Multiquip ST70 User Manual

PARTS AND OPERATION MANUAL

MODEL ST-70

Structural Concrete Pump

(Hatz Diesel Engine)

Revision #4 (05/29/07)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Diesel engine exhaust and some of

PAGE 2 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

NOTE PAGE

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help .......................................... 3

Table Of Contents ................................................... 4

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

ST-70

Specifications .......................................................... 6

Pump Warranty ....................................................... 7

Safety Instructions ............................................. 8-10

Important Hand Signals ........................................ 11

General Information ......................................... 12-13

Concrete Mix Information ................................ 14-17

Slump Test Procedure ........................................... 18

Operation (How it Works) ...................................... 19

Initial Start-up Procedure ................................. 22-25

Operating Procedures...................................... 26-30

Towing Information ........................................... 31-33

Explanation Of Codes In Remarks Column .......... 34

Suggested Spare Parts ......................................... 35

Decals Safety ................................................... 36-37

Service Information

Wiring Schematic:

1) Interior Control Panel (Inside Door) ............... 74

2) Schematic Electrical Control Box .............. 75-76

3) Interconnect Electrical Control Box ................ 77

Hydraulic Diagram ........................................... 78-79

Optional Radio Control.......................................... 80

Safety Service Procedures ................................... 81

Maintenance Check Schedule ......................... 82-83

Pressure Setting Sequence .................................. 84

Accumulator Circuit ............................................... 85

Hydraulic System Troubleshooting ........................ 86

Electrical System ................................................... 87

Changing Concrete Cylinder Piston Cups ............ 88

Changing the Wear Plate and Ring ...................... 89

Wheel Bearings ..................................................... 90

Terms and Conditions Of Sale — Parts ................. 91

Component Illustrations

Control Panel Installation................................. 38-39

Control Panel Front ..........................................40-41

Control Panel Interior .......................................42-44

Main Drive Pumps ...........................................46-47

Manifold (Control) ............................................48-49

Accumulator .....................................................50-51

Hydraulic/Concrete Cylinders ..........................52-53

Shuttle Tube Assy ............................................54-55

Hopper Assy ....................................................56-57

Remixer Control Assy ...................................... 58-59

Throttle Assy .................................................... 60-61

Engine and Frame ........................................... 62-63

Oil Cooler Assy ................................................ 64-65

Fuel and Hydraulic Tank .................................. 66-67

Battery,Tail Lights,Water Separator,Gauges ...68-69

Axle and Brakes............................................... 70-71

Hydarulic Surge Brake and Hitch ..................... 72-73

NOTE: Specification and part number are subject to change without notice.

PAGE 4 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

Effective: January 1st, 2006

Ordering parts has never been easier!

PARTS ORDERING PROCEDURES

Choose from three easy options:

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■

View Parts Diagrams

■

Order Parts

■

Print Specification Information

Goto www.multiquip.com and click on

Order Par ts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax.

Domestic (US) Customers dial:

1-800-6-PARTS-7 (800-672-7877)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

If you have an MQ Account, to obtain a Username and Password, E-mail us at:

parts@multiquip.com.

To obtain an MQ Account, contact your District Sales Manager for more information.

Use the

internet

Standard orders

complete part numbers.*

Fax

your order in and qualify for a 2% Discount

Standard orders

complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

and qualify for a 5% Discount

for all orders which include

International Customers

their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

should contact

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❒

❒❒

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❒❒

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❒❒ ❒❒

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www.multiquip.com

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 5

When ordering parts, please supply:

❒❒

Dealer Account Number

Dealer Name and Address

Shipping Address (if different than billing address)

Return Fax Number Applicable Model Number

Quantity, Part Number and Description of Each Part

NOTE

All orders are treated as and will ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

❒

❒❒

Standard Orders

Specify Preferred Method of Shipment:

✓

UPS/Fed Ex

■

Priority One

■

Ground

■ Next Day

■

Second/Third Day

✓ DHL ✓

Tr u c k

ST-70 SPECIFICATIONS

PERFORMANCE U.S. METRIC

Pumping Rate — Volume Output 70 yd/hr.* (54m/hr)* Maximum Aggregate Size 1 1/2" minus (38 mm)

Verticle Pumping Height ................................................. 300 ft.*..................................................................... (91m)*

Horizontal Pumping Distance ......................................... 1200 ft.* ................................................................... (366m)*

Engine — Diesel ............................................................. HATZ 4M40L: 80HP(59.68KW)

Hopper Capacity 10 cu. ft. capacity with optional forward/reverse re-mixer

Line Size ........................................................................ 3", 4" or 5" dia.

Electrical System ............................................................ 12 v D.C.

Hydraulic Oil System ...................................................... 58 gal.

Fuel Tank Capacity ......................................................... 20 gal.

Weight (with fluids) ......................................................... 4700 lb. ................................................................... (2132kg)

Tire Size ......................................................................... 7.35 - 14, 8 ply

Brakes ............................................................................ 12" dia. Hydraulic Surge

All Steel Trailer Frame

DIMENSIONS

L x W x H ........................................................................ 149" X 67" X 55" ...................................................... (356 X 170 X 140cm)

Weight (Shipping)........................................................... 4,700 lbs. ................................................................ (2132kg)

*These figures will vary with Pump Model, concrete mix design, line size, job site conditions and engine option. Mayco reserves the right to change and modify the above specifications or design without notice or obligation.

PAGE 6 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

MAYCO PUMP WARRANTY

Mechanical Drive Models

MAYCO PUMP, hereinafter referred to as “Manufacturer’, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal use and service, for a period of one year after the date of delivery to the original retail purchaser. Manufacturer will, at its option, replace or repair at a point designated by the Manufacturer any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate the Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair the of the defective parts.

