Multiquip ST-45HRM User Manual

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OPERATIONS & PARTS MANUAL

SERIES

MODEL ST-45HRM

STRUCTURAL CONCRETE PUMP

(HATZ DIESEL ENGINE)

FINAL REVISION

Revision #4 (07/16/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

Proposition 65 W arning

PAGE 2 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mq@multiquip.com Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

MAYCO PARTS

800-306-2926 310-537-3700

SERVICE DEPARTMENT

800-421-1244 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-421-1244, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-537-3927

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-537-4259

FAX:

310-631-5032

FAX:

310-537-1173

altered without written permission. All other trademarks are the property of thier respective owners and used with permission. This manual

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 are

based on the 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.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

Mayco ST-45HRM w/ Hatz Diesel Engine.

Illustrations, descriptions, references and technical data contained in this

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 3

TABLE OF CONTENTS

MAYCO ST-45HRM STRUCTURAL CONCRETE PUMP

Proposition 65 Warning .............................................2

Here’s how To Get Help............................................. 3

Table of Contents ...................................................... 4

Parts Ordering Procedures ...................................... 5

Pump Specifications ..................................................6

Engine Specifications ................................................ 7

Dimensions .............................................................. 8

Safety Message Alert Symbols .......................... 9-10

Rules for Safe Operation ................................... 11-13

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

Operating Procedures....................................... 24-28

Inspection .......................................................... 29-31

Initial Start-Up Procedure ................................. 32-35

Towing Guidelines ............................................. 36-37

Trailer Safety Guidelines ................................... 38-40

Towing Information ............................................ 41-42

Wiring Diagram (Tail Lights) ....................................43

Maintenance (Pump) ........................................ 44-52

Hydraulic Hose Connections ............................. 54-56

Manifold Port Locations ...........................................57

Appendix — Concrete Mix Information ............. 58-59

Appendix — Slump Test Procedure ........................60

Troubleshooting (Engine) ........................................61

Troubleshooting (Hydraulic System) ....................... 62

Troubleshooting (Electrical System) ....................... 63

Troubleshooting (Brake System).............................64

PARTS ILLUSTRATIONS

Explanation Of Code In Remarks Column .............. 64

Suggested Spare Parts ...........................................65

Appendix — Recommended

Shotcrete System ............................... 66

Appendix — Recommended

Shotcrete Accessories ........................ 68

Decal Placement ................................................70-71

Axle Assembly ....................................................74-75

Brakeline Assembly ............................................76-77

Hopper Assembly ...............................................78-79

Hopper Attachment Assembly ........................... 80-81

Hopper Interior Assembly ..................................82-83

Shuttle Cylinder Assembly ................................. 84-85

Fuel and Hydraulic Tank Assembly .................... 86-89

Front Cover Assembly........................................ 90-91

Heat Exchanger Assembly .................................92-93

Engine and Frame Assembly .............................94-96

Throttle and Water Filter Assembly ....................96-97

Hydraulic Pump Assembly ................................. 98-99

Lubrication Pistons Assembly ........................100-101

Electrical System Assembly ........................... 102-103

Accumulator Assembly...................................104-105

Manifold Assembly .........................................106-107

Remixer Control Assembly .............................108-109

Battery Assembly ...........................................110-111

Lubrication Panel ........................................... 112-113

Taillight Assembly ...........................................114-115

Control Box Interior Door Assembly...............116-117

Control Box Mounting Assembly ...................118-119

Control Box Assembly ...................................120-121

Control Box Door Wiring Diagram ......................... 122

Control Box Interior Wiring Diagram ..................... 123

Terminal Block Wiring Diagram ............................. 124

Control Box Electrical Schematic ................... 125-126

Interconnect Hydraulic Control Box ...................... 127

Hydraulic Diagram ............................................... 128

Optional Radio Control.......................................... 129

NOTE

PAGE 4 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

Specification and part number are subject to change without notice.

Terms and Conditions Of Sale — Parts ................ 130

Mayco Pump Warranty .......................................... 131

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ 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:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mq@multiquip.com Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

MAYCO PARTS

800-306-2926 310-537-3700

SERVICE DEPARTMENT

800-421-1244 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-421-1244, 310-537-3700,

EXT. EXT.

279 279

310-537-3927

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-537-4259

FAX:

310-631-5032

FAX:

310-537-1173

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE POST OFFICE BOX 6254 CARSON, CALIFORNIA 90749 310-537-3700 • 800-421-1244 FAX: 310-537-3927 E-MAIL: mq@multiquip.com INTERNET: www.multiquip.com

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

ST-45 PUMP — PUMP SPECIFICATIONS

dohteMgnipmuPnotsiPgnitacorpiceR

etaRgnipmuP*ruohrep.sdy.uc54otpU

eziSetagerggAmumixaM)mm83(sunim.ni2/1-1

hgieHgnipmuPlacitreV)m67(.tf052fossecxEotpU

ecnatsiDgnipmuPlatnoziroH*)m503(.tf0001

snoitacificepSpmuP54-TS.1elbaT

LrednilyC)sretiL5.62(snollaG7

yticapaCxoBnoitacirbu

yticapaCdiulFciluardyH)sretiL912(snollaG85

yticapaCknaTleuF)sretiL67(snollaG02

yticapaCreppoHreximerver/dwflanoitpohtiw.tf.uc01

esoHlairetaM

)elbac.tf52(lortnoCetomeRlanoitpo

snoisnemiD61egaPeeS

)sdiulfhtiw(thgieW)gk472,9(.sbl602,4

gieW)gk809,8(.sbl040,4

)gnippihs/yrd(th

.aid.ni5,.ni4,.ni3

)mm721,mm6.101,mm2.67(

eziSeriT)mm653xmm781(.ni41x.ni53.7

PAGE 6 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

snotitidnocetisbojdnadesuezisenil,pmuls,ngisedximnognidnepedyravlliwtuptuoemuloV*

ST-45 PUMP — ENGINE SPECIFICATIONS

ledoMENIGNELESEIDPH7514M3ZTAH

snoitacificepSenignE.2elbaT

ekortSXeroB

.ni31.4x.ni20.4

)mm501x201(

oitaRnoisserpmoC7.81

D)cc375,2(.uc751

tnemecalpsi

yticapaCliOebuL

niM/xaM

.tq4.5/.tq1.9

)L1.5/L6.8(

enignE

deepSenignE

001±mpr578

eldIlluF

epyTyrettaB)

hA341/88(V21

)edarGliO(03-W01EAS

noitacirbuLenignE

)ssalCecivreS(FSroGS

dohteMgnitratStratScirtcelE

thgieWteNyrD)gk552(sbl265

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 7

ST-45 PUMP — DIMENSIONS

SNOISNEMID.3ELBAT

.FERSNOISNEMID

A).mc3.411(.ni54

B).mc5.114(.ni261

C).mc16(.ni42

D).mc4.581(.ni37

E).mc2.271(.ni86

Figure 1. ST-45 Structural Concrete Pump Dimensions

PAGE 8 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 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

NOTE

Before using this pump , ensure that the operating individual has read and understands all instructions in this manual.

instructions for the safe and efficient operation of the Multiquip Mayco

ST-45 Structural Concrete

Refer to the engine manufacturers instructions for data relative to its safe operation.

pump.

HAZARD SYMBOLS

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,

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.

Explosive Fuel

Diesel fuel

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.

is extremely flammable, and its

DANGER: You WILL be KILLED or

SERIOUSLY injured if you do not follow directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you do not follow directions.

CAUTION: You CAN be injured if you

do not follow directions

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.

Burn Hazards

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.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep and clothing away from all moving parts to prevent injury.

fingers, hands, hair

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 9

ST-45 PUMP — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the ON/OFF switch in the OFF

position. NEVER perform maintenance on the unit with the ignition key in the ON position.

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.

This

pump

surrounding environment could

NOTE

be damaged if you do not follow instructions.

, other property, or the

Respiratory Hazard

ALWAYS wear approved

protection.

respiratory

Sight and Hearing hazard

ALWAYS wear approved

hearing

protection.

eye

and

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.

PAGE 10 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — RULES FOR SAFE OPERATION

■

CAUTION:

Failure to follow instructions in this manual may

death!

lead to serious injury or even 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 ST-45 structural concrete ump:

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), protection equipment when operating the pump .

hearing

This

and

eye

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

■

The engine section of this pump requires an adequate free flow of cooling air.

■

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 Fire or explosion could result from

vapors

hot!

components can cause serious burns.

smoke

NEVER

around or near the machine.

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

gas.

carbon monoxide

fuel

, 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

■

Topping-off to filler port is dangerous, as it tends to spill fuel.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 11

bodily harm or even death.

ST-45 PUMP — RULES FOR SAFE OPERATION

■

ALWAYS remove the

unattended.

■

ALWAYS block the

ignition key

wheels

on the unit when using on a

when leaving the pump

Transporting

■

slope.

■

ALWAYS maintain this equipment in a safe operating

■

condition at all times.

■

ALWAYS stop the engine before servicing, adding fuel or oil.

■

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

Towing

■

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 from the equipment at all times.

■

Before start-up, check the hopper and remove all foreign matter and debris.

inexperienced

and

unauthorized

people away

■

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.

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 5,000 lbs. load.

If unit is equipped with ball hitch coupler, use only 2" all steel ball rated for minimum of 5,000 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 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 operate unit with the

■

DO NOT disconnect hose couplings or nozzle while under

hood open

Maintenance Safety

■

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 technical questions or information

HATZ Engine Owner's Manual

for engine

recommended by Multiquip for this equipment. Damage to the equipment and or injury to user may result.

DO NOT tow unit in excess of 45 MPH on highways..

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.

PAGE 12 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — RULES FOR SAFE OPERATION

Battery

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irr itation, insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

2. 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.

3. ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

4. ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

5. ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

always

wear safety glasses. Use well

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

■

In emergencies nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

fire extinguisher

first aid kit

always

know the location of the

keep a phone on the job site

and

fire department

. This

6. In case the battery liquid (dilute sulfuric acid) comes in contact with

clothing or skin

plenty of water.

7. 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.

, rinse skin or clothing immediately with

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 13

ST-45 PUMP — OPERATION AND SAFETY DECALS

Machine Safety Decals

The ST-45 structural concrete pump is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. Figure 1 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. ST-45 Operation and Safety Decals

PAGE 14 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — OPERATION AND SAFETY DECALS

Figure 3. ST-45 Operation and Safety Decals

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 15

ST-45 PUMP — IMPORTANT HAND SIGNALS

Figure 1 display's the basic hand signals commonly used in concrete pumping operations.

Figure 4 Operation Hand Signals

PAGE 16 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 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 Model ST-45 will pump a wide variety of concrete pump mixes. But, there are guidelines that must be followed. Use this information in conjunction with the

Procedures

Operating

(pages 24-28).

