Multiquip ST-45HRM User Manual
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
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
© COPYRIGHT 2004, MULTIQUIP INC.
Multiquip Inc, the MQ logo and the Mayco logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or
altered without written permission. All other trademarks are the property of 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
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PAGE 6 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — ENGINE SPECIFICATIONS
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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
or
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
on
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
of
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)
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