This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect its performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear.

Hydraulic Drive Models

MAYCO PUMP, hereinafter referred to as “Manufacturer”, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal use and service, for a period of one year or 2000 hours after the date of delivery to the original retail purchaser. The Manufacturer will, at its option, replace or repair at a point designated by Manufacturer any part or parts which shall appear to the satisfaction of Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair of the defective parts.

This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect it’s performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear.

THIS WARRANTY AND MANUFACTURER’S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 7

ST-70 — SAFETY INSTRUCTIONS

READ THIS PARTS AND OPERATION MANUAL THOROUGHLY BEFORE USING THIS MACHINE. It describes the safe, proper and most efficient way to operate it. KNOW YOUR MACHINE!



When operating concrete pumps the safety regulations of the responsible employers’ liability insurance company must be observed. The observation of these regulations shall be the responsibility of the contractor and operator.



The following are some supplementary recommendations:



All safety devices and provisions against accidents such as warning labels and information signs, coverings, etc. must be in place. Do not remove or tamper with them. If they are missing, replace them.



Check the operational reliability of the machine each time before it is put into operation. Any defects found must be repaired immediately.



Allow the machine to be operated and maintained by qualified personnel only.



Before leaving the machine, protect it from unauthorized use and unintentional movements.



Unauthorized presence in the immediate area of the concrete pump is not allowed. Warn persons who are in the immediate area. Stop work if persons do not leave the area after having been warned.



Wear personal protective equipment when operating the machine.

TRAVEL AND TRANSPORTATION

The machine must not be moved with extended outriggers. Before traveling, check the transportation safety devices of

the outriggers, the tire pressure and the functioning of the brakes.

Use hoisting units with transport devices complying with safety requirements.

Hoisting cables or equipment are to be applied only at the lifting points provided.

TOWING:

1. Read the Atwood Hydraulic Surge Brake Installation

Instructions.

2. The pump should not be towed in excess of 55 MPH (less

depending on road conditions). It can be towed with any truck rated to pull a 5000 lb. load.

3. Before towing, check with local and state laws for proper

compliance. (Refer to page 31) a. Secure the hitch on the ball and attach the breakaway

cable and safety chain to the towing vehicle.

b. Raise all stand pipes and secure.

4. Use only a 2” one-piece, all-steel, machined or forged ball

rated at 5000 lbs. minimum capacity.

5. Do not tow the pump with concrete in the hopper.

ARNING! DANGER OF AMPUTARNING! DANGER OF AMPUT



ARNING! DANGER OF AMPUT

ARNING! DANGER OF AMPUTARNING! DANGER OF AMPUT

Never place your hands or any part of your body in the hopper or allow anyone else to do so while the engine is running or when there is accumulator hydraulic pressure or series injury could result.

TION!TION!

TION!

TION!TION!

6. Do not tow the pump with the concrete reducers attached.

7. Check all wheel lug bolts for proper tightness prior to towing.

PAGE 8 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

ST-70 — SAFETY INSTRUCTIONS

STABILIZER JACK

Prior to jacking check the soil conditions. If necessary, enlarge the support foot area by placing square timbers underneath.

Keep a sufficient distance from excavations; slopes could break away because of support pressures.

On inclines and slopes place chocks behind the wheels. Jack the pump in such a manner that it is in a horizontal (level)

position. Check the position of the pump frequently.

CONCRETE PUMP

To avoid splashes due to suction of air, the agitator hopper must always be filled with concrete up to the mixing shaft.

DO NOT OPERATE ANY CONCRETE PUMP WITHOUT THE HOPPER GRILL FIRMLY IN PLACE.

NEVER ALLOW ANY HANDS NEAR THE SHUTTLE CRANK VALVE OR IN THE AGITATOR HOPPER WHILE THE MACHINE IS RUNNING.

PIPELINES

PIPELINES AND CLAMPS MUST BE OF SUFFICIENT SIZE FOR THE PUMP’S CAPACITY.

The pipeline connections must not be opened under working pressure. Before the pipeline is opened, pressure must be relieved by sucking back the concrete. Secure the couplings after the assembly of the pipeline.

When laying pipeline use as few bends as possible. Horizontal pipelines must be adequately supported. When installing a vertical pipeline, the best method is to use upright struts that can be anchored to the building.

It is preferable to install pipelines within the building whenever possible. See Operator’s Manual and “Pumping Concrete” booklets for more information on pipeline installations.

CAUTION:

material could cause the lines to whip or move in such a manner that it could cause injury to anyone working near the hosses or lines.

If the hoses or lines are blocked for any reason, or if the lines are kinked when starting up or during the pumping cycle, the pump pressure could straighten out the kink or force out the blockage. This rapid surge of

When moving hoses from one site application to another, it is

WARNING! DANGER OFWARNING! DANGER OF

WARNING! DANGER OF

WARNING! DANGER OFWARNING! DANGER OF AMPUTAMPUT

AMPUT

AMPUTAMPUT

Never place your hands or any part of your body in the hopper or allow anyone else to do so while the engine is running or when there is accumulator hydraulic pressure or series injury could result.

Refer to Operation section of this manual for more details.

TION!TION!

TION!

TION!TION!

important to walk the entire system and visually inspect for any kinks or sharp bends in the hose. You must and straighten them before starting or resuming the pumping operation.

Inspect the lines at all times to prevent the above conditions.

MAINTENANCE AND REPAIR

MAKE SURE THAT THE ACCUMULATOR PRESSURE GAUGE READS ZERO BEFORE ALLOWING ANYBODY TO PUT THEIR HANDS INTO HOPPER OR SHUTTLE AREA.