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 17

ST-45 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 Model ST-45 be will working in. Therefore, the mixes on pages 58-59 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.

5. The proper amount of water to make a workable slump and plasticize the mix.

In addition, the Mayco Structural Concrete ST-45 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.

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.

PAGE 18 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 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.

Figure 5. Pumping Cycle 1

Figure 6. Pumping Cycle 2

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 5).

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 6), 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.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 19

ST-45 PUMP — PUMP COMPONENTS

Figure 7. Major Pump Components

PAGE 20 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — PUMP COMPONENTS

Figure 7 illustrates the location of the major components for the ST-45 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 5,000 lbs.

2. Documentation Box – Contains engine and pump operation, parts and maintenance information.

3. Hydraulic Oil Tank/Cap– Remove cap to add hydraulic fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if level is low.

4. Fuel Tank/Cap – Fill with diesel fuel. Fuel tank (cell) holds approximately 20 gallons (88 liters). DO NOT top off fuel. Wipe up any spilled fuel immediately

5. Battery – This unit uses a +12 VDC type battery. use gloves and eye protection when handling the battery.

6. 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.

7. Lubrication Box – This box is empty when shipped from the factory. Please fill with 7 gallons ( 26.5 liters) of SAE motor oil for first time use. Also check the dual clean-out point on bottom of lubrication box for a secure tight fit.

ALWAYS

13. Lubrication Panel – This console allows for the remote lubrication of components on the pump.

14. Rear Running Lights – ALWAYS check and make sure both the right and left running lights are functioning correctly before towing the pump.

15. Accumulator – Stores hydraulic oil under pressure and releases it to the shuttle cylinder and provides the required pressure to activate the hydraulic system.

16. Remixer Control Lever – Controls the forward/reverse motion of the hopper remixer paddles.

17. Manifold – Aluminum block that controls the flow of hydraulic pressure to the various hydraulic motors and other components required to control the pump.

18. Hydraulic Pump – This unit incorporates an axial variable displacement hydraulic piston pump.

19. 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..

8. Tires — This trailer uses two ST205-750 x14C type tires. Tire inflation pressure is the most important factor in tire life. Pressure should be checked to 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.

9. Shuttle Cylinder – Under pressure, the shuttle cylinder shears concrete passing from the concrete cylinder to the delivery line durring the cycle phase. The Accumulator provides the pressure needed to ensure enough force is provided during cycle.

10. 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.

11. Hopper/Hood – Lift hood to fill. Concrete from a Redi-Mix 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.

12. Remixer Motor – Drives the remixer paddles inside the hopper. The motor direction is controled by the remixer control lever.

50 psi cold

before

20. Stroke Volume Control Dial – Turns CW/CCW to increase

21. Control Box – Contains the mechanical and electrical

22. Tow End Jack Stand – Use this jack stand to level and

23. Pumping Pressure Gauge – Used to monitor pressure in

24. Accumulator Pressure Gauge– Used to monitor

25. Hydraulic Oil Sight Glass – Use to determine the

26. Hopper Discharge Sleeve – Connect hoses or steel

or decrease the number of strokes per minute of the pump.

components required to run the pump. See page 22 for components.

support the tow end of the pump.

the concrete cylinders and shuttle tube.

accumulator pressure. Pressure should read at least 1750 psi for correct pump operation.

amount of hydraulic oil remaining in tank. The sight glass also contains a temperature gauge for monitoring the temperature of the hydraulic oil.

pipes to the discharge sleeve for pouring concrete.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 21

ST-45 PUMP — CONTROL BOX COMPONENTS

Figure 8. Pump Control Box Components

1. Engine Tachometer – Monitors the engine RPM’s and hours of operation for the engine.

2. Emergency Stop Button – Press emergency stop button to stop pump in an emergency. Turn knob counter clockwise to disengage the stop button.

3. Hourmeter – Display's the number of hours the pump has been in use.

4. 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.

5. Battery Indicator Lamp– Indicates a low battery charge. Replace or charge battery. this lamp is on.

6. Oil Pressure Indicator Lamp– When lit, indicates correct operational pressure for running the ST-45. NEVER operate the ST-45 if this lamp is off.

7. Air Filter Indicator Lamp – Indicates the engine air filter is functioning properly. NEVER operate the ST-45 if this lamp is off.

NEVER operate the ST-45 when

8. Direction Control Switch– This 2 position switch controls

9. Pump Operation Switch– This 2 position switch controls

10. Pressure Test Switch– Activates a self-diagnostic routine

11. Pumping Control Switch – This 3-position switch controls

12. Cooling Fan Switch – If hydraulic oil temperature exeeds

13. Remote Cable Connector – Insert the remote control input

the direction of flow for any mix in the pump. The position sets the pumping direction to forward and the

position sets the pumping direction to reverse.

most

the operation of the pumping components and engine. The

center

engine and the to operate.

which tests the pressure of the pumping system, which can be read on the Pumping Pressure Gauge.

the pumping of the pump. The with the remote control unit, the normal pumping operation, and the (OFF) prevents pumping.

75° F, set the pump operation switch to engine and turn the cooling fan switch to the right most position to activate cooling fan.

cable into this connector.

position allows the operation of the pump and

right most

position allows only the engine

left most

position is for use

center

position is for

right most

center

right

position

PAGE 22 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — ENGINE COMPONENTS

Figure 9. Pump Control Box Components

INITIAL SERVICING

The

pump's

lubrication and filled with fuel prior to operation. Refer to the manufacturers Engine manual for instructions & details of operation and servicing.

1. 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.

2. Dip Stick – Remove dipstick to determine if the engine oil level is low. If low add oil as specified in Table 4, page 30.

3. Speed Control Lever – This lever is connected to the throttle control which is located on the side of the engine compartment cover. Use this lever to control engine speed.

4. Oil Filter – Prevents dirt and other debris from entering the engine. Service the oil filter as recommended in the maintenance section of this manual.

5. Side Oil Drain Plug – Remove this plug to drain engine oil from the engine crankcase. For best results drain engine oil when oil is warm.

engine (Figure 9) must be checked for proper

6. Air Filter/Cover – Prevents dirt and other debris from

7. Starter/Solenoid – This engine uses a 12 VDC , 2.7kW

8. Front Oil Drain Plug – Remove this plug to drain engine

9. V-Belt Cover – Remove this cover to gain access to the V-

entering the fuel system. Release the latches on the side of the air filter cover to gain access to filter element.

(3.7 HP) starter motor with solenoid.

oil from the engine crankcase. For best results drain engine oil when oil is warm.

belt. When replacing V-belt , use only recommended type V-belt.

NOTE

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 ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 23

ST-45 PUMP — OPERATING PROCEDURES

OPERATING SUGGESTIONS

1. A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job.

2. 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). This procedure lubricates the hose and prevents separation and blockages in the hose.

Getting the concrete to flow through

NOTE

CAUTION

Inspect the lines at all times to prevent the above conditions

3. It is important that once the slurry procedure is completed, and you have started concrete 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 at the start is if a blockage occurs.

4. 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:

the hose at the start of the pumping cycle can be one of the most critical operations of the pour. ( operate the throttle when starting, NOT REMOTELY)

If hoses or lines are or if the lines are 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

move

in a manner that could cause injury to

personnel.

blocked

kinked

when starting up or

Manually

for any reason,

whip

C. If it is necessary to wait 10 minutes or more for another

D. When pumping stiff mixes and there is waiting time

E. When the pumping job requires a stiffer mix, the

F. Hose sizing is very important: We strongly recom-

5. 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.

6. 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.

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.

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.

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 redimix 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.

mend 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.

A. Leave the hopper full of concrete at the time of

shutdown. It is important not to let the wash too much water into the hopper, as this could cause separation of the concrete in the hopper.

B. If the

shutdown

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.

PAGE 24 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

period exceeds 2 to 3 minutes, turn

redi-mix

driver

NOTE

Over-greasing any your Mayco pump will not damage the bearing.

bearing

ST-45 PUMP — OPERATING PROCEDURES

WARNING

Common sense tells us that if you drive a truck into a brick wall, something is going to be damaged. The same holds true with your concrete pump. If you repeatedly pull the throttle all the way out and try to force your

pump to push through 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.

blockages

due to

B. MBVR – air entraining, acts as a lubricant.

C. Calcium Chloride – commonly referred to as C.C., is

D. Super Plasticizers – acts as an accelerator. The

E. Red Label – acts as a water retarder and an accelerator.

WARNING

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

concrete can cause severe damage or

breakage of the axle and axle springs, excess

strain and pressure on the hub and bearing assembly.

Pumping Tips

full hopper

F. Fly Ash – is used to help increase the strength of the

NOTE

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.

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.

Red label will be used mainly on commercial jobs.

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.

The effects of heat and excessive time on concrete:

7. 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:

8. 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.

Admixtures:

9. 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.

10. 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.

11. Leaking manifold seals or hose coupling gaskets which leak water can cause separation and subsequent jamming at that point.

Priming the Pump and Delivery System with Slurry

12. It is CRITICAL to the successful operation of a concrete pump that the manifold and all delivery hose, pipe 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.

A. With the entire delivery system connected to the pump.

B. There are several things you can use for the prime. A

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.

few examples are Cement and lime at a 50/50 mixture, slick pac, bentonite clay.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 25

ST-45 PUMP — OPERATING PROCEDURES

C. Mix the prime to the consistency of a smooth batter. D. Position the first ready-mix truck at the hopper. Check

the concrete. DO NOT discharge concrete into hopper at this time.

The bentonite is not compatible with

NOTE

concrete. DO NOT pump it into the forms discharge it out of the formed area.

16. The shuttle tube is plugged if volume at the discharge end of the hose stops, the hose is soft and the hydraulic oil pressure gauge reads 3000 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

E. Pour approximately two 5 gallon buckets of prime into

the first hose and connect it to the pump.

F. With the pump in FORWARD at 25-30 strokes per

minute, slowly discharge the concrete from the readymix 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.

G. 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.

Clearing Concrete Blockage

13. Damaged hoses with internal restrictions can cause blockages.

14. If a blockage occurs in a hose, the point of trouble. The hose will be soft immediately past the blockage. If this happens at the start, disconnect the hose at the first coupling past the blockage.

walk the hose

until you find

“Reverse” Pumping Procedure

A. Switch the pump into

B. Remix the concrete in the hopper. C. Switch the pump into

If concrete still does not move, proceed to the Shuttle Tube Inspection Procedure.

Shuttle Tube Inspection Procedure

A. Stop the pump. Switch off the engine. B The senior or most experienced operator must warn all

DO NOT open any of the delivery system joint clamps.

reverse

medium-slow (approx. 12 strokes per min.) try to pull the “pack” back into the hopper with 5 or 6 reverse

strokes.

forward

“Reversing” procedure three times.

others to stand at least 20 feet away from the machine and turn their heads to face away from the pump.

