P1
Cut Flush
P4
Butt Splice
Plugs
4
TO
START/STOP
SOLENOID
Figure 5. Connections Between Control Box and Relay
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 3
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Plug P1
Plug P1
Outside Terminal # 6
(Ignition B+)
Outside Terminal # 4 Splice
B+ Power (Fuse)
12 AWG Purple Wire
10 AWG Purple Wire
#86
#87
#85
#30
10 AWG Red Wire
Plug P4 Terminal # 4
(Cut Wire Flush)
Opposite End to Deutz
Start/Stop Solenoid
16 AWG Black Wire
Starter Ground Point
Figure 6. Relay P/N EM515799 Relay Schematic Diagram
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 4
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6.„ Once„„the„language„is„selected,„place„the„CONTROL„
switch„to„the„center„off„position.
COnTROL bOX pROgRamming
NOTICE
7.„ Turn„the„IGNITION„switch„to„OFF„then„ON„again„to„
memorize„final„configuration.
Control„boxes„come„pre-programmed„from„the„factory„
and„configured„to„Model„LS300.„It„is„necessary„to„
reprogram„the„model„configuration„to„match„your„unit.„
machine model Configuration
1.„ Turn„the„IGNITION„switch„to„the„ON„position.„Do„not„
start„engine.
See„Figure„7„to„identify„control„box„switches.
2.„ Place„the„FLOW„DIRECTION„switch„to„reverse.
3.„ Place„the„AUTOMATIC/JOG„switch„to„jog.
4.„ Place„the„CONTROL„switch„to„remote.
Digital Screen
Ignition Switch
Reset Switch
5.„ Manually„hold„the„CYLINDER„STROKE„switch„to„the„
jog„B„position.„While„holding„the„switch„to„the„jog„B„
position,„toggle„the„RESET„switch„down„5„times.„after
the fifth time, move the CYLinDeR STROke switch
to the jog a position.„While„holding„the„switch„to„the„
jog„A„position,„toggle„the„RESET„switch„down„to„the„
desired„model„(LS60TD„or„LS600).
RESET
SET
SCROLL
OFF
ON
VOLUME
DECREASE
INCREASE
FLOW
DIRECTION
START
IGNITION
CONTROL
6.„ Once„the„model„is„selected,„place„the„CONTROL„
switch„to„the„center„off„position.
FORWARD
REVERSE
LOCAL
CENTER
OFF
CYLINDER STROKE
7.„ Turn„the„IGNITION„switch„to„OFF„then„ON„again„to„
memorize„final„configuration.
JOG “A”
JOG “”
AUTOMATIC
JOG
MULTIQUIP INC. CARSON, CALIFORNIA 9046 USA
310-537-3700 800-421-1244 WWW.MULTIUIP.COM
REMOTE
Automatic/Jog
Switch
Control Switch
Cylinder Stroke
Switch
Flow Direction
Switch
Figure 7. Control Box Switches
Language Selection
1.„ Turn„the„IGNITION„switch„to„the„ON„position.„Do„not„
start„engine.
2.„ Place„the„FLOW„DIRECTION„switch„to„reverse.
3.„ Place„the„AUTOMATIC/JOG„switch„to„jog.
4.„ Place„the„CONTROL„switch„to„remote.
5.„ Manually„hold„the„CYLINDER„STROKE„switch„to„the„
jog„B„position.„While„holding„the„switch„to„the„jog„B„
position,„toggle„the„RESET„switch„down„5„times.„On„
the„fifth„time,„the„digital„screen„will„display„the„current„
set„language.„Toggle„RESET„switch„again„to„change„
language,„if„desired.