Refer to maintenance section of this manual for more details.

TURN OFF THE ENGINE AND DISCONNECT THE BATTERY CABLES BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 9

ST-70 — SAFETY INSTRUCTIONS

MODEL ST-70

THE OPERATOR IS IN COMPLETE CHARGE OF THE PUMP AND DELIVERY SYSTEM AND IS RESPONSIBLE FOR HIS/ HER OWN SAFETY AND TO WARN AND KEEP ALL OTHERS OUT OF DANGER.

Do not attempt to operate this equipment without a thorough understanding of this Parts and Operation Manual:

1. To prevent damage to equipment or injury to personnel, the following instruction must be followed carefully:

A. A copy of this manual and all others shall accompany the

pump at all times.

B. This equipment shall be operated only by experienced

operators or students under the direct supervision of an experienced operator.

C. No unauthorized persons shall be permitted to assist or

remain in the vicinity of the unit while it is in operation, or during the, inspection, cleaning or repair for the make-ready operation.

O. Never fill the fuel tank while the engine is running or hot.

Avoid the possibility of spilled fuel which may cause a fire.

P. Always carry a fire extinguisher of adequate size and a

first aid kit.

Q. Always wear a safety helmet and safety glasses when on

a job site pumping.

R. Always have the hopper grate securely in place when

pumping.

S. Pump in reverse when the shuttle valve or delivery system

is plugged.

T. Guards, grates, covers, etc. MUST NOT be removed or

altered.

U. If a failure or malfunction occurs, stop the pump and make

all necessary repairs immediately.

V. Electrical and manual controls must always be in working

order. W. NEVER stand on the hopper grate. X. Always position the pump on safe, solid, level ground, using

the jack stands.

D. This equipment shall not be towed or operated by individuals

who cannot read and understand the signs, decals or operating instructions.

E. This equipment shall not be operated by individuals under

the influence of alcohol or drugs.

F. Before towing, check the hitch and secure the breakaway

cable and safety chain to the towing vehicle.

G. Tow only with a vehicle and hitch rated to pull a 5000 lb.

load.

H. Use only a 2" one-piece, all-steel machined or forged ball

rated for a minimum of 5000 lbs.

I. Before start-up, check the hopper and remove all

obstructions.

J. Keep hands, feet and human body parts out of the hopper

when the engine is running.

K. The engine must be turned off before performing any

service operations. The engine is remote controlled and

may start pumping any time the engine is running. L. Do not use worn hoses or hose couplings – inspect daily. M. Replace any worn or damaged hoses, or couplings,

immediately. N. Do not disconnect the hose couplings or nozzles while

under pressure.

PAGE 10 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

IMPORTANT HAND SIGNALS

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 11

ST-70 — 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.

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.

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.

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-70 will pump a wide variety of concrete pump mixes. But, there are guidelines that must be followed. Use this information in conjunction with “The Delivery System” on page 32, Sections 18 thru 18.10.

PAGE 12 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

ST-70 — 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-70 be will working in. Therefore, the mixes on pages 14 through 17 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.

In addition, the Mayco Structural Concrete ST-70 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 30, 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.

3. Sufficient cement to produce the required design strength of the concrete and provide the lubricating binder to pump the concrete through the delivery system.

Use a minimum of:

500 lbs. of cement/cu yd for 2500 p.s.i. concrete after 28 days.

530 lbs. of cement/cu yd for 3000 p.s.i. concrete after 28 days.

600 lbs. of cement/cu yd for 4000 p.s.i. concrete after 28 days.

4. Admixture pump-aid if necessary.

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

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 13

ST-70 — CONCRETE MIX INFORMATION

Job Identification* _______________________________________ Date* ______________________________________

Architect* ______________________________________________ General Contractor* ___________________________

Structural Engineer* ______________________________________ Concrete by* ________________________________

THE PROPORTIONS SHOWN HERE ARE A RECOMMENDATION BASED ON TESTS OF SAMPLES RECEIVED BY THE LABORATORY. TESTS PERFORMED BY SUPPLIERS OR MANUFACTURERS OR ON PRIOR KNOWLEDGE OF THE MATERIALS INVOLVED AND IS LIMITED TO INFORMATION DERIVED FROM THESE SAMPLES TESTS BY OTHERS OR TO THAT PRIOR KNOWLEDGE.

IT IS UNDERSTOOD THAT THE CHEMICAL AND/OR PHYSICAL CHARACTERISTICS OF THESE MATERIALS ARE SUBJECT TO VARIATIONS THAT MAY ADVERSELY AFFECT THE FINISHED PRODUCT AND THAT THIS MIX DESIGN IS NOT TO BE USED EXCEPT AT THE USERS OWN RISK UNLESS THESE VARIATIONS ARE DETERMINED AND COMPENSATED FOR IN A MANNER APPROVED BY THE LABORATORY IN WRITING.

Specifications requirements: 2500 P.S.I. in 28 DAYS 3" SLUMP PUMP MIX 4" DIA LINE

SIEVE ANALYSIS PER CENT PASSING U.S. STANDARD SIEVE

MATERIAL ......... 1 1/2............ 1 ...............3/4 ..................................................................................................................

FAI WCS ....................................................................... 100 ........ 97............ 84 ........... 70 ....... 45 ........ 25 ..... 10 ....... 97.5

FA2 ...................................................................................................................................................................................

CA1 #4-3/8" .............................................. 100 ............. 95 .......... 13 ............ 3 ............................................................... 90.5

CA2 #3-1 ................................ 100 ...........96 ............... 61 .......... 6.............. 1 ............................................................... 91.0

CA3 ..................................................................................................................................................................................