. With pump speed at a

. If it is still plugged, repeat

15. Elevate the hose at that point with the blockage area hanging down. 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. 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.

CAUTION

Use extreme care! The hose line is under

pressure

PAGE 26 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

and can cause serious injury.

CAUTION

C. The operator will position themself beside the reducing

Saftey glasses MUST be worn at all times when operating the ST-45. Failure to follow saftey guidlines can result in serious injury.

elbow at the pump outlet. Wearing slip the end of a pry bar (24" length of reinforcing steel rod) under the latch of the hose clamp and flip it up.

safety glasses

ST-45 PUMP — OPERATING PROCEDURES

D. Carefully knock the end of the hose away from the

reducer. 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. The senior operator may then remove the inspection

cover plate from the shuttle tube by using a long

extension wrench and the 24" pry bar.

If, for any reason, the mix should set up in the system, the following procedure (

WARNING

Make sure the accumulator pressure gauge reads ZERO psi. prior to performing any maitinance or inspection.

H. Chip the blockage out with the pry-bar. I. Flush the shuttle tube with water. J. Replace and seal the inspection cover plate on the

shuttle tube. K. Before resuming operation of the pump, perform the

“Reverse” Pumping Procedure to relieve pressure on

the shuttle tubes.

17. If it is necessary to wait 1/2 hour or more for another load of concrete, and to prevent setting of the mix in the system, it is advisable to consider the following factors

A through D

(

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?

) affecting the concrete :

18. Down-Hill Pumping – can be difficult on some jobs. The slurry procedure would be the same as explained on the pages titled Operating Suggestions. It is suggested that a sponge 2”x 4”x 6” be placed in the hose before the start of pumping. Wet the sponge before placing it in the hose.

The reason for using the wet sponge is to keep the slurry from running too far ahead of the concrete and so reducing 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.

E through H

E. Disconnect the hose from the pump and wash the pump

out immediately.

F. Reconnect the hose and fill the hopper with water.

G. 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.

H. 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 factors (E through H) affecting the mix.

) is suggested:

NOTE

When disconnecting hoses, use

EXTREME CAUTION! The hose is

pressure!

under

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 27

19. Vertical Pumping – When pumping vertically up the side of a building, above 40 feet, we would recommend the installation of to support the pipe. Ninety degree, long radius pipe sweeps should be installed at the top and bottom of the steel line.

steel pipe

securely fastened at intervals as necessary

ST-45 PUMP — OPERATING PROCEDURES

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 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 90 degree elbow is recommended. The suggested place to tie off is on the hose, under the clamp.

NOTE

all hose

It is strongly recommended that steel pipe be used on all vertical

, it is recommended

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 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.

pumping for safety and convenience.

20. 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.

21. Snap-Joint – 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.

22. New Pumps – All new pumps are ‘water pressure tested” at the factory This procedure permits a thorough inspection of

PAGE 28 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER operate the pump in a confined area or enclosed area structure that does not provide

free flow of air

ample

ST-45 PUMP — INSPECTION

FUEL CHECK

5. Read the fuel sight tube (Figure 10) on top of the fuel tank to determine if the pump's engine fuel is low .

ALWAYS wear approved protection before operating the pump .

NEVER place hands or feet inside the while the engine is running. ALWAYS shut-down the engine before performing any kind of maintenance service on the pump.

NEVER operate the pumps's engine with the engine hood removed. The possibility exists of

hands, long hair

entangled with the V-belt, causing injury and bodily harm.

NOTE

Before Starting

1. Read safety instructions at the beginning of manual.

eye

and

hearing

hopper

, and

clothing

See Figures 5 & 6 on pages 20-22 for the location of any control or component referenced in this section.

becoming

. ALWAYS make

Figure 10. Fuel Sight Tube

6. If fuel is low, remove fuel filler cap and fill with (Figure 11).

fuel

#2 diesel

2. Clean the the engine cooling air inlet, and air filter.

3. Check the air filter with a new one as required.

4. Check fastening nuts and bolts for tightness.

entire pump

air filter

, removing dirt and dust, par ticularly

for dirt and dust. If air filter is dirty, replace

CAUTION:

Handle fuel safely. Diesel fuel is highly

flammable

mishandled. DO NOT DO NOT attempt to refuel mixer if the engine is

hot or running. ALWAYS before refueling.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 29

and can be dangerous if

smoke

while refueling.

allow engine to

cool

Figure 11. Adding Diesel Fuel

ST-45 PUMP — INSPECTION

ENGINE OIL CHECK

7. Remove the engine oil dipstick from its holder (Figure 12).

Figure 12. Engine Oil Dipstick

8. Make sure pump/engine is placed on level ground.

12 The oil listed in Table 47 is recommended to ensure

better engine performance. Use class CD or higher grade motor oil.

9. Pull the engine oil dipstick (Figure 13) from its holder.

Figure 13. Engine Oil Dipstick

Hydraulic Oil

13. Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass (Figure 14).

Figure 14. Hydraulic Oil Sight Glass

10. Verify that oil level (Figure 13) 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.

PAGE 30 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — INSPECTION

14. If the hydraulic oil level is low, remove the cap just above the

oil level sight glass (Figure 15) 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).

16. Remove the

pull

then (Figure 17).

17. Position both rear stabilizers stands on firm (not loose)

level

18. Align the hole on the stabilizer stand with the hole on the frame body and

19. Insert the cotter pin into handle tee bolt eye to lock the stabilizer stand.

cotter pin

the handle tee to release the stabilizer stand

ground (Figure 18).

from the handle tee bolt eye, and

insert

handle tee bolt.

Figure 15. Hydraulic Oil Filler Hole

REAR STABILIZER STAND

To reduce excessive vibration and rocking of the ST-45 Concrete Pump, set the rear stabilizers as follows:

15. Locate both the left and right rear stabilizer stands (Figure 16).

Figure 17. Rear Stablizer Stand

Figure 18. Rear Stablizer Stand Deployment

Figure 16. Locatiing Rear Stabilizer Stands

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 31

ST-45 PUMP — INITIAL START-UP PROCEDURE

Starting

CAUTION :

DO NOT attempt to operate this concrete

pump until the Safety, General Information and Inspection sections have been read and understood.

EMERGENCY STOP SWITCH

1. Locate the Emergency Stop Switch (Figure 19) on the Hydraulic Pump Control Box. Use this switch in the event of a emergency.

IGNITION SWITCH

3. To start the engine, insert the key (Figure 20) into the ignition switch and turn the key to the ON position.

4. Observe that the indicator lights are “ON” (Figure 21).

Figure 20. Ignition Switch

Batter, Air Filter

BATTERY

OIL

PRESSURE

and

Oil Pressure

AIR FILTER

status

Figure 19. Emergency Stop Switch

2. Turn the Emergency Stop switch counter-clockwise (open). This will allow the engine to start.

If the Emergency Stop switch is in the

NOTE

“CLOSED” position (stop), engine will not start. To start the engine, make sure the Emergency Stop switch is in the “OPEN” position (fully extended).

Place all switches on the Hydraulic Control Box in the ”OFF” (up position).

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

NOTE

Air Filter, Oil Pressure

(Figure 21) should all be “OFF”.

The battery indicator light may remain on if the engine is idling, or on some models of the ST-45. Increasing the engine RPM’s slightly should correct the problem.

and

Battery

indicator lights

CAUTION :

If any of the status indicator lights referenced in the ignition section (step 4) remain “ON”, turn off the engine and correct the problem.

DO NOT continue to run the equipment.

PAGE 32 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — INITIAL START-UP PROCEDURE

PUSH-IN, THEN PULL

TO SET THROTTLE

(RPM’s)

PUSH ALL THE WAY IN

TO IDLE ENGINE

CONTROL SWITCH

5. Turn the Pump Control switch (Figure 22) to the “ON” position, a

thumping

sound (cylinder stroke) should be heard. The thumping sound represents the number of strokes per minute (volume) of the pump.

Figure 22. Pump Control Switch

6. Turn the Volume Control (Figure 23),

lock nut

counterclockwise (CCW) to release the volume control knob.

8. While monitoring the tachometer, (Figure 25) use the Engine Throttle Control to set the engine speed to 1500 RPM by following steps 8A-8C.

Figure 25. Engine

Tachometer

A. Unlock the throttle cable. To unlock the throttle cable, turn

the inner most knob counter clockwise (Figure 26.)

UNLOCKING

THROTTLE

UNLOCK

ADJUSTMENT

KNOB (COARSE)

(PUSH/PULL)

LOCK

THROTTLE

ADJUSTMENT

KNOB (FINE)

(TURN CW/CCW)

KNOB

Figure 23. Volume Control

6. Use the volume control, to set the pump volume to approximately 10 strokes per minute. Turning the volume control clockwise (CW)

decrease

will

pump volume,and

counterclockwise (CCW) will

increase pump

Figure 24. Hydraulic Oil Temperature Gauge

volume.

7. Let the pump cycle until the hydraulic oil temperature (Figure 24) is approximately 50 to 60 degrees fahrenheit.

NOTE

Use a wristwatch or stop watch to determine the number of pump strokes within 1 minute.

Figure 26. Throttle Control Knob (Un-locking)

B. Push the outermost button, Figure 27 (coarse adjust-

ment) inward, then pull outward until engine RPM reaches desired speed.

C. Turn the unlocking knob (figure 26) clockwise to lock

engine RPM in place.

Figure 27. Throttle Control Knob (RPM Adjust)

9. Turn the Control Off switch (Figure 10) to the “OFF“ position.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 33

ST-45 PUMP — INITIAL START-UP PROCEDURE

ENGINE SPEED

10. Turn the Operation Pump/Engine switch to the “ENGINE” position (Figure 28).

Figure 28. Operation Pump Engine

Switch

NOTE

11. While monitoring the tachometer (Figure 25), use the Engine Throttle Control to set the engine speed to 2550 RPM (maximum speed) using steps 8A-8C

12. The Accumulator Pressure Gauge (Figure 29) should read approximately 1750 pounds per square inch (psi).

The pump should not be cycling at this time. Only the ENGINE should be running.

13. Make sure the Operation Pump/Engine switch is in the “ENGINE“ position (Figure 28), and that only the engine is running.

14. Turn the fan switch (Figure 30) to the “ON“ position and listen for fan to start.

Figure 30. Fan On/Off Switch

15. Turn the fan switch to the “OFF“ position and listen for fan to stop. If machine exceeds 170°F or to cool the machine down, turn the operation switch (Figure 28) back to the “ENGINE“ position. Run engine at high RPM with cooling fan on for 10 to 15 minutes.

PRESSURE TEST

16. The Pressure Test switch (Figure 31) is a self-diagnostic test switch, that when activated will test the pressure of the system. This switch will be discussed in the maintenance and troubleshooting section of this manual.