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 5
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COnTROL paneL COmpOnenTS
5
3
1
4
12
N
RESET
00
SCROLL
SET
11
VOLUME
ON
OFF
START
INCREASE
DECREASE
ACCUMULATOR
PRESSURE
2
8
IGNITION
13
FLOW
CONTROL
00
DIRECTION
7
REMOTE
LOCAL
FORWARD
REVERSE
CENTER
OFF
CYLINDER STROKE
AUTOMATIC
JOG
JOG “A”
JOG “B”
PUMPING
REMOTE
PRESSURE
6
9
10
Figure 8. Digital Control Panel Components
1.„ emergency Stop button —„Press„emergency„stop„
button„to„stop„pump„in„an„emergency.„Turn„knob„
counterclockwise„to„disengage„the„stop„button.
9.„ Cylinder Stroke Control Switch —„This„2-position„
switch„controls„the„pumping„function.„The„leftmost„
position„(AUTOMATIC)„sets„the„pump„to„automatic„
cycling.„Set„the„switch„to„this„position„for„normal„pump„
operation.
2.„ ignition Switch —„Insert„the„ignition„key„here„to„start„
the„engine.„Turn„the„key„clockwise„to„the„ON„position,„
then„continue„turning„clockwise„to„the„START„position„
and„release.„To„stop„the„engine„turn„the„key„fully„
counterclockwise„to„the„STOP„position.
„
The„rightmost„position„(JOG)„changes„the„pump„from„
automatic„to„manual„cycling.„This„allows„the„cylinders„
to„be„manually„cycled„using„the„Manual„Cylinder„
Jogging„Switch.
3.„ Digital Readout Screen —„Displays„and„monitors„the„
various„functions„of„the„machine.
10.„ manual Cylinder Jogging Switch —„This„„2-position„
switch„allows„the„operator„to„manually„jog„the„cylinders„
to„assist„in„clearing„material„line„packs„and„is„used„to„
test„pumping„pressure.
4.„ Scroll Switch —„Allows„the„operator„to„scroll„the„
various„readout„screens.
5.„ Reset Switch —„Allows„the„operator„to„reset„the„
stroke„counter.
„
The„ leftmost„ position„ jogs„ Cylinder„“A”„and„the„
rightmost„position„jogs„Cylinder„“B”.
6.„ Remote Cable Connector —„Insert„the„remote„control„
input„cable„into„this„connector.
11.„ Stroke volume Control Switch —„Increases„or„
decreases„the„number„of„strokes„per„minute„of„the„
pump„(not„used„on„model„LS60TD).
7.„ Direction Control Switch —„This„2-position„switch„
controls„the„direction„of„flow„for„any„mix„in„the„pump.„
The„leftmost„position„sets„the„pumping„direction„to„
forward„and„the„rightmost„position„sets„the„pumping„
direction„to„reverse.
12.„ accumulator pressure gauge —„This„ gauge„
monitors„the„internal„pressure„of„the„Accumulator„tank.„
Normal„internal„pressure„should„read„approximately„
1750„PSI„during„pumping.
8.„ pumping Control Switch —„This„3-position„switch„
controls„the„pumping„of„the„pump.„The„rightmost„
position„(REMOTE)„is„for„use„with„the„remote„control„
unit,„the„leftmost„position„(LOCAL)„is„for„normal„
pumping„operation,„and„the„centermost„position„
(CENTER„OFF)„prevents„pumping.
13.„ main pressure gauge —„This„ gauge„monitors„
the„system„pressure„while„pumping„material.„The„
maximum„pressure„rating„is„4400„PSI„ „50.
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 6
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Screen 5
DigiTaL ReaDOuT SCReenS
primary Screen
Displays„the„ON/OFF„electrical„signal„status„of„the„various„
12„volt„solenoids„(Swing„A„circuit,„Main„A„circuit,„Main„B„
circuit).
Screen 1
INDICATES
SWING A
Indicates„the„various„modes„of„the„switch„settings.
CIRCUIT IS OFF
5
SWING A OFF
Monitors„engine„RPM„-„Idle„speed„900,„High„speed„
2550.„Battery„charge„indicator„-„Normal„charge„13+„volts.„
Indicates„electrical„malfunction.