............................................... 100 ........... 98 ............... 85 ..........50 ............ 40 ........... 33 ....... 21 ........12 ..... 4 .........

Source of Coarse & Fine Aggregates -* Cement – Type* Mix No*

Cement Sks/Cu. Yd. ................................................................ 5.3

Cement – Lbs. ........................................................................ 500

Sand, Lbs. W.C.S. ................................................................... 1550

No. 4 Gravel (3/8"), Lbs. .......................................................... 500

No. 3 Gravel (1"), Lbs. ............................................................. 1220

No. 2 Gravel (1-1/2"), Lbs. .......................................................

Water, Lbs............................................................................... 290

Total Weight ........................................................................... 4060

Water, gal. per yd. ................................................................... 34.8

Water, gal./Sk. per yd. ............................................................. 6.5

Slump, calculated ................................................................... 3"

Admixture ............................................................................... 3 fl. oz. POZZOLITH 300N/100 * OF CEMENT

Max. Water Allowable ............................................................. *

* THIS INFORMATION PROVIDED BY ENGINEER OR BATCH PLANT THE ABOVE MIX DESIGN IS TYPICAL OF A PUMPABLE MIX. TO BE USED AS A GUIDELINE ONLY. REFER TO LOCAL

AGENCY FOR JOB SPECIFICATION.

3-5

PAGE 14 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

ST-70 — CONCRETE MIX INFORMATION

Job Identification* _______________________________________ Date* ______________________________________

Architect* ______________________________________________ General Contractor* ___________________________

Structural Engineer* _____________________________________ Concrete by* ________________________________

Specifications requirements: 3000 P.S.I. in 28 DAYS 4" SLUMP PUMP MIX 4" DIA LINE

SIEVE ANALYSIS PER CENT PASSING U.S. STANDARD SIEVE

MATERIAL ......... 1 1/2............ 1 ...............3/4 ..................................................................................................................

FAI WCS ....................................................................... 100 ........ 98............ 86 ........... 70 ....... 48 ........ 24 ..... 8 ......... 97.5

FA2 ...................................................................................................................................................................................

CA1 #4-3/8" .............................................. 100 ............. 94 .......... 16 ............ 4 ............................................................... 90.5

CA2 #3-1 ................................ 100 ...........93 ............... 57 .......... 6.............. 1 ............................................................... 91.0

CA3 ..................................................................................................................................................................................

............................................... 100 ........... 97 ............... 83 ..........51 ............ 41 ........... 33 ....... 23 ........11 ..... 4 .........

Source of Coarse & Fine Aggregates -* Cement – Type* Mix No*

Cement Sks/Cu. Yd. ................................................................ 5.

Cement – Lbs. ........................................................................ 525

Sand, Lbs. W.C.S. ................................................................... 1520

No. 4 Gravel (3/8"), Lbs. .......................................................... 480

No. 3 Gravel (1"), Lbs. ............................................................. 1230

No. 2 Gravel (1-1/2"), Lbs. .......................................................

Water, Lbs............................................................................... 295

Total Weight .................................................................... 4050

Water, gal. per yd. ................................................................... 35.4

Water, gal./Sk. per yd. ............................................................. 6.3

Slump, calculated ................................................................... 4"

Admixture ............................................................................... 3 fl. oz. POZZOLITH 300N/100 * OF CEMENT

Max. Water Allowable ............................................................. *

* THIS INFORMATION PROVIDED BY ENGINEER OR BATCH PLANT THE ABOVE MIX DESIGN IS TYPICAL OF A PUMPABLE MIX. TO BE USED AS A GUIDELINE ONLY. REFER TO LOCAL

AGENCY FOR JOB SPECIFICATION.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 15

ST-70 — CONCRETE MIX INFORMATION

Job Identification* _______________________________________ Date* ______________________________________

Architect* ______________________________________________ General Contractor* ___________________________

Structural Engineer* _____________________________________ Concrete by* ________________________________

Specifications requirements: 4000 P.S.I. in 28 DAYS 4" SLUMP PUMP MIX 5" DIA LINE

SIEVE ANALYSIS PER CENT PASSING U.S. STANDARD SIEVE

MATERIAL ......... 1 1/2............ 1 ...............3/4 ..................................................................................................................

FAI WCS ....................................................................... 100 ........ 97............ 84 ........... 56 ....... 36 ........ 22 ..... 8 ......... 97.5

FA2 ...................................................................................................................................................................................

CA1 #4-3/8" .............................................. 100 ............. 95 .......... 13 ............ 3 ............................................................... 90.5

CA2 #3-1 ................................ 100 ...........95 ............... 64 .......... 8.............. 1 ............................................................... 91.0

CA3 ................... 100 ............. 93 ............. 64 ............... 18 .......... 2 ................................................................................. 90.0

.......................... 100 ............. 98 ............. 90 ............... 73 .......... 49 ............ 40 ........... 26 ....... 17 ........ 10 ..... 4 .........

Source of Coarse & Fine Aggregates -* Cement – Type* Mix No*

Cement Sks/Cu. Yd. ................................................................ 6.4

Cement – Lbs. ........................................................................ 600

Sand, Lbs. W.C.S. ................................................................... 1480

No. 4 Gravel (3/8"), Lbs. .......................................................... 400

No. 3 Gravel (1"), Lbs. ............................................................. 470

No. 2 Gravel (1-1/2"), Lbs. ....................................................... 800

Water, Lbs............................................................................... 300

Total Weight .................................................................... 4050

Water, gal. per yd. ................................................................... 36

Water, gal./Sk. per yd. ............................................................. 5.6

Slump, calculated ................................................................... 4"

Admixture ............................................................................... 3 fl. oz. POZZOLITH 300N/100 * OF CEMENT

Max. Water Allowable ............................................................. *

* THIS INFORMATION PROVIDED BY ENGINEER OR BATCH PLANT THE ABOVE MIX DESIGN IS TYPICAL OF A PUMPABLE MIX. TO BE USED AS A GUIDELINE ONLY. REFER TO LOCAL

AGENCY FOR JOB SPECIFICATION.