Figure 31. Pressure Test On/Off Switch

Figure 29. Accumulator Pressure Gauge

HOPPER REMIXER CONTROL

COOLING FAN

This section is intended to make sure the fan is working properly. Under normal conditions the fan should be turned on when the hydraulic oil temperature begins to approach 75 degrees fahrenheit.

A. Located to the left of the Hydraulic Temperature gauge is

the Hopper Remixer Control lever (Figure 32).

B. Turn the Operation Pump/Engine switch to the “ENGINE“

position (only the engine should be running).

CAUTION

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.

Figure 32. Hopper Remixer Control Lever

PAGE 34 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — INITIAL START-UP PROCEDURE

C. Push the Hopper Remixer Control lever “DOWNWARD“

(Figure 31) and observe that the blades (Figure 33) inside the hopper are turning in a clockwise direction (forward).

Figure 35. Handheld Remote Cable Unit

Figure 33. Hopper Remixer Blades (Rotation)

CYLINDER LUBRICATION BOX

WARNING

D. Push the Hopper Remixer Control lever “UPWARD“ (Figure

32) and observe that the blades (Figure 33) inside the hopper are turning in a counter-clockwise direction (reverse).

OPTIONAL RADIO REMOTE CONTROL

14. The MAYCO ST-45 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 34) or a hardwire method, which utilizes a 25-ft. extension cable. The manual remote cord (Figure 35) should be installed under the main control box. Contact your MAYCO representative for further information.

15. As the rubber piston cups naturally wear, fine cement

Before checking lubricaton level, stop the engine and remove the engine starter key. We recommend using soluble type oil (water & oil mixture). The oil level should be checked every day prior to pumping. The oil level should be maintained at a height of 5 inches or about ½ the concrete cylinder height.

Important Notice! During freezing

NOTE

particles will accumulate in the box. Once the concrete paste reaches a height of about ½ inch from the bottom. The box should be drained and cleaned. To clean, remove the drain plug located at the bottom of the box.

temperature after pumping, completely drain the water box and cover the hopper. Frozen liquid will restrict the piston travel and cause severe damage to the pump.

Figure 34. Handheld Receiver/Transmitter

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 35

Once the box is drained, start the engine and stroke the cylinder (keep hands out of box) ten to fifteen times. While stroking, spray water inside of the box to thoroughly clean out all contamination. When the box is clean, replace drain plug, add new lubrication and install the top cover.

ST-45 PUMP — TOWING GUIDELINES

Towing Safety Precautions

CAUTION

■

Check with your county or state safety towing regulations department before towing your

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 45 MPH, however before towing your pump, check your local state, and county vehicle towing requirements. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place

chocked blocks

while parked.

■

Depending on soil conditions and location it may be necessary to place bumper to prevent

■

Inflate tires to correct pressure, inspect tires for cuts, and excessive wear. See Table 5 (Tire Wear Troubleshooting).

underneath wheel to prevent

support blocks

tipping

concrete pump

underneath the trailer's

, while parked.

rolling,

■

Check wheel mounting lug nuts with a torque wrench. Torque wheel lug nuts as described in the "

Requirements

■

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.

■

DO NOT transport pump with fuel in the fuel tank.

CAUTION

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 5,000 lbs. (2,268 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 36. Remember to

cross

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 were 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.

Lug Nut Torque

", Table 7.

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.

the safety chains.

PAGE 36 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — TOWING GUIDELINES

Figure 36 shown below illustrates the typical towing application that should be used when towing the pump.

Figure 36. Towing Applications

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 37

ST-45 PUMP — TRAILER SAFETY GUIDELINES

Trailer Safety Precautions

CAUTION

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

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 3,500 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 43 for proper wiring connections.

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.

7. Tires Ply – The tire ply (layers) number is rated in letters; 2ply, 4-ply, 6-ply, 8-ply, 10-ply etc. This unit employes 4-ply tires.

PAGE 38 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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.

CAUTION

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.

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 5 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

NOTE

ALWAYS

removing or installing force fitted

wear safety glasses when

parts. Failure to comply may result in serious injury.

stnemeriuqeReuqroTnoisnepsuS.6elbaT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/105-XAM54-NIM

TLOBELKCAHS

TLOBEYEGNIRPS

EPYTREDLUOHS

TLOBELKCAHS

YLBMESS

ATLOB-TUNNIATER

Suspension

The leaf suspension springs and associated components (Figure 37) 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 (suspension) immediately. Torqed suspension components as detailed in Table 6.

.YLEERFETATORTSUMSTRAP.YLNOTIFGUNS

OTDEDIVORPERASNIPRETTOCROSTUNGNIKCOL

05-XAM03-NIM

Figure 37. Major Suspension Components

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 39

ST-45 PUMP — TRAILER SAFETY GUIDELINES

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 38. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 7.

stnemeriuqeReuqroTtuNguL.7elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

NOTE

NEVER!

use an pneumatic air gun

to tighten wheel lug nuts.

Figure 38. Wheel Lug Nuts Tightening Sequence

PAGE 40 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 — TOWING INFORMATION

Towing Information

WARNING

Use jack stand to lift tongue. DO NOT lift by hand as back injury could result.

CAUTION

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

NOTE

5. To make sure that the actuator 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 actuator is securely attached.

6. Insert a padlock or bolt through the lock hole for added protection.

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.

8. Make sure the breakaway cable is in a released position with the indicator bead touching or resting against the cable spring stop. (Figure 40).

Take care not to damage the actuator when backing up the towing vehicle for hook-up.

1. Position actuator ball socket above 2" ball.

2. Hold the release lever in the open position (Figure 39).

3. Lower the trailer tongue until the ball rests in the ball socket.

4. Close the release lever.

CAUTION

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

Figure 39. Trailer Hitch Release Lever

CAUTION

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.

NOTE

Figure 40. Trailer Hitch Release Handle

DO NOT use the breakaway cable as a

parking brake.

Safety chains must ALWAYS be used.

Check the location of the breakaway cable periodically during each trip. The indicator should rest against the spring stop. Accidental application will cause the brakes to drag and heat up, causing a failure.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 41

ST-45 — TOWING INFORMATION

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 or Atwood Service Center.

12. The direction lever must be positioned in the “Towing Position” (Figure 41).

Figure 41. Towing Hitch Direction Lever

5. If the pump is to be uncoupled from the tow vehicle after backing with the lever knob engaged, block all pump wheels and pull forward slightly to take strain off of the actuator. Uncouple the actuator by lifting the release handle and raising the trailer tongue. Make sure the lever knob is in the “Towing Position” when uncoupling from the trailer.

CAUTION

Before towing the pump, always ensure that the directional lever (Figure 41) has been disengaged and is in the “Towing Position.”

13. Do not use the Atwood brake actuator with a sway controller, unless prior Atwood Engineering approval of the sway control system has been received.

14. You are now ready to tow your pump.

CAUTION

Avoid sharp turns. This could bend, create extreme stress or fracture either the actuator or trailer tongue.

BACKING UP

1. Refer to the previous steps 1 through 14 for Towing.

2. Before backing up a slope or through soft ground, pull the

trailer forward slightly to assure that the actuator socket is in the fully forward position.

3. Move the directional lever on the side of the actuator

downward from the “TOWING” position along the curved slot in the actuator frame to the “BACK-UP” position (Figure 41). The slot has a notch at the bottom of its travel. Push the directional lever down to engage the locking notch.

4. Back the trailer up.

PAGE 42 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — WIRING DIAGRAM (TAIL LIGHTS)

Figure 42. Trailer Tail Lights Wiring Diagram

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 43

ST-45 PUMP — MAINTENANCE (PUMP)

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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. You will be required to put your hand in the concrete cylinders or near the shuttle tube. You are at

AMPUTATION

if the engine is running or if pressure is in the

EXTREME RISK

of injury or

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

MUST

gauge

read ZERO. ALWAYS relieve the accumulator circuit to zero pressure prior to performing any maintenance on the pump.

1. Following the “Clearing Concrete Blockage” operating procedure on page 26, ensure that there is no blockage in the hose and line or in the shuttle tube (using the Shuttle Tube Inspection Procedure, page 26-27). 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.

PAGE 44 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 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 Model ST-45 has been used to pump small aggregate concrete (pea rock, 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, page 26-27) and remove all remaining concrete.

9. When the Model ST-45 has been used to pump large aggregate concrete ( step 8 once per week.

¾" to 1 ½") follow the instructions in

½" minus) or mixes with high

WARNING

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-

NOTE

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.

HYDRAULIC OIL SYSTEM MAINTENANCE

1. When changing the hydraulic oil or topping off the reservoir, use only the following type. (Reservoir capacity 58 gal.)

Hydraulic oil: Shell Oil Tellius 68 or

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.

WARNING

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 will be the end result.

2. Lubrication: Grease daily/Hour

■

Main hydraulic cylinders - 2 Place

Mobil DFE 26 Texaco Rand HDC

DO NOT mix oil brands! This may impair quality.

■

ENGINE (Hatz Model 3M41 57HP Diesel)

The ST-45 is equipped with a Model 3M41 57HP 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.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 45

Remix bearings - 2 Place

■

Axle crank - 1 Place

■

Suttle cylinders - 2 Place

■

“S” tube outlet flange - 3 Place

Grease Type: Lithium Based EP

Texaco Multitak 20 Lubriplate ED-2

ST-45 PUMP — MAINTENANCE (PUMP)

BATTERY MAINTENANCE

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 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.

eye protection

and

rubber gloves

, since

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.

NOTE

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.

Lubricate the hitch ball with conventional automotive grease or a lubricant made for hitch balls.

CAUTION :

Wear

safety glasses

, protective clothes, and

mask

rubber gloves when working

with battery.

Check the battery regularly and make sure that each electrolyte level is to the bottom of the vent well (Figure 43). If necessary add only distilled water in a well-ventilated area.

face

CAUTION

DO NOT fill the master cylinder reservoir with

used brake fluid. DO NOT fill the reservoir beyond fluid will damage paint.

3. Check the brake fluid level in the master cylinder reservoir. Keep it filled to within

4. At the beginning of each year, inspect the brakes for excessive wear, replace the linings if necessary.

NOTE

½" from top. DO NOT overfill; brake

½" from the top of the reservoir.

Wheel bearings and seals should be inspected and packed at this time.

Figure 43. Battery Electrolyte Levels

PAGE 46 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — MAINTENANCE (PUMP)

ST45 PRESSURE SETTING SEQUENCE

To set

maximum

1. With the engine turned “OFF”, loosen the ¼” hydraulic hose attached to the compensator valve located on the top of the Main Delta Q Pump.

2. Loosen the valve (Figure 44).

3. Turn the

clockwise

compensator.