MAIN A OFF
MAIN B OFF
INDICATES
MAIN A
INDICATES
MAIN B
CIRCUIT IS OFF
CIRCUIT IS OFF
„
Screen 6
Displays„the„ON/OFF„electrical„signal„status„for„the„
Proximity„Switch„A,„Proximity„Switch„B,„Engine„Fuel„
Solenoid,„and„Unloader„Solenoid.
INDICATES
INDICATES
PROXIMITY A
CIRCUIT IS OFF
PROXIMITY B
CIRCUIT IS ON
Secondary Screens
6
PROX A OFF
PROX B ON
FUEL SOL OFF
UNLOADER OFF
Screen 2 (not used on model LS60TD)
INDICATES
INDICATES
FUEL SOLENOID
CIRCUIT IS OFF
UNLOADER
Displays„the„position„of„the„VOLUME„CONTROL„switch„
by„indicating„whether„the„increase„or„decrease„position„
is„on„or„off.
CIRCUIT IS OFF
Screen 7
INDICATES VOLUME
SWITCH IS NOT IN
THE - POSITION
Displays„the„number„of„times„the„main„hydraulic„cylinders„
stroke„and„the„yards„per„hour„output.„This„indicator„can„be„
reset„to„zero„by„the„RESET„switch„on„the„control„panel.
2
FLOW DEC OFF
FLOW INC ON
INDICATES VOLUME
SWITCH IS IN THE
+ POSITION
INDICATES THE
NUMBER OF
STROKES
INDICATES
THROTTLE
IS ON
7
THROTTLE ON
STROKES: 20
STROKES/MIN 8.2
YDS/HR 10.7
Screen 3
INDICATES THE
NO. OF YARDS
PER HOUR
INDICATES THE
NO. OF STROKES
PER MINUTE
Displays„the„number„of„hours„the„engine„and„pump„
have„been„used„and„the„number„of„faults„the„pump„has„
registered.„All„three„indicators„can„be„reset„to„zero„by„the„
RESET„switch„on„the„control„panel.
Screen 8
Displays„the„electrical„status„of„the„engine„fuel„solenoid.„To„
test„the„12-Volt„solenoid„status,„activate„with„the„RESET„
switch„on„the„control„panel.
INDICATES NO.
OF HOURS
INDICATES NO.
OF HOURS
PUMP HAS
BEEN USED
ENGINE HAS
BEEN USED
INSTRUCTION
3
E HRS: 00000.0
OR MESSAGE
PMP HRS: 00000.0
FAULTS: 00000000
RESET TO CLEAR
8
TO TEST FUEL
INDICATES NO.
OF FAULTS
SOL PRESS RESET
FUEL SOL OFF
MESSAGE OR
INSTRUCTION
DETECTED
INDICATES THE
FUEL SOLENOID
Screen 4
IS OFF
Screen 9
Displays„the„number„of„strokes„the„main„hydraulic„cylinders„
have„gone„through.„This„indicator„can„be„reset„to„zero„by„
the„RESET„switch„on„the„control„panel.
Displays„the„communication„status„of„the„(optional)„radio„
remote„control.„To„activate„a„new„remote„control„connection,„
use„the„reset„switch„on„the„control„panel.
INDICATES A
RUNNING
INDICATES
COUNT OF
THAT RADIO
4
NO. OF STROKES
STROKE CTR: 0000
9
REMOTE IS ON
RADIO ADDRESS
COMMUNICATING
PRESS RESET TO
PRESS RESET TO
ZERO STROKE CTR
LEARN A NEW ONE
MESSAGE OR
INFORMATION
IINSTRUCTION
OR MESSAGE
LS60TD anD LS600 — COnTROL bOX RepLaCemenT — Rev. #1 (03/23/12) — page 7
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ꢀ LS60TDꢀandꢀLS600
Control Box Replacement
HERE’S HOW TO GET HELP
PLEASE„HAVE„THE„MODEL„AND„SERIAL
NUMBER„ON-HAND WHEN„CALLING
United StateS
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
mexico
United Kingdom
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
Canada
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
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of their respective owners and used with permission.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this document are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Your„Local„Dealer„is:
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