PAGE 16 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

ST-70 — CONCRETE MIX INFORMATION

DNASETERCNOC—SISYLANAEVEIS

EZISEVEIS

4# 001-59 89 2 2

8 001-08 98 11 9

61 58-05 17 92 81

03 06-52 74 35 42

05 03-01 32 77 42

001 01-2 7 39 61

002

33CMTSA

SCEPS

The sand content of pumpable concrete is very important. It is one of the two major ingredients that change due to regional location (the other is the rock or gravel).

Above is a typical sieve analysis of washed concrete sand (W.C.S.) to A.S.T.M. C33 specifications.

SSAP%

MUCCA

56.2=.M.FsuludoMsseneniF 56.2

1#ELPMAS

%VIDNI

TER

The total of the “Accumulated % Retained” is the Fineness Modulus (F.M.). The ideal F.M. is between 2.50 and 2.75, but the correct F.M. does not guarantee pumpability. Besides having a correct F.M. the percentage of sand by weight that passes through the No. 50 sieve must be between 15 and 30 and through the No. 100 sieve 5 and 10. The total of #50 and 100 mesh particles must be between 25 and 35 percent.

This fine material plus the cement will provide the necessary film of lubrication to move the concrete inside the delivery system.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 17

1. To obtain a representative sample, take 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

3. Fill the cone 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. (See figure A.)

4. Fill cone another 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. (See figure B.)

5. Fill cone to overflowing. 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. (See figure C.)

full by volume and rod 25 times with a 1/2"

!/3

which will make the cone

@/3

full by

SLUMP TEST PROCEDURE

6. Remove the excess concrete from the top of the cone, using the tamping rod as a screed. (See figure D.)

7. Lift the cone vertically with a slow even motion. Do not jar the concrete or tilt the cone during this process. (See figure E.) Invert the withdrawn cone, and place it next to, but not touching the slumped concrete.

8. Lay a straight edge 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 (See Figure F). The slump operation must be complete in a maximum elapsed time of 1½ minutes. Discard the concrete. DO NOT use it in any other tests.

PAGE 18 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

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 hydraulic pressure is applied to one of the two hydraulic cylinders causing the hydraulic piston, which is connected to the concrete piston, to discharge concrete into the delivery line. The rod sides of the drive cylinders are hydraulically connected together creating a “slave circuit.” As one cylinder is discharging concrete, the hydraulic oil from the rod side of the drive cylinders is being transferred through the slave circuit causing the opposite cylinder to move back on the suction stroke filling the cylinder with concrete. This operation is made possible by the shuttle tube located in the hopper and is sequenced to operate in conjunction with the cycling of the drive cylinders.

TO TANK

ST-70 — OPERATION (How it Works)

HIGH PRESSURE OIL FROM PUMP

PROXIMITY

SWITCH

HYDRAULIC

CYLINDERS

SLAVE

PROXIMITY SWITCH

OIL

PISTON

CUP

CONCRETE

CYLINDERS

SHUTTLE TUBE

SLAVE

OIL

TO TANK

The ST-70 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 1

CYLINDER A — INTAKE STROKE

CYLINDER B — DISCHARGE STROKE

Figure 2

CYLINDER A — DISCHARGE STROKE

CYLINDER B — INTAKE STROKE

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 19

INITIAL START-UP PROCEDURE

This section is intended to assist the operator with the initial start-up of the MAYCO ST-70 Concrete Pump. It is extremely important that this section be read carefully before attempting to use the pump in the field.

DO NOT proceed to the Operating Procedures (field use) of this manual until this section is thoroughly understood.

NOTE:

Failure to understand the operation of the MAYCO ST-70 Concrete pump could result in severe damage to the pump or personal injury.

Figure 1 illustrates the basic operating controls and indicators on the MAYCO ST-70 Concrete pump. Each of the items referenced will be discussed. The sequence will be as follows:

1. Engine Oil

2. Hydraulic Oil

3. Fuel

4. Rear Stabilizer Stands

5. Emergency Stop Switch

6. Ignition Switch

7. Status Indicators

8. Control Switch, Engine Throttle Control

9. Volume Control

10. Engine Speed, Cooling Fan

11. Pressure Test

12. Hopper Remixer Control Lever

13. Manual and Radio Control

14. Cylinder Lubrication

Figure 1. MAYCO ST–70 Controls and Indicators

PAGE 20 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

INITIAL START-UP PROCEDURE

COTTER PIN

BOLT EYE

REAR STABILIZER STAND

HANDLE TEE BOLT

STABILIZER FOOT PAD

Engine Oil

1. Pull the engine oil dipstick from the engine side panel as

shown in Figure 2.

If the hydraulic oil level is low, remove the cap just above the oil level sight glass 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

ENGINE SIDE PANEL

DFE26)

FUEL

3. Determine if engine fuel is low (Figure 5). If fuel level is low, remove the fuel filler cap and fill with diesel fuel.

THROTTLE CABLE

SOLENOID

RED (POSITIVE)

WHITE (NEGATIVE

OIL DIPSTICK

OIL FILTER

Figure 2.

Engine Oil

Determine if engine oil is low. If oil level is low, add correct amount of engine oil to bring oil level to a normal safe operating level. See Figure 3.

REAR STABILIZER STAND

Figure 5.

Fuel Sight Tube

To reduce excessive vibration and rocking of the ST-70 Concrete Pump set the rear stabilizer as follows:

OIL DIPSTICK

ADD ENGINE OIL

SAFE OPERATING OIL LEVEL

MAX

MIN

Figure 3.

4. Locate both left and right rear stabilizer stands (Figure 6).

Engine Oil Dipstick

Hydraulic Oil

2. Determine if the hydraulic oil level is low by observing the level of the oil in the Hydraulic Oil Sight Glass (Figure 4).

NORMAL LEVEL

L O W

150

100

250

150

HYDRAULIC OIL LEVEL SIGHT GLASS

LOW LEVEL ADD OIL

HYDRAULIC OIL TEMPERATURE GAUGE

Figure 4.

A. Remove the

then

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

ground.

C. Align the hole on the stabilizer stand with the hole on the

frame body and

Hydraulic Oil Sight Glass

Figure 6.

Rear Stabilizer Stand

cotter pin

pull

the handle tee to release the stabilizer stand.

from the handle tee bolt eye, and

level

insert

handle tee bolt.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 21

INITIAL START-UP PROCEDURE

D. Insert the cotter pin into handle tee bolt eye to lock the

stabilizer stand.

Emergency Stop Switch

5. Locate the Emergency Stop Switch (Figure 7) on the Hydraulic Pump Control Box. Use this switch in the event of a emergency.

7. Observe that the Air Filter and Oil Pressure status indicator lights are ON (Figure 9). The Battery status indicator light should be OFF

A. Turn the key to the

to start.

B. In warm weather let engine warm-up for 5 minutes. In cold

weather let engine warm-up for 10 minutes.

Emergency Stop

Figure 7.

Switch

C. The Air Filter, Oil Pressure and Battery indicator lights

(Figure 9) should

AIR FILTER

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

NOTE:

If the Emergency Stop switch is in the closed position (stop), engine will not start. To start the engine, make sure the Emergency Stop switch is in the open position (fully extended).

NOTE:

If any of the status indicator lights referenced in the ignition section (step 4) are ON, turn off the engine. DO NOT continue to run the engine.

Ignition Switch

NOTE:

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

6. To start the engine, insert the key (Figure 8) into the ignition

Control Switch

8. Turn the Control Off switch (Figure 10) to the ON position,

thumping

a thumping sound represents the number of strokes per minute (volume) of the pump.

switch and turn the key to the ON position.

IGNITION

CONTROL

OFF

REMOTE

START

position and listen for the engine

all be off.

OIL

PRESSURE

Status indicator Lights

BATTERY

Figure 9.

sound (cylinder stroke) should be heard. The

OFF

START

Figure 8.

Ignition Switch

Control Off Switch

PAGE 22 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

Figure 10.

0 0

THROTTLE CONTROL

TURN CLOCKWISE TO INCREASE ENGINE SPEED

TURN COUNTER CLOCKWISE TO DECREASE ENGINE SPEED

INITIAL START-UP PROCEDURE

9. Turn the Volume Control (Figure 11),

lock nut

counterclockwise (CCW) to release the volume control knob.

VOLUME CONTROL

LOCK NUT

VOLUME CONTROL

CCW

DECREASEINCREASE

Figure 11.

Volume Control

A. Use the volume control, to set the pump volume to

approximately 10 strokes per minute. Turning the volume control clockwise (CW) will counterclockwise (CCW) will

decrease

increase pump

pump volume, and

volume.

NOTE:

RPM X 100

TACH

HOURS

3010

Figure 13.

Engine Tachometer

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

B. Let the pump cycle until the hydraulic oil temperature

C. While monitoring the tachometer, (Figure 13) turn the

(Figure 12) is approximately 50 to 60 degrees fahrenheit.

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

Engine Speed

150

200

100

10. Turn the Operation Pump/Engine switch to the

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

250

150

should be running.

Figure 12. Hydraulic Oil

Temperature Gauge

engine Throttle Control (Figure 14) until the engine speed reaches 1500 RPM.

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 23

Figure 14.

Engine Throttle Control

engine

position (Figure 15).

OPERATION

PUMP

ENGINE

Figure 15. Operation

Pump/Engine Switch

INITIAL START-UP PROCEDURE

A. While monitoring the tachometer, (Figure 13) turn the

engine Throttle Control (Figure 14) clockwise until the engine speed reaches 2550 RPM (maximum speed).

B. The Accumulator Pressure Gauge (Figure 16) should read

approximately 1750 pounds per square inch (psi).

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

NOTE: Do not stroke cylinders. The operator may also spray the hydraulic tank and components with water.

PRESSURE TEST

12. The Pressure Test switch (Figure 18) is a self-diagnostic test switch, that when activated will test the pressure of the system. This switch will be discussed in the maintenance

500

1500

LHA

2000

2500

3000

and troubleshooting section of this manual.

ACCUMULATOR PRESSURE GAUGE

0-3000 PSI

Figure 16. Accumulator

Pressure Gauge

11. COOLING FAN

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.

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 between 75 degrees fahrenheit.

Make sure the Operation Pump/Engine switch is in the

engine

position (Figure 15), and that only the engine is running. Turn the Fan switch (Figure 17) to the ON position and listen for

13. HOPPER REMIXER CONTROL

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

the Hopper Remixer Control lever (Figure 19).

B. Turn the Operation Pump/Engine switch to the engine

position (only the engine should be running).

fan to start.

PRESS TEST

OFF

Figure 18.

Pressure Test On/Off Switch

PUSH UP TO REVERSE BLADE ROTATION (CCW)

FAN OFF

PUSH DOWN

Figure 17.

TO OPERATE (CW BLADE ROTATION)

Hopper Remixer

Control Lever

Fan On/Off Switch

PAGE 24 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

Figure 19.

INITIAL START-UP PROCEDURE

OFF

A B

HANDHELD

REMOTE CONTROL TRANSMITTER

REMOTE CONTROL RECEIVER

ANTENNA INPUT

CONTROL SWITCHES

MOUNT ON MAYCO ST-45 FRAME

BODY

SIGNAL CABLE

HAND HELD REMOTE

UNIT

CONTROL SWITCHES

25 FT. CABLE

C. Push the Hopper Remixer Control lever

downward

(Figure

19) and observe that the blades (Figure 20) inside the hopper are turning in a clockwise direction (forward).

BLADES

CONTROL SWITCHES

FORWARD

REVERSE

(CCW)

SHAFT ROTATION

(CW)

Figure 20.

Hopper Remixer

15. CYLINDER LUBRICATION BOX

Blades (Rotation)

D. Push the Hopper Remixer Control lever

upward

(Figure

18) and observe that the blades (Figure 20) inside the hopper are turning in a counter-clockwise direction (reverse).

everyday prior to pumping. The oil level should be maintained at a height of 5 inches or about ´½ the concrete cylinder height.

14. OPTIONAL RADIO REMOTE CONTROL

The MAYCO ST-70 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

21) or a hardwire method, which utilizes a 25-ft. extension cable. The manual remote cord (Figure 22) should be installed under the main control box. Contact your MAYCO representative for further information.

Important Notice! During freezing 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.

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. The box should be drained and cleaned. To clean, remove the drain plug located at the bottom of the box. Once the Box is drained, start the

CONTROL SWITCHES

MOUNT ON MAYCO ST-45 FRAME BODY

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.

REMTRON

REMOTE CONTROL TRANSMITTER

REMOTE CONTROL RECEIVER

REMTRON

Any questions regarding the above mentioned procedure, please call the Mayco Service Department: 1-800-30-MAYCO.

HAND HELD REMOTE UNIT

25 FT. CABLE

Figure 22.

Handheld Remote Cable Unit

WARNING

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

SIGNAL

ANTENNA INPUT

CABLE

Figure 21.

Handheld Receiver/

Transmitter

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 25

ST-70 — OPERATING PROCEDURES

Important Rules for the Setup and Operation of

Mayco Model ST-70 Hydraulic Concrete Pump

1. The Mayco pump must be operated by experienced operators, who are qualified with the particular model being used, or students under the direct supervision of an experienced operator. The operator is in complete charge of the pump and delivery system. Know and warn all others of the DANGERS that are present when using, maintaining or being around this pump and delivery system. KNOW YOUR MACHINE!

2. The operator must become familiar with the controls and gauges by a careful study of the owners manual.

3. The operator must become aware and understand the danger involved in the operation and maintenance of the pump.

4. The operator must know the limitation of the pump described in this manual.

5. The concrete pump is capable of developing high pressures on the concrete. Proper care must be used in the maintenance of pipes and hoses and hose couplings for safe operation.

6. Only experienced operators, or students under the direct supervision of an experienced operator shall perform any maintenance, cleaning, repair or setup operations.

7. Unauthorized persons must not be permitted to assist or remain in the immediate vicinity of the unit while it is in operation.

8. The Mayco pump must not be operated by individuals who cannot read and understand the owners manual in the language in which it is printed.

9. The Mayco pump must not be operated by anyone under the age of 18 years.

10. The Mayco pump must not be operated by anyone under the influence of alcohol or drugs.

11. Locate the pump in an area as level as possible, where two or more ready-mix trucks will have access to the hopper.

12. Begin pumping by placing the hoses or pipe at the farthest point of discharge.

13. Concrete will flow with less back pressure through pipe than through hose. Bends in hose or pipe will also require more pressure. The operator should take these facts into consideration when laying out the system.

14. Vertical and down-hill pumping are more difficult than horizontal pumping. Vertical pumping requires higher pumping pressure. Down-hill pumping can cause separation of the concrete, which can cause a blockage. Back pressure must be kept in the line at all times during down-hill pumping.

15. When the pump is parked in the street, position it so that the control panel (right side) is closest to the curb. – ALWAYS THINK SAFETY!

16. Lower and lock the rear jackstands in place before any concrete is discharged into the hopper.

17. THE DELIVERY SYSTEM To successfully pump concrete it is critical to use the correct

size and type of delivery system. The rules that govern the size of the delivery system apply

to all concrete pumps, not just Mayco pumps.

The inside diameter of the hose and pipe must be three to four (3 to 4) times the size of the largest aggregate in the mix that is to be pumped.

The rock size and percentage shown is of the total rock content in the mix. The balance of the rock must be properly blended down through all of the smaller sizes.

The same applies to the sand portion of the mix. Consult the ready-mix company and ensure that they are willing

and able to deliver properly blended aggregates in their concrete. 3" inside diameter is the smallest system of hose, pipe and elbows that is recommended for pumping “Hard Rock”, large aggregate concrete.

Remember – The larger the size of the delivery system, the less pressure required to move the concrete.

Use this information in conjunction with “Concrete Mix Design” on pages 12 thru 17.

Example: 1-1/2" rock (8 to 10% max. content by weight) requires

a 5" dia. concrete delivery system. 1" rock (10 to 15% max. content by weight) requires a

4" dia. concrete delivery system. ¾" and under rock (10 to 15% max. content by weight)

requires a 3" dia. concrete delivery system.

PAGE 26 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

ST-70 — OPERATING PROCEDURES

18 Priming the Pump and Delivery System with Slurry.

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.

18.1 With the entire delivery system connected to the pump. Except for the first hose. Pour 5 gallons of water into the second hose and push in your clean out ball and reconnect. This will help hold back the prime.

18.2 What you can use to mix the prime: There are several things you can use for the prime. Here

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

NOTE: The bentonite is not compatible with concrete. Do not pump it into the forms discharge it out of the formed area.

Mix the prime to the consistency of a smooth batter.

18.4 Position the first ready-mix truck at the hopper. Check the concrete. Do not discharge concrete into hopper at this time.

18.5 Pour the prime into the first hose and connect it to the pump.

NOTE: You should use two 5 gallon buckets of prime.

19. Waiting for concrete trucks to arrive: If there are delays:

19.1 Stop the pump with a full hopper.

19.2 Run the remixer, alternating forward and reverse,

19.3 Add water to stiff mixes, if necessary.

19.4 If shutdown period exceeds 3 to 4 minutes, turn off engine

19.5 Start the engine, cycle the pump slowly 1 or 2 strokes

19.6 If shutdown period reaches 1 hour (or less, depending

to push through blockages due to separation of material in the hose or manifold, you will soon have breakdowns and costly repairs which are not covered under the warranty. If a blockage exists, find where it is and clear it before further pumping. Do not use extra horse power, it will only make it worse.

whenever the engine is running.

to prevent vibration from separating the mix in the hopper. Separation will cause a blockage in the manifold when pumping is resumed.

and run remixer every 10 minutes.

on the age and temperature of the concrete), pump out and clean the delivery system and pump. (See page 24 for clean up 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 force your pump

18.6 With the pump in FORWARD at 25-30 strokes per minute, slowly discharge the concrete from the ready-mix truck into the hopper and completely fill it. Keep the pump running continuously until concrete is discharging at the end of the delivery system. If the pump is stopped during this procedure, a blockage may occur (see page 22, Section 4).

18.7 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.

1. When pumping long distances or pumping stiff mixes, you

2. Leaking hose coupling gaskets (which leak water) cause

ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07) — PAGE 27

can expect a drop in volume, compared to shorter lines and wetter mixes due to higher pumping pressures and cavitation.

separation and subsequent jamming at that point.

ST-70 — OPERATING PROCEDURES

3. Damaged hoses with internal restrictions can cause blockages.

4. If a blockage occurs in the hose, STOP the pump, “walk the hose” until you find the point of trouble. (The hose will be soft immediately past the blockage.) Elevate the hose at that point with the blockage hanging down. Using a hammer, you can pound the down stream edge of the packed area until it free flows or shakes out of the hose. Pumping can now be resumed. If this method does not clear the pack FOLLOW THE INSTRUCTIONS IN Section 7, paragraph

7.1 thru 7.5 of this page.

5. “Down-hill pumping” can be difficult. When the pump is stopped, the material can flow slowly and cause the hose to collapse. When pumping is resumed, you can expect a blockage at the point of hose collapse. To prevent this, the hose can be “kinked off” at the discharge end when the pump is stopped, to stop gravity flow. The use of stiffer mixes when pumping down-hill will stop gravity flow.

6. When pumping vertically:

6.1 When pumping vertically up the side of a building, above 40 feet, we recommend the installation of steel pipe securely fastened at intervals as necessary to support the pipe. Ninety-degree, long-radius pipe sweeps should be installed at the top and bottom of the steel line. Use a 25 ft. hose, or short section, off the pump. For the balance of the horizontal distance to the vertical line, use 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.

6.2 When pumping vertically using all hose, it is recommended not to go higher than 50 feet with hose. The hose should be tied off at intervals of 10 feet, if possible. Special attention should be given when tying 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 90 degree elbow is recommended. The suggested place to tie off is under the clamp coupling that connects the hose to the 90 degree elbow.

Note: It is strongly recommended that pipe be used on all vertical pumping for safety and convenience. If it is absolutely necessary to use hose, then use section 6.2 as a guide.

7. 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.)

Follow these instructions carefully:

7.1 DO NOT open any of the delivery system joint clamps.

7.2 Switch the pump into “Reverse”: With pump speed at medium-slow (approx. 12 strokes per

min.) try to pull the “pack” back into the hopper with 5 or 6 reverse strokes, remix the concrete in the hopper.

Switch the pump into “Forward”. If it is still plugged, repeat “Reversing” procedure three

times. If concrete still does not move, see 7.3 and 7.4 below. The

last action MUST be “pumping in reverse” to relieve the pressure in the shuttle tube.

7.3 Stop the pump. Switch off the engine.

7.4 The senior or most experienced operator must warn all others to stand at least 20 feet away from the machine and turn their heads to face away from the pump.

The operator will position himself/herself beside the reducing elbow at the pump outlet, then, wearing safety glasses slip the end of a pry bar (24" length of reinforcing steel rod) under the latch of the hose clamp and flip it up.

Carefully knock the end of the hose away from the reducer. Chip the concrete out of the reducer with the pry bar. 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, then remove the clean-out plug on the bottom of the hopper, discharging the concrete.

Only 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. Make sure the accumulator pressure gauge reads zero prior to removing cover.

WARNING: NEVER PLACE YOUR HANDS OR ANY PART OF YOUR BODY IN THE HOPPER OR ALLOW ANYONE ELSE TO DO SO.

PAGE 28 — ST-70 — PARTS & OPERATION MANUAL — REV. #4 (05/29/07)

+ 64 hidden pages