4. Start the engine and loosen the jam nut located on the

maximum relief valve cartridge

5. Run the engine at maximum RPM (2550) and turn the volume control knob volume position (Figure 45).

pump pressure:

Figure 44. Compensator Valve

jam nut

compensator adjustment nut

until tight. Tighten the ¼” hose leading to the

located on the end of the compensator

(Figure 44)

(Figure 45).

counter-clockwise

to maximum

6. On the electrical control panel, turn the

switch

“ON” position. Using an allen wrench, adjust the

valve

from the

7. Hold the main relief valve adjusting bolt with a wrench and tighten the jam nut. Using the test switch, double check the pressure reading to make sure the setting has not changed.

8. Turn the engine off and loosen the hose from the compensator valve. Loosen the jam nut and turn the

compensator adjustment nut clockwise

9. Start engine and run at maximum RPM with volume control at maximum volume (fully

pressure test switch

The pumping pressure gauge should now read 3300 PSI. It may be necessary to repeat the above steps to achieve the proper pressure settings. After the adjustment, make sure the compensator valve jam nut is locked tight.

pump control

(Figure 22) and the

test switch

(Figure 31) to the

main relief

(Figure 45) to 3500 PSI. The reading can be taken

pumping pressure gauge

Figure 46. Pumping Pressure Gauge

½ turn. Tighten the ¼” hydraulic hose.

counter-clockwise

(Figure 31) to the “ON” position.

(Figure 46).

(Figure 44)

counter-

). Turn the

MAXIMUM RELIEF

VALVE CARTRIDGE

JAM NUT

MAIN

RELIEF VALVE

VOLUME

CONTROL

Figure 45. Hydraulic Drive Pump Manifold

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 47

ST-45 PUMP — MAINTENANCE (PUMP)

CYLINDER LUBRICATION BOX

CAUTION

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 reccomend a using a soluble type oil (water & oil mixture)

Important notice! During freezing

NOTE

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

temperatures, completely drain the Lubrication Box and cover the hopper after each use. Frozen liquid will restrict the piston travel and cause damage to the pump.

) ten to fifteen times.

ST45 ACCUMULATOR CIRCUIT

DANGER

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

nitrogen

service department or your local Hydac representative for proper charging procedure.

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 48) charged with 1100 PSI of dry nitrogen. The accumulator stores one gallon of hydraulic oil, which is, under 1750 PSI of pressure.

Figure 48. Accumulator

dry

to charge the accumulator. Contact your Mayco

3. While stroking, spray water inside of the box to thoroughly clean out all contamination (Figure 47).

4. When the box is clean replace drain plug, add new lubrication and install the top cover.

Figure 47. Cleaning the Lubrication Box

PAGE 48 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

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

pressure gauge

2. To determine the 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.

accumulator

(Figure 29) should read 1750 PSI.

actual accumulator PSI, stop the engine

ST-45 PUMP — MAINTENANCE (PUMP)

PILOT RELIEF

VALVE CARTRIDGE

LOCK NUT

ADJUSTMENT

SCREW

SETTING PRESSURE IN THE ACCUMULATOR CIRCUIT

1. Attach a

3000 PSI test gauge

(Mayco P/N 98016) to port

of the main manifold block (Figure 49).

PRESSURE TEST GAUGE

3000 PSI

P/N: 98016

Figure 49. Accumulator Circuit Pressure Test Gauge

2. Loosen the lock nut on the

unloading valve cartridge

(Figure 50) and using an allen wrench, turn the adjusting screw

clockwise

until it is completely closed.

4. Loosen the lock nut for the the accumulator circuit

relief valve cartridge

(Figure 51), located at port G4. Using

pilot

an allen wrench, turn the adjusting screw until pressure gauge reads 1950 PSI and tighten lock nut. Turn the engine off and on several times to make the pressure continues to read 1950 PSI.

Figure 51. Pilot Relief Valve Cartridge Adjustment

5. Turn the

unloading valve cartridge

counter-clockwise

until the pressure reaches

adjusting screw

1750 PSI

on the accumulator pressure gauge (Figure 29). Start and stop the pump several times to make sure the accumulator circuit pressure is holding at 1750 PSI.

ADJUSTMENT

SCREW

UNLOADING

VALVE CARTRIDGE

LOCK NUT

Figure 50. Unloading Valve Cartridge Adjustment

3. Turn the

pump control switch

(Figure 22) to the “ON”

position and run engine at 2550 RPM.

6. Tighten the lock nut on the unloading valve cartridge. Your

accumulator circuit pressure should now be properly adjusted.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 49

ST-45 PUMP — MAINTENANCE (PUMP)

CHANGING THE CONCRETE CYLINDER PISTON CUPS

The Rubber piston cups will occasionally require replacement depending on the following factors.

■

The fluid level and cleanliness of the lubrication box.

■

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

ALWAYS relieve the accumulator circuit to ZERO pressure prior

to performing any maintenance on the pump.

6. Remove the three 3/8 – 16 x 3” bolts (Lubrication Pistons

Assy, Item 20) from the piston. Remove the front faceplate (Lubrication Pistons Assy, Item 19).

7. Install two the 3/8’ 16x3” bolts (Lubrication Pistons Assy,

Item 20) back into the piston – do not tighten. Use the two bolts as leverage to remove the rubber piston cup (Lubrication Pistons Assy, Item 17) and rear components.

8. 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 P/N 16460. Coat the concrete cylinder with grease.

9. The new “O” ring (Lubrication Pistons Assy, Item 12) 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 90

0.059” deep and 0.157” wide at the top.

10. Install the “O” Ring P/N 14407 around the oiler plate

(Lubrication Pistons Assy, Item 13). Install the plate into the concrete cylinder utilizing the studs for alignment.

11. Install the felt holder (Lubrication Pistons Assy, Item 14)

over the oiler plate. Install felt ring (Lubrication Pistons Assy, Item 15) into felt holder. Install the bronze ring (Lubrication Pistons Assy, Item 16)

apart. The cut should be a v-shaped design,

CYLINDER CUP REPLACEMENT PROCEDURE

1. Remove the two hydraulic hoses (Hopper Assy., Item 34) connected to the remix motor. Plug the ports with fittings(not provided) to prevent hydraulic hose leakage.

2. Remove the hopper discharge nipple (Hopper Interior Assembly, Item 21) and loosen sleeve seal. Inspect and replace if wear is excessive.

3. Remove the two tie rod nuts (Hopper Attachment, Item 19) and the four eyebolt nuts (Hopper Attachment, Item 22) securing the hopper to the pump frame.

4. Using an approved lifting device, remove the hopper (Hopper Assy, Item 1) using extreme care not to damage the hopper seal (Hopper Assy, Item 2).

5. Start the engine and turn on the pressure test switch (Figure

31). 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 (Figure 29) 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.

NOTE

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.

NOTE

Felt ring must be saturated with 30 wt. oil prior to installation.

Before installing 3/8” bolt, coat the back of bolt heads with silicon sealant. Torque all three bolts equal at 55 ft. lbs. each.

PAGE 50 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — MAINTENANCE (PUMP)

CHANGING THE WEAR PLATE AND RING

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. Remove the two hydraulic hoses (Hopper Assy., Item 34) connected to the remix motor. Plug the ports with fittings(not provided) to prevent hydraulic hose leakage.

2. Remove the hopper discharge nipple (Hopper Interior Assembly, Item 21) and loosen sleeve seal. Inspect and replace if wear is excessive.

3. Remove the two tie rod nuts (Hopper Attachment, Item 19) and the four eyebolt nuts (Hopper Attachment, Item 22) securing the hopper to the pump frame.

4. Using an approved lifting device, remove the hopper (Hopper Assy, Item 1) using extreme care not to damage the hopper seal (Hopper Assy, Item 2).

Wear Plate Installation

1. Install the two cylinder “O” rings (Hopper Interior Assy, Item 10).

2. 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 (Hopper Interior Assy, Item 13) into the nun plate.

2. Install the steel insert ring (Hopper Interior Assy, Item A) inside of the rubber energizer ring (Hopper Interior Assy, Item 13B).

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.

5. Remove the four 1/2” 1 ¼ “ bolts (Hopper Interior Assy, Item

43) that hold the suttle tube to the nun-plate and remove shuttle tube (Hopper Interior Assy, Item 41).

Using two small pry bars remove the rubber energizer ring (Hopper Interior Assy, Item 13B), steel insert ring (Hopper Interior Assy, Item A) and wear ring (Hopper Interior Assy, Item 13).

The energizer ring and wear ring

NOTE

6. Clean out all concrete build up in and around the nunplate area with a wire brush.

7. Inspect the wear components for indications of wear. The wear plate (Hopper Interior Assy, Item 52) has two wear surfaces. If it becomes necessary to replace, the plate can be reversed to the opposite side to expose a new flat surface. To replace or reverse the plate, remove the five allen head counter sink bolts. Then remove the two cylinder “O” rings and clean the entire back surface.

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.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 51

ST-45 PUMP — MAINTENANCE (PUMP)

WHEEL BEARINGS

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.

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 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.

to 1/4 turn or to the nearest

EXTENDED STORAGE INSTRUCTIONS

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.

3. Remove wheel and drum assemblies and spray a good anticorrosion 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.

PAGE 52 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

NOTE PAGE

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 53

LUBRICATION

PISTONS

ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS

Figure 53 is provided to show the hydraulic hose connections on the ST-45 for reference when performing inspections and maintenance on the pump.

FRONT OF MACHINE

MANIFOLD

REMIXER CONTROL

FRONT OF MACHINE

LUBRICATION

PISTONS

HEAT EXCHANGER

HYDRAULIC

DRIVE PUMP

NOTES

HOSES SHADED FOR VISUAL CLARITY.

PAGE 54 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

FRONT OF MACHINE

Figure 53. Hydrauilc Hose Connections

ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS

Figure 53. Hydrauilc Hose Connections (Continued)

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 55

ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS

Figure 53. Hydrauilc Hose Connections (Continued)

PAGE 56 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 — MANIFOLD PORT LOCATIONS

Figure 54 is provided to show the locations and names for the two manifold block ports on the ST-45 for reference when peforming maintenance on the pump.

Figure 54. Manifold Ports

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 57

APPENDIX — ST-45 PUMP 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. 6.5 designed for 2,500 lbs. in 28 days Gallons per sack 7.1 Washed Sand-#200 wash 1.3 Organic matter-OK Specific gravity (SSD) Sand-2.58; Pea Gravel-2.60

Sieve analysis-percent passing

Material 1.5” 1” 3/4” 3/8” #4 #8 #16 #30 #50 #100 #200 W.C. Sand 100 99.7 79.1 60.4 36.5 14.3 4.0 1.1 Pea Gravel 100 3.0 % Comb. 100 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: 17.78 cu. ft. Specific gravity of aggregates in one cu. yard: 2.58 Weight of aggregates in one cu. yard batch: 2850 lbs.

% BATCH SPEC. GRAVITY ABS. VOL. W.C. Sand 65 1800 2.58 11.56 PEA GRAVEL 35 1000 2.60 6.22 WATER 46 gal. 1 CEMENT 6.5 sk. 611 TOTAL 27.00 ADMIXTURE: None SLUMP 4” REMARKS 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.

PAGE 58 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

APPENDIX — ST-45 PUMP CONCRETE MIX INFORMATION

A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 59

APPENDIX — ST-45 PUMP SLUMP TEST PROCEDURE

1. To obtain a representative sample (concrete), take sev-

eral 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 41-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.

Figure 41-C. Slump Test

4. Fill cone another 1/3 (Figure 41-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.

5. Fill cone to overflowing (Figure 41-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.

6. Remove the excess concrete (Figure 41-D) from the top

of the cone, using the tamping rod as a screed.

Figure 41-B. Slump

Test (2/3 Full)

2/3 FULL

(Full-Overflow)

FULL

(OVERFLOW)

Figure 41-D. Slump Test

(Removing Excess Concrete)

7. Lift the cone vertically (Figure 41-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 41-E. Slump Test

8. Lay a straight edge (Figure 41-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 maxi

BULLET POINTED

STEEL ROD

1/3 FULL

1/2 DIAMETER

24 INCHES LONG

FOOT PIECE

Figure 41-A. Slump Test (1/3 Full)

(Cone Invert)

Figure 41-F. Slump Test

(Measurement)

PAGE 60 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 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.

GNITOOHSELBUORTENIGNE.9ELBAT

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MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 61

ST-45 PUMP — TROUBLESHOOTING (HYDRAULIC 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 Hydraulic 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.

GNITOOHSELBUORTMETSYSCILUARDYH.01ELBAT

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PAGE 62 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — TROUBLESHOOTING (ELECTRICAL 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 Electrical System Troubleshooting (Table 11) 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.

GNITOOHSELBUORTMETSYSLACIRTCELE.11ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

llup,noitidnocerusserpmumixamanisimetsysciluardyhehtfI

,ekortsgnipmupafonoitelpmocretfA

setacidnieguagerusserpgnipmup

.spotselcycdnaerusserphgih

tonseodhctiwselcycycnegremE

pmupelcyc

?ycneuqerf

?yaler4-KytluaF

oidaragnittimetonsihctiwsytimixorP

teht

lehttahctiws

.pmupeht

.yaler4-Kytluafaevahuoy

ehtedisnidetacol(hctiwselcycycnegremeehtnoelggo

ytimixorpehtecalper,selcycpmupehtfI.uoysdrawot)xoblortnoc

hsupuoynehwselcycpmupehtfI.xobnoitacirbu

fodnegniwotehtnohctiwsytimixorpehtecalper,nwodelggoteht

53#slanimretot)eriwrepmuj(tcennoC.eriwrepmujtohaesU neewtebedamsitcatnocnehW.1#kcolblanimretno63#dna

htetacidnidluowsihT.selcycpmupehtdnaslanimretowteseht

pmupdnadetavitcasihctiwsretratS

tratstonseod

nuroteunitnoctonlliwenigneztaH

desaelersiyekretfa

tratstonlliwenigneztaH

otslevarttnerrucontub,snurenignE

74-23#stiucric

enigne,nodenrutsipmupnehW

esaercnitonlliws'MPR

nehwesrevertonlliwpmupehT

lortnocetomerybdetarepo

tonlliwthgilerusserplioenignE

etavitca-ed

etavitca-edtnowthgilegrahcyrettaB

?sesufytluaF

?deliafsahedoid1-D

?3#rotcudnoc,5-BTotrewopoN

?pots/tratsevlavtengamotrewopoN

?yaler2-KytluaF yrassecenfiyaler2-KecalperdnakcehC

?tiucricehtgnitelpmoctonyaler6-K

?42-1BTtatiucricnepO

?eruliafyaler5-K yrassecenfiyaler5-KecalperdnakcehC

?eruliaftinugnidneserusserpliO yrassecenfitinugnidnesecalperdnakcehC

?edoid2-DytluaF C-404U1edoidhtiwecalpeR

?yrettabgnigrahctonrotanretlA .tinurotanretlaecalper/riaperdnakcehC

.tnelaviuqero5185GGEN/Pedoid

yrassecenfiyaler1KecalperdnakcehC

yrassecenfiyaler6-KecalperdnakcehC

.sesufnwolbecalpeR.lenaplortnocnixobesufkcehC

.rettabottxen,dionelosenignewolebknilesufkcehC

pma6htiwdedeenfiecalpeR.xoblortnocniedoid1DkcehC

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 63

ST-45 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 11) 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.

GNITOOHSELBUORTMETSYSEKARB.21ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?gniraebleehwdetaehrevO .esaerghtiwkcapdnagniraebleehwecalpeR

?diulfekarbwoL .metsysekarbdeelbdnalliF

.kcuhcrorettahc,kaeuqssekarB

?rednilycretsamrotatucadezeiS .rednilycretsamdliubeR/ecalpeR

?esioneohsekarB .yrassecenfiecalperroseohstsujdA.smurdtcepsnI

?rednilycleehwgnikaeL .metsysekarbdeelbdnarednilycleehwecalperdnakcehC

?leveldiulfekarbwoL .metsysekarbdeelbdnadiulfekarbdevorppatodhtiwlliF

?egamademarfrotautcaekarB .tinurotautcaetelpmocecalpeR

?dehcnipgniebenilekarB .enilekarbecalpeR

llup,etarepootliaf,haehrevosekarB

ylroopnoitcnufro,edisehtot

?rotautcadezieS .rotautcadliuberroecalpeR

?gnirpsnruternekorB .gnirpsecalpeR

?detsujdaylreporpmisekarB .tnemtsujdakcehC

metsyselbacyawa-kaerB

?detavitcayllaitrap

.tcerrocdnaesuacenimreteD.dellupebthgimelbacyawa-kaerB

elbactsniagastserrosehcuotdaebrotacidnilitnuelbacnopuyrP

tneverpdnasekarbemarfehtesaelerylluflliwsihT.potsgnirps

.gard

PAGE 64 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

NOTE PAGE

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 65

ST-45 PUMP — EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #, +, %, or <, belong to the same assembly or kit

NOTE

If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

The contents of this catalog are subject to change without notice

PAGE 66 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 — SUGGESTED SPARE PARTS

ST-45 STRUCTURAL CONCRETE PUMP

1 Units

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 RING

2 .......... EM16816-1 ........... ENERGIZER RING

1 .......... EM16816-2 ........... INSERT RING

2 .......... EM98065 .............. SLEEVE SEAL

1 .......... EM98022 .............. WEAR PLATE

2 .......... EM97024 .............. SWITCH, PROXIMITY

1 .......... EM50417 .............. CUP

1 .......... EM20709-1 ........... SOLENOID

2 .......... EM97050 .............. RELAY

1 .......... EM97048 .............. RELAY

1 .......... EM97036 .............. SWITCH, PUMP CONTROL

1 .......... EM97045 .............. SWITCH, OPERATION PUMP/ENG

1 .......... EM98065 .............. RUBBER RING

ST-45 STRUCTURAL CONCRETE PUMP

3 Units

Qty. P/N Description

1 .......... EM16459 .............. PIN

2 .......... EM18801 .............. CONCRETE CYLINDER

2 .......... EM16462 .............. FELT HOLDER

6 .......... EM98050 .............. PISTON CUP, ORANGE

8 .......... EM16493 .............. FELT RING

2 .......... EN98033 .............. OIL PLATE

2 .......... EM14408 .............. BRONZE RING

4 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE )

3 .......... EM98021 .............. WEAR RING

4 .......... EM16816-1 ........... ENERGIZER RING

2 .......... EM16816-2 ........... INSERT RING

4 .......... EM98065 .............. SLEEVE SEAL

2 .......... EM98022 .............. WEAR PLATE

4 .......... EM97024 .............. SWITCH, PROXIMITY

3 .......... EM50417 .............. CUP

2 .......... EM20709-1 ........... SOLENOID

4 .......... EM97050 .............. RELAY

2 .......... EM97048 .............. RELAY

2 .......... EM97021 .............. SOLENOID

2 .......... EM97036 .............. SWITCH, PUMP CONTROL

2 .......... EM97045 .............. SWITCH, OPERATION PUMP/ENG

1 .......... EM98065 .............. RUBBER RING

NOTE

Part numbers on this Suggested Spare Parts List may supercede or replace the P/N shown in the text pages of this book.

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 67

APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE SYSTEM

RECOMMENDED SHOTCRETE SYSTEM

AIR COMPRESSOR

(125 TO 250 CFM)

1415

3/4 STANDARD

AIR HOSE

1/2 STANDARD

AIR HOSE

Figure 39. Shotcrete System

PAGE 68 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE SYSTEM

RECOMMENDED SHOTCRETE SYSTEM

NO. PART NO. PART NAME QTY. REMARKS

1 EM28904 COUPLING, 3” H-D “CF” 2 EM23946 ELBOW, 3"x90° 3 EM28903 COUPLING, 2.5” H-D w/GASKET & PIN 4 EM28005DD REDUCER, 3”x2.5”x36” H-D ENDS 5 EM28061 PIPE, 2.5”x120w x 10’ H-D 6 EM24849 HOSE, 2.5”x2”x36” H-D 7 EM28001DD REDUCER, 2.5”x2”x36” H-D 8 EM23815D REDUCER, 2.5”x2” w/AIR VIBRATOR 9 EM28902 COUPLING, 2” H-D w/GASKET & PIN 10 EM23101 AIR VIBRATOR ASSY. 11 TBD 2”x2” ELBOW 12 EM24841 HOSE, 2”x25’ H-D w/ENDS 13 EM23808D NOZZLE ASSEMBLY, 2” H-D 14 EM23806 NOZZLE TIP, RUBBER 1-3/8” 15 EM23807 NOZZLE TIP, RUBBER 1.25”

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 ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 69

APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

NOTE

Figure 40. 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 re-assembly. DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air passages clean.

PAGE 70 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS

1 EM26107 HOPPER SCREEN ....................... 1............. W/AIR VIBRATOR MOUNTING

2 EM23101 AIR VIBRATOR 1 3 EM132 BOLT, 1/2-13X2 2 4 EM23407 AIR HOSE 1 5 EM23408 BUSHING 1 6 EM23411 VALVE 1 7 EM912073 NIPPLE 2 8 EM23409 COUPLING 1 9 EM923346 WASHER, 1/2 LOCK 2 10 EM406 NUT, HEX 1/2-13 2 11 EM23818 2"X25' GROOVED HOSE

EM24841 2"X25' RAISED HOSE

EM23845 2"X50' GROOVED HOSE 12 13 14 15 16 17 18 19

20 AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO

21 EM23808 NOZZLE ASSEMBLY ................... 1 ............. INCLUDES ITEMS W/

EM23802 VIC ADAPTER / EM23802D H.D 1

EM23803 GUN BODY 1

EM20816 “O” RING 1

EM23804 AIR INSERT 1

EM23805 NOZZLE CLAMP 1

EM23806 NOZZLE TIP, 1-3/8", SHORT 1

EM23807 NOZZLE TIP, 1-1/4", LONG 1

EM911076 STREET ELBOW 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 71

DECAL PLACEMENT

ST-45 PUMP — DECAL PLACEMENT

PAGE 72 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — DECAL PLACEMENT

DECAL PLACEMENT

NO. PART NO. PART NAME QTY. REMARKS

1 511709 DECAL, 800-30-MAYCO 1 2 EM97082 DECAL, ST-45 2 3 34536 DECAL, OWNERS MANUAL 1 4 EM97070 DECAL, ACCUMULATOR PRESSURE 1 5 EM97070 DECAL, PUMPING PRESSURE DECAL 1 6 EM93000 DECAL, CAUTION - GREASE 2 HOURS 4 7 EM98022 DECAL, WARNING - CHECK MANUAL 1 8 EM696 DECAL, CAUTION - TOWING DECAL 1 9 EM97072 DECAL, CAUTION - OP. INSTRUCTIONS 2 10 TBD DECAL, HOPPER REXMIXER 1 11 EM985 DECAL, HYDRAULIC OIL 1 12 EM97071 DECAL, CAUTION - MINIMUM OIL LEVEL 1 13 EM97084 DECAL, MAINTENANCE 1 14 EM955 DECAL, CAUTION - REFER TO MANUAL 1 15 EM97083 DECAL, WARNING - ACCUM. SAFETY 1 16 TBD DECAL, REMOTE OUTLET 1 17 EM965 DECAL, VOLUME CONTROL 1 18 TBD DECAL, SHUTTLE TUBE DANGER 1 19 EM1023 DECAL, MAYCO 2

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 73

AXLE ASSY.

ST-45 PUMP — AXLE ASSY.

PAGE 74 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — AXLE ASSY.

AXLE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM25611 AXLE 1 2 EM16608 LEAF SPRING 2 3 EM16607 SADDLE, SPRING 2 4 EM16605 U BOLT WITH NUTS AND WASHERS 4 5 EM923347 9/16” LOCK WASHER 8 6 EM16612 9/16” LOCK NUT 8 7 EM16609 LINK SHACKLE L1A 4 8 EM166081 BUSHING, PLASTIC 2 9 EM966259 SHACKLE BOLT 4 10 EM16612 LOCK NUT 4 11 EM16611 BOLT 2 12 EM16612 LOCK NUT 2 13 EM16610 DRUM, BRAKE 2 14 EM166141 BRAKE ASSY. 2 16 EM492451 BOLT, 3/8”- 24 X 1 HEX HEAD 10 17 0166A 3/8” LOCK WASHER 10 18 EM492574 NUT 3/8”- 24 10 19 EM26615 15 INCH TIRE AND WHEEL 2 20 EM924006 COTTER PIN 2 21 EM26519 LUG NUT, CHROME 12 22 EM26520 CAP, 15” CHROME 2 23

24 EM513087 FENDER LEFT-SIDE 1 25 981635 BOLT, HHC 1/2- 13 X 3/4 8 26 6109180 WASHER LOCK 1/2" 8

EM511418 FENDER RIGHT-SIDE 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 75

SUSPENSION FRENOS ASSY.

BREAKLINE ASSY.

ST-45 PUMP — BRAKELINE ASSY.

PAGE 76 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — BRAKELINE ASSY.

BREAKLINE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 TBD NUT 2 2 TBD LOCK WASHER 2 3 EM16602 SURGE BRAKE ACTUATOR 1 4 TBD BOLT 1 5 EM166021 ACTUATOR COVER 1 6 EM16116 BRAKE LINE KIT 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 77

HOPPER ASSY.

ST-45 PUMP — HOPPER ASSY.

PAGE 78 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — HOPPER ASSY.

HOPPER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM25174 HOPPER ASSY. 1 2 EM16184 HOPPER SEAL 3/8” X 1/2 1 3 EM25863 REMIXER, SHAFT 1 4 EM23305 SHAFT, ADAPTOR 1 5 EM963610 CAPSCREW 4 6 0166A LOCK WASHER 3/8” 4 7 EM25301 SHAFT, DRIVE END 1 8 EM963610 CAPSCREW 4 9 0166A LOCK WASHER 3/8” 4 10 EM916001 GREASE FITTING 1 11 EM18137 SHAFT GASKET 4 12 EM18138 SPACER 16 13 EM181361 SPACER PLATE 4 14 EM621 1/2” WILLIAMS WASHER 4 15 EM18135 BEARING FLANGE 2 16 6109180 LOCK WASHER 1/2” 8 17 EM492397 BOLT, HEX 1/2”- 13 X 2 1/2” 8 18 EM916001 GREASE FITTING 1 19 EM50141 MOUNT, REMIX MOTOR 1 20 EM501411 MOTOR MOUNT PLATE 1 22 EM25425 MOTOR, HYDRAULIC REMIX 1 23 EM750 KEY 1/4” X 3/8” X 1 1 23 505719 KEY 1/4” SQ. 1 24 EM963692 CAPSCREW 1/2” X 13 X 1 1/2” 2 25 6109180 LOCK WASHER 1/2” 2 26 506203 FITTING 2 27 EM708601 PISTON CUP HOLDER 1 28 EM50417 PISTON CUP 1 29 EM708602 HANDLE 1 30 492378 BOLT 4 31 0166A LOCK WASHER 4 32 492465 ALLEN SCREW 4 33 512791 MOTOR COUPLING 1 34 EM25483 HOSE 2

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 79

TANQUE TRANSMISIONHATZ 57HP ASSY.

HOPPER ATTACHMENT ASSY.

ST-45 PUMP — HOPPER ATTACHMENT ASSY.

PAGE 80 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — HOPPER ATTACHMENT ASSY.

HOPPER ATTACHMENT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM70134-1 SPLASH PLATE 1 2 EM16159 HINGE PIN 1 3 EM491686 COTTER PIN 1/8” x 1-3/4” 2 4 EM70134-2 SPLASH PLATE PIN 1 5 EM505723 COTTER PIN 5/32” x 1-1/2” 1 18 EM16166 ROD TIE, 1”- 8 NC X 28 2 19 EM505728 NUT, HEX 1” NC 6 20 EM14165 EYE BOLT 4 21 EM619 WILLIAMS WASHER 3/4” 4 22 EM968446 NUT, HEX 3/4” 4 23 EM505121 BOLT, HEX 4 24 EM968446 NUT, HEX 3/4” 4 25 505123 BOLT 1/2” N/C X 2.1/2” 2

26 EM968446 BOLT 1/2” N/C X 2.1/2”....................................... 2 ............. REPLACES 492558

27 6109160 NUT, HEX 1/2” X 13 3

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 81

HOPPER INTERIOR ASSY.

ST-45 PUMP — HOPPER INTERIOR ASSY.

PAGE 82 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — HOPPER INTERIOR ASSY.

HOPPER INTERIOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM16145 SWING AXLE BUSHING 1 9 EM284 1- 14 X 5 STUD GR8 1 10 EM16175 O- RING 1 11 EM16170 SHUTTLE AXEL RING SEAL 1 12 EM16176 O- RING 1 13 EM98022 WEAR RING, HARD FACED 1 13A EM16816-2 RING, INSERT STEEL 1 13B EM16816-1 RING, ENERGIZED RUBBER 1 14 EM98039 BEVELED RING 4 16 EM16804 DISCHARGE SLEEVE 1 17 EM104 BOLT 1/2- 13 X 5 4 18 EM923348 5/8” LOCK WASHER 4 19 EM25803 DISCHARGE PLATE BEARING 1 20 EM98065 SEAL 1 21 512215 DISCHARGE NIPPLE 1 22 EM491701 GREASE FITTING 3 23 EM210 BOLT, HEX 1/2” NC X 3 1/4 G5 6 24 EM6109180 1/2” LOCK WASHER 6 41 EM16811 SHUTTLE TUBE 1 42 EM25843 NUN PLATE 1 43 EM492393 BOLT, HEX HEAD 1/2” NC X 1 1/4 4 44 491719 PIN 1 45 EM923348 5/8 LOCK WASHER 4 47 EM20816 O- RING 1 48 EM16802 INSPECTION PLATE 1 49 EM963102 CAP SCREW, HEX BOLT 4 50 6109180 1/2” LOCK WASHER 4 51 EM16188 HOPPER SCREEN 1 52 EM295 BOLT, COUNTERSUCK 3/4-10 X 2 1 53 EM969023 NUT LOCK 5/8” 2 54 EM265 BOLT, FLAT HEAD 5/8”- 11 X 3” 2 55 EM295 BOLT, FLAT HEAD 3/4”- 10 X 2” 2 56 EM264 BOLT, HEX SOC 1/2”- 13 X 3” 1 57 EM16190 “O” RING 2

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 83

SHUTTLE CYLINDER ASSY.

ST-45 PUMP — SHUTTLE CYLINDER ASSY.

PAGE 84 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — SHUTTLE CYLINDER ASSY.

SHUTTLE CYLINDER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM16145 SWING AXLE BUSHING 1 2 510684 GREASE FITTING 3 EM16169 THRUST WASHER 1 4 EM25236 SHUTTLE CRANK, SPLINED SHAFT 1 5 EM505490 GREASE FITTING 1 6 EM16814 TENSIONER 1 7 EM458 NUT 1- 14 1 8 EM417 NUT FLEX LOCK 1 26 EM254549 PIVOT BRACKET 1 27 492397 BOLT, HEX 1/2”- 13 X 2 1/2” 4 28 492600 1/2” FLAT WASHER 4 29 6109180 1/2” LOCK WASHER 4 30 492584 1/2” LOCK NUT 4 31 EM505490 FITTING 1 32 EM25500 FITTING 1 33 EM509372 HOSE 1 34 EM25459 FITTING 1 35 EM509373 HOSE 1 36 EM25434 SHUTTLE CYLINDER 1

37 EM254542 CLEVIS PIN 3/4” ................................................ 1 ............ BOTTOM OF ITEM 36

38 EM717 COTTER PIN 2 39 EM254541 FEMALE CLEVIS 2

40 EM26126 CLEVIS PIN ....................................................... 1 .............TOP OF ITEM 36

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 85

REAR HOOD ASSY

FUEL AND HYDRAULIC TANK CONNECTIONS ASSY

ST-45 PUMP — FUEL AND HYDRAULIC TANK CONNECTIONS ASSY.

PAGE 86 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — FUEL AND HYDRAULIC TANK CONNECTIONS ASSY.

FUEL AND HYDRAULIC TANK CONNECTIONS ASSY

NO. PART NO. PART NAME QTY. REMARKS

5 EM963610 BOLT 3/8” 2 6 3019092 WASHER FLAT 3/8” 2 7 EM969013 NUT LOCK 3/8” 2 8 EM25169 GASKET, RUBBER 2 9 EM251191 TANK COVER PLATE 1 10 EM25184 RESEVOIR GASKET 1 11 492364 BOLT HHC 5/16” X 18 X 1” 20 12 EM923343 WASHER LOCK 5/16” DIAMETER 20 13 EM16478 SIGHT GAUGE, HYDRAULIC OIL 1 24 EM16517 BUSHING 912 X 2 RED, REMOVER 1 25 EM18436 ELBOW, 90 DEGREE MALE 1 26 EM50424 STRAINER, 2.5 SUCTION 1 27 EM50466 O- RING 1 28 EM27441 ELBOW 1 29 EM635 LOCK 1/2” HI COLLAR 4 31 EM509437 HOSE 1 32 EM26471 CLAM 2” 4 33 EM27442 ELBOW 1 34 EM963692 BOLT 1/2” UNC X 1- 1/2” 4 35 EM635 LOCK 1/2” 4 36 509436 O-RING 1 43 EM90766 GAUGE 3000 PSI 1 44 EM25523 ADAPTER 4- 4- GTX- S 1 45 EM97067 GAUGE 5000 PSI 1 46 EM491396 ELBOW 1 47 EM16414 VALVE NEEDLE 1 49 EM16477 CAP HYDRAULIC OIL TANK 1 50 492267 BOLT, ALLEN 3/16” DIAMETER 6 51 511010 COVER PLATE 1 52 511012 GASKET 1 53 492357 BOLT HHC 1/4”- 20 X 12 8 54 2101402 WASHER LOCK 1/4” DIAMETER 8 55 EM25217 FUEL FILLER CAP- BR 1 57 20426 90 58 508827 HOSE, FUEL GAUGE 1 60 EM20421 FITTING, BALL END CNTRL, CABLE 1 61 509517 HOSE 1 62 509516 HOSE 1

° FITTING 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 87

REAR HOOD ASSY.

FUEL AND HYDRAULIC TANK ASSY. (CONTINUED)

ST-45 PUMP — FUEL AND HYDRAULIC TANK ASSY. (CONTINUED)

PAGE 88 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — FUEL AND HYDRAULIC TANK ASSY. (CONTINUED)

FUEL AND HYDRAULIC TANK ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

1 509772 RESERVOIR, FUEL AND HYDRAULIC OIL 1 2 509786 ELBOW, SUCTION 1 3 510591 ELBOW 1 4 491164 SUCTION NIPPLE 3/4” 1 14 EM18447 PLUG 3/4” PIPE SQ H 1 15 509369 ADAPTER 1/2- FF- S 1 16 491237 GATE VALVE 1/2” NPT FEMALE VALVE 1 17 506094 PLUG 1/2” NPT GALVANIZED 1 18 16512 RETURN FILTER ASSY. 1 19 EM963610 CAP SCREW 4 20 0166A WASHER, LOCK 3/8” DIAMETER 4 21 16433 ELBOW 1 22 16516 TUBE 1 23 EM16513 DEFUSER 1 37 510674 NIPPLE 1-1/4” x 2-1/2” 1 38 509794 COUPLING GALV 1 1/4” 1 39 EM509795 ELBOW, 1- 1/4 PIPE/ 1- 1/4 JIC 1 40 510675 HOSE 1 41 EM510676 ELBOW 1 42 EM509371 HOSE 1 61 20426 FITTING 1 62 512769 HOSE, FUEL 1 63 506208 CLAMP, HOSE 2 64 20426 FITTING 1 68 EM20763 FILTER, FUEL 1 69 EM165121 RETURN FILTER ELEMENT 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 89

FRONT COVER ASSY.

ST-45 PUMP — FRONT COVER ASSY.

PAGE 90 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — FRONT COVER ASSY.

FRONT COVER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

7 EM963003 BOLT 1/4” NC X 3/4” 19 8 EM923057 WASHER, FLAT 1/4” 23 9 2101402 WASHER, LOCK 1/4” DIAMETER 15 10 EM510271 COVER, FRONT 1 14 29057 DOCUMENT BOX 1 17 EM969079 NUT LOCK NYLON 1/4” 4 18 4384102 CAP, AIR INTAKE 1 19 510687 COVER, TOP 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 91

RADIATOR ASSY.

HEAT EXCHANGER ASSY.

ST-45 PUMP — HEAT EXCHANGER ASSY.

PAGE 92 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — HEAT EXCHANGER ASSY.

HEAT EXCHANGER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM509802 GUARD, HEAT EXCHANGER 1 2 EM963610 BOLT 3/8” 4 3 3019892 WASHER, FLAT 3/8” 6 4 EM969013 NUT, LOCK 3/8” 4 5 EM25171 GASKET, RUBBER 1 6 EM98049 HEAT EXCHANGER 1 7 492364 SCREW HHC 5/16” X 18 X 1” 4 8 EM923023 WASHER, FLAT 5/16” 4 9 2105164 NUT, NYLON 5/16”- 18 4 10 EM509805 COVER 1 11 EM963003 BOLT 1/4” NC X 3/4” 6 12 EM923057 WASHER, FLAT 1/4” 6 13 2101402 WASHER, LOCK 1/4” 6 14 EM25498 FITTING, HYDRAULIC 1 15 EM25566 TEE, FITTING 1 16 EM509401 ELBOW 1 17 EM509400 HOSE 1 18 EM98048 CLAMP 1 20 EM492625 WASHER LOCK 7/16” 2 21 EM509344 TEE, FITTING 1 22 EM509345 FITTING 1 23 EM509402 NUT 1 24 EM509378 HOSE, HYDRAULIC 1 25 EM510984 HOSE, HYDRAULIC 1 26 EM509374 HOSE, HYDRAULIC 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 93

ENGINE AND FRAME ASSY

ST-45 PUMP — ENGINE AND FRAME ASSY.

PAGE 94 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — ENGINE AND FRAME ASSY.

ENGINE AND FRAME ASSY

NO. PART NO. PART NAME QTY. REMARKS

1 TBD NUT 4 2 020310080 NUT 4 3 EM23118 SHOCK MOUNT 4 4 EM01005 CONNECTOR LINK, CHAIN 2 5 TBD NUT 4 6 509405 FRAME, MAIN 1 7 503117 BOLT, HEX 3/8” 2 8 3019092 WASHER 3/8” 2 9 EM969013 NUT, NYLOC 1 10 508776 RUBBER PAD 1 11 EM25610 JACK STAND, FRONT 1 29 EM70186 JACK STAND, REAR 2 30 EM745 PIN 2 31 EM744 CLEVIS PIN 1/2” X 4” 2 32 EM20732 CONNECTOR 2 35 EM942 TAG, IDENTIFICATION 1 36 491744 RIVET 2 37 EM60701 HATZ DIESEL ENGINE 57HP 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 95

THROTTLE AND WATER FILTER ASSY.

ST-45 PUMP — THROTTLE AND WATER FILTER ASSY.

THROTTLE AND WATER FILTER ASSY.

PAGE 96 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — THROTTLE AND WATER FILTER ASSY.

THROTTLE AND WATER FILTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

29 EM509414 BRACKET 1 31 EM969013 NUT LOCK 3/8” 1 32 EM509510 SPRING 1 33 EM959119 CLEVIS YOKE 1/4- 28 1 34 492357 SCREW HHC 1/4”- 20 X 12 1 35 EM959179 NUT LOCK NYLON 1/4” 1 36 EM207091 KIT, SOLENOID W/BRACKET 1 37 EM968435 NUT 1/4”- 20” HEX 2 38 EM26315 SAFETY LINK ASSEMBLY 1 39 EM963003 BOLT 1/4” NC X 3/4” 4 40 2101402 WASHER, LOCK 1/4” DIAMETER 4 41 EM923057 WASHER, FLAT 1/4” 4 42 492561 NUT, HEX 1/4”- 20 4 43 510229 CABLE THROTTLE ASSY. 1 44 EM501102 BUSHING, LOCK 1 45 EM491089 BOLT 1 46 492364 SCREW HHC 5/16” X 18 X 1” 1 47 2105164 NUT NYLON 5/16- 18 2 48 510732 HOSE CLAMP 1 49 EM510733 HOSE 1 50 510725 CLAMP 1 51 EM510731 CAP, RAIN 1 52 EM509449 BRACKET 1 53 EM269 M10 X 30MM SOC HDCS 2 54 EM16747 FILTER ASSY, WATER SEPERATOR 1 55 EM963003 BOLT 1/4” NC X 3/4” 3 56 2101402 WASHER, LOCK 1/4” DIAMETER 3 57 EM20426 FITTING 4 58 506208 CLAMP 2 61 512790 HOSE, FUEL 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 97

HYDRAULIC PUMP ASSY.

ST-45 PUMP — HYDRAULIC PUMP ASSY.

PAGE 98 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

ST-45 PUMP — HYDRAULIC PUMP ASSY.

HYDRAULIC PUMP ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2 EM16306 COUPLING, ENGINE 1 3 EM146 BOLT 12 MM X 1” ALLEN HEAD 6 4 EM16303 COUPLING, CHAIN 1 5 EM16302 COUPLING, PUMP 1 6 EM16741 COVER, ENGINE 1 7 EM162 BOLT 10 X 25MM SOC. HEAD 10 8 EM98025 PUMP, PISTON 1 9 EM510902 SCREW 2 10 EM635 WASHER, LOCK 1/2” 2 11 492600 WASHER, FLAT 1/2” DIAMETER 2 12 EM25507 FITTING 8C5 X- S 1 13 EM25429 ELBOW 6801- 04- 04 1 14 EM509366 HOSE 1 15 EM505533 O- RING 1 16 EM97001 MANIFOLD ASSY. 1 17 EM509341 BOLT, ALLEN 3/8”- 16 X 5” 4 18 EM25497 FILTTING 1 20 EM25429 ELBOW 6801- 04- 04 1 22 EM97002 PUMP, DUAL GEAR 1 23 EM963610 CAP SCREW 2 24 0166A WASHER, LOCK 3/8” DIAMETER 2 25 EM25498 FITTING - ADAPTOR 1 26 EM16524 FITTING, 90° 1 28 506195 FITTING, 90° 1 60 509637 HOSE 1 61 509370 HOSE 1 63 510984 HOSE 1 64 509374 HOSE 1 65 509371 HOSE 1

MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 99

LUBRICATION PISTONS ASSY.

ST-45 PUMP — LUBRICATION PISTONS ASSY.

PAGE 100 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)

Multiquip ST-45HRM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual