OPERATION AND PARTS MANUAL
STRUCTURAL
CONCRETE PUMP
MODEL ST-45HRM CE
(HATZ ENGINE)
Revision #0 (02/23/04)
MULTIQUIP (UK)
HANOVER MILL
FITZROY STREET
ASHTON-UNDER-LYNE
LANCASHIRE, OL7 OTL
UNITED KINGDOM
PH. 0161-339-2223
FAX. 0161-339-3226
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Proposition 65Warning
Thank you for your purchase of the Mayco/Multiquip ST45
concrete pump. It has been engineered and designed for
maximum performance and safety. For long service life and
improved reliability, please follow all safety, operating and
maintenance instructions referenced in this manual.
This concrete pump is to be soley used for the pumping of concrete
and is not intended for any other purpose. The pumping of
flammable or combustable materials is strictly prohibited. NEVER
operate this pump in an explosive environment.
All warranties are voided if the pump is not used for its intended
purpose.
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS/SERVICE/WARRANTY
LANCASHIRE, OL7 OLT
UNITED KINGDOM (UK) CALL:
PHONE: 161-339-2223
FAX:
161-339-3226
PAGE 2 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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TABLE OF CONTENTS
PARTS ILLUSTRATIONS
MAYCO ST-45HRM CE
CONCRETE PUMP
Decal Placement ................................................76-77
Safet Grids Assembly.........................................78-79
Hub and Drum Assembly ...................................80-81
Brake Components Assembly............................82-83
Towing Coupler Assembly..................................84-85
Hopper Assembly...............................................86-87
Hopper Attachment Assembly ...........................88-89
Hopper Interior Assembly ..................................90-91
Shuttle Cylinder Assembly .................................92-93
Fuel and Hydraulic Tank Assembly ....................94-97
Front Cover Assembly........................................98-99
Heat Exchanger Assembly.............................100-101
Engine and Frame Assembly .........................102-103
Throttle and Water Filter Assembly................104-105
Hydraulic Pump Assembly .............................106-107
Lubrication Pistons Assembly ........................108-109
Electrical System Assembly ...........................110-111
Accumulator Assembly...................................112-113
Manifold Assembly .........................................114-115
Remixer Control Assembly ............................116-117
Battery Assembly ...........................................118-119
Lubrication Panel ...........................................120-121
Control Box Interior Door Assembly ..............122-123
Control Box Mounting Assembly ...................124-125
Control Box Assembly ...................................126-127
Control Box Door Wiring Diagram ......................... 128
Control Box Interior Wiring Diagram ..................... 129
Terminal Block Wiring Diagram ............................. 130
Control Box Electrical Diagram ......................132-134
Hydraulic Diagram ............................................... 135
Optional Radio Control.......................................... 136
Wiring Diagram (Tail Lights)................................. 137
Here’s how To Get Help.............................................2
Table of Contents ......................................................3
Pump Specifications..................................................4
Engine Specifications ................................................5
Dimensions .............................................................. 6
Noise Measurement..................................................7
Safety Message Alert Symbols ............................ 8-9
Rules for Safe Operation .................................. 10-12
Operation and Safety Decals ............................ 13-15
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
Trailer Safety Guidelines ................................... 36-37
Towing Information............................................ 38-41
Braking System ................................................. 42-47
Troubleshooting (Brake System).............................48
Torque Tables ..........................................................49
Maintenance (Pump) ........................................ 50-58
Hydraulic Hose Connections............................. 59-61
Manifold Port Locations ..........................................62
Appendix — Concrete Mix Information ............. 64-65
Appendix — Slump Test Procedure ........................66
Troubleshooting (Engine)........................................67
Troubleshooting (Hydraulic System) .......................68
Troubleshooting (Electrical System) .......................69
Appendix — Recommended
Terms and Conditions Of Sale — Parts ................ 138
Mayco Pump Warranty .......................................... 139
Shotcrete System ..........................70-71
Appendix — Recommended
Shotcrete Accessories...................72-73
Explanation Of Code In Remarks Column ..............74
Suggested Spare Parts ...........................................75
NOTE
Specification and part
number are subject to
change without notice.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 3
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ST-45HRM CE CONCRETE PUMP — PUMP SPECIFICATIONS
Table 1. ST-45 Pump Specifications
Pumping Method
Reciprocating Piston
Up to 34.4 cu. meters per hour*
(45 cu. yds. per hour*)
Pumping Rate
Maximum Aggregate Size
Vertical Pumping Height
38mm (1-1/2 in. minus)
Up to Excess of 76m (250 ft.)
305m* (1000 ft.)
Horizontal Pumping Distance
Cylinder Lubrication Box Capacity
Hydraulic Fluid Capacity
26.5 Liters (7 Gallons)
219 Liters (58 Gallons)
76 Liters (20 Gallons)
Fuel Tank Capacity
283 liters (10 cu. ft. ) with optional
fwd/rev remixer
Hopper Capacity
Material Hose
76.2 mm, 101.6 mm, 127 mm
(3 in., 4 in., 5 in. dia.)
Remote Control (25 ft. cable)
Dimensions
optional
See Page 6
Weight (with fluids)
Weight (dry/shipping)
1,907 kg (4,206 lbs.)
1,832 kg (4,040 lbs.)
* Volume output will vary depending on mix design, slump, line size used and job site condititons
PAGE 4 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— ENGINE SPECIFICATIONS
Table 2. Engine Specifications
Model
HATZ 3M41 57HP DIESEL ENGINE
102 x 105 mm
(4.02 in. x 4.13 in.)
Bore X Stroke
Compression Ratio
Displacement
18.7
2,573 cc (157 cu. in)
Lube Oil Capacity
Max/Min
(8.6 L / 5.1 L)
9.1 qt. / 5.4 qt.
Engine
Engine Speed
Full Idle
875 rpm 100
Battery Type
12 V (88/143 Ah)
SAE 10W-30 (Oil Grade)
SG or SF (Service Class)
Engine Lubrication
Starting Method
Dry Net Weight
Electric Start
255 kg (562 lbs.)
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 5
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ST-45HRM CE CONCRETE PUMP— DIMENSIONS
Figure 1. ST-45HRM CE Concrete Pump Dimensions
PAGE 6 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— NOISE MEASUREMENT
EC Declaration of Conformity
In accordance with EN 45014:1998
We
of
Multiquip (UK) Ltd
Hanover Mil, Fitzroy Street Ashton Under Lyne OL7 0TL
declare that:
Equipment
Model name/number
Concrete conveying and spraying apparatus
(S/N’s 220704 and 220705)
Is in accordance with the following directives:
98/37/EC
The Machinery Directive
89/336/EEC
2000/14/EC
Electromagnetic Compatibility Directive
The noise Emission in the Environment by Equipment for Use
Outdoors Directive
has been designed and manufactured to the following specifications:
pr EN 12001:1995
Conveying, spraying and and distributing machines for concrete and mortar –
safety requirements.
BS EN 292-2:1991
BS EN 982:1966
Safety of machinery.Basic concepts
Safety of machinery.Safety requirements for fluid power systems and their
components. Hydraulics
BS EN 61000-6-4:2001
Electromagnetic compatibility (EMC). Generic standards. Emission standard
for industrial environments.
Noise measurements have been made in accordance with BS EN ISO 3744:1995 with internal control of production (Schedule 8/AnnexV).The
declared noise values are as follows:
Measured Sound Power Level
103 db (LwA)
Guaranteed Sound Power Level
106 db (LwA)
I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications.
The unit complies with all essential requirements of the Directives.
Signed by: ................................................................................................................
Name:
Position
Done at
On
L.Whitelegg
Ashton-Under-Lyne
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 7
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ST-45HRM CE CONCRETE PUMP— SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
FORYOUR SAFETY ANDTHE 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.
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.
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
operation of the Multiquip Mayco
ST-45HRM CE Structural Concrete
pump. Refer to the engine
manufacturers instructions for data
relative to its safe operation.
Explosive Fuel
Before using this concrete pump , ensure that the operating
individual has read and understands all instructions in this
manual.
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
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,
Burn Hazards
DANGER: You WILL be KILLED or
SERIOUSLY injured if you do not follow
directions.
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.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you do not follow
directions.
Rotating Parts
CAUTION: You CAN be injured if you
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
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.
PAGE 8 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
Respiratory Hazard
ALWAYS place the ON/OFF switch in the OFF
position. NEVER perform maintenance on the
unit with the ignition key in the ON position.
ALWAYS wear approved respiratory
protection.
Over Speed Conditions
Sight and Hearing hazard
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.
ALWAYS wear approved eye and
hearing protection.
This pump, other property, or the
surrounding environment could
be damaged if you do not follow
instructions.
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.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 9
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ST-45HRM CE CONCRETE PUMP— RULES FOR SAFE OPERATION
■
■
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
CAUTION:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is
for industrial use only.
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.
The following safety guidelines should always be used when
operating the MAYCO ST-45 concrete pump:
■
NEVER touchthehotexhaustmanifold,
muffler or cylinder.Allow these parts to
cool before servicing engine or pump .
GENERAL SAFETY
■
DO NOT operate or service this equipment
beforereadingthisentiremanual.
■
HighTemperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact
with hot! components can cause serious burns.
■
■
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.
■
The engine section of this pump requires an adequate free
flow of cooling air. NEVER operate the pump in any enclosed
or narrow area where free
flow of the air is restricted. If
the air flow is restricted it
will cause serious damage
to the pump or engine and
may cause injury to
people. Remember the
pump's engine gives off
DEADLY carbon monoxide
gas.
■
■
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■
■
ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
NEVER operate this equipment under the
influence or drugs or alcohol.
ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool.
■
■
ALWAYS check the machine for loosened threads or bolts
before starting.
■
NEVER smoke around or near the machine.
Fire or explosion could result from fuel
vapors, or if fuel is spilled on a hot! engine.
ALWAYS wear proper respiratory (mask), hearing and eye
protection equipment when operating the pump .
■
■
NEVER operate the pump in an explosive
atmosphere or near combustible materials. An explosion or
fire could result causing severe bodily harm or even death.
Topping-off to filler port is dangerous, as it tends to spill fuel.
PAGE 10 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP — RULES FOR SAFE OPERATION
■
■
■
ALWAYS remove the ignition key when leaving the pump
unattended.
Transporting
■
ALWAYS shutdown engine before transporting the pump.
ALWAYS block the wheels on the unit when using on a
slope.
■
Tighten fuel tank cap securely and close fuel valve to prevent
fuel from spilling.
ALWAYS maintain this equipment in a safe operating
condition at all times.
■
Drain fuel when transporting pump over long distances or
bad roads.
■
■
ALWAYS stop the engine before servicing, adding fuel or oil.
Towing
■
■
■
Before towing, check the hitch and secure the safety chain to
the towing vehicle.
NEVER run engine without air filter. Severe engine damage
may occur.
When towing, an adequate safety chain must be fastened to
the frame, refer toTowing Guidelines.
■
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operation techniques before using pump.
This equipment shall not be towed or operated by individuals
who cannot read understand the signs, decals or operating
instructions.
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.
■
■
■
■
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 operate this equipment unless all guards and safety
devices are attached and in place.
CAUTION must be exercised while servicing this equipment.
Rotating and moving parts can cause injury if contacted.
DO NOT tow unit in excess of 45 MPH on highways..
Keep all inexperienced and unauthorized people away
from the equipment at all times.
Maintenance Safety
■
Before start-up, check the hopper and remove all foreign
matter and debris.
NEVER lubricate components or attempt service on a running
pump .
DO NOT use worn or damaged hose couplings, inspect all
hoses and couplings for wear.Replace any worn or defective
hose or couplings immediately.
■
ALWAYS allow the pump a proper amount of time to cool
before servicing.
■
■
Keep the pump in proper running condition.
■
■
■
Keep hands out of the hopper when the engine is running.
Fix damage to the pump immediately and always replace
broken parts.
DO NOT operate unit with the hood open.
DO NOT disconnect hose couplings or nozzle while under
pressure. Relieve pressure by manually activating pressure
relief valve at manifold.
■
■
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.
■
■
■
■
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 HATZ Engine Owner's Manual for engine
technical questions or information recommended by
Multiquip for this equipment. Damage to the equipment and
or injury to user may result.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 11
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ST-45HRM CE CONCRETE PUMP— RULES FOR SAFE OPERATION
Battery
Emergencies
The battery contains acids that can cause injury to the eyes and
skin.To avoid eye irritation, always wear safety glasses.Use well
insulated gloves when picking up the battery. Use the following
guidelines when handling the battery:
■
ALWAYS know the location of the nearest fire extinguisher.
1. DO NOT drop the battery.There is the possibility of risk that the
■
ALWAYS know the location of the nearest and first aid kit.
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
■
In emergencies always know the location of the
nearest phone or keep a phone on the job site.
Also know the phone numbers of the nearest
ambulance, doctor and fire department. This
information will be invaluable in the case of an
emergency.
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.
6. In case the battery liquid (dilute sulfuric acid) comes in contact
with clothing or skin, rinse skin or clothing immediately with
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.
PAGE 12 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE 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 1. ST-45 Operation and Safety Decals
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 13
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ST-45HRM CE CONCRETE PUMP— OPERATION AND SAFETY DECALS
Figure 2. ST-45 Operation and Safety Decals
PAGE 14 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— OPERATION AND SAFETY DECALS
Figure 3. ST-45 Operation and Safety Decals
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 15
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ST-45HRM CE CONCRETE PUMP— IMPORTANT HAND SIGNALS
Figure 4 display's the basic hand signals commonly used in concrete pumping operations.
Figure 4 Operation Hand Signals
PAGE 16 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— GENERAL INFORMATION
Concrete Mix Design
There are four ways in which this seal can be lost:
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.
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.
The term “aggregates” describes all of the solid materials, from
the largest rock to the smallest grain of sand, contained in the
concrete mix.
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.
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 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 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.
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.
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 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 Operating
Procedures (pages 25-29).
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 17
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ST-45HRM CE CONCRETE PUMP— GENERAL INFORMATION
In addition, the Mayco Concrete ST-45HRM CE Pump can be
used to pump a large aggregate hard rock as follows:
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.
1. Pea rock 12.7mm (1/2" minus) pump with mixes being as
low as 30% rock and 70% sand. (See page 50, 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.)
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
64-65 will provide a basic guideline for establishing the proper
mix design for your area.
3. “Mud Jacking”, high pressure grouting.
Use this information to specify your requirements to your local
ready-mix batch plant, contractor and civil engineer.It may take
minor adjustments to make a mix pumpable, so you should
explain your needs.
The elements that have to be controlled and consistently
maintained by the batch plant are:
1. The sizing and mix percentage of rocks, gap graded from
the largest down through the smallest sizes.
2. Sand with a sieve analysis that has the proper percentage
of fines, ASTM C33 spec.
3. Sufficient cement to produce the required design strength
of the concrete and provide the lubricating binder to pump
the concrete through the delivery system.
Use a minimum of:
227 Kg (500 lbs.) of cement/cu yd for 17.2 mPa (2500 p.s.i.)
concrete after 28 days.
240 kg (530 lbs.) of cement/cu yd for 20.7 mPa (3000 p.s.i.)
concrete after 28 days.
272 kg (600 lbs.) of cement/cu yd for 27.6 mPa (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.
PAGE 18 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HOW ITWORKS
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 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.
Figure 5. Pumping Cycle 1
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 19
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ST-45HRM CE CONCRETE PUMP— PUMP COMPONENTS
Figure 7. Major Pump Components
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ST-45HRM CE CONCRETE PUMP— PUMP COMPONENTS
13. Lubrication Panel – This console allows for the remote
Figure 7 illustrates the location of the major components
for the ST-45 Structural Concrete Pump. The function of
each component is described below:
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.
1. Tow Hitch Coupler – See the Towing Information
section in this manual.
15. Accumulator – Stores hydraulic oil under pressure and
releases it to the shuttle cylinder and provides the
required pressure to activate the hydraulic system.
2.
Documentation Box – Contains engine and pump
operation, parts and maintenance information.
3. Hydraulic OilTank/Cap– Remove cap to add hydraulic
fluid. Fill with Shell Oil Tellus 68, Mobil Oil DFE26 or
equavalent if hydraulic oil level is low.
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.
4.
Fuel Tank/Cap – Fill with #2 diesel fuel. Fuel tank (cell)
holds approximately 88 liters (20 gallons). DO NOT top off
fuel. Wipe up any spilled fuel immediately
18. Hydraulic Pump – This unit incorporates an axial variable
5. Battery –This unit uses a +12VDC type battery.ALWAYS
displacement hydraulic piston pump.
use gloves and eye protection when handling the battery.
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.
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.
To place the engine in idle, press the top button inward all
the way..
20. StrokeVolume Control Dial – Turns CW/CCW to increase
8.
9.
Tires — Tire inflation pressure is the most important factor
in tire life. Pressure should be checked before operation.
DO NOT bleed air from tires when they are hot. Check
inflation pressure weekly during use to insure the maximum
tire life and tread wear.
or decrease the number of strokes per minute of the pump.
21. Control Box – Contains the mechanical and electrical
components required to run the pump. See next page for
control box description.
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.
22. Tow End Jack Stand – Use this jack stand to level and
support the tow end of the pump.
23. Pumping Pressure Gauge – Used to monitor pressure in
the concrete cylinders and shuttle tube.
24. Accumulator Pressure Gauge– Used to monitor
accumulator pressure. Pressure should read at least 12.1
mPa (1,750 psi) for correct pump operation.
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.
25. Hydraulic Oil Sight Glass – Use to determine the
amount of hydraulic oil remaining in tank. The sight
glass also contains a temperature gauge for monitoring
the temperature of the hydraulic oil.
11. Hopper/Hood – Lift hood to fill. Concrete from a Redi-Mix
truck is poured into this hopper.The hopper can hold 283
liters (10 cu. ft) of concrete with optional forward/reverse
mixer.NEVER put hands or any other parts of you body into
the hopper.
26. Hopper Discharge Sleeve – Connect hoses or steel
pipes to the discharge sleeve for pouring concrete.
27. Emergency Stop Button – Press emergency stop button
to stop pump in an emergency.Turn knob counter clockwise
to disengage the stop button.
12. Remixer Motor – Drives the remixer paddles inside
the hopper. The motor direction is controled by the
remixer control lever.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 21
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX COMPONENTS
Figure 8. Pump Control Box Components
1. Engine Tachometer – Monitors the engine RPM’s and
8. Direction Control Switch– This 2 position switch controls
the direction of flow for any mix in the pump. The center
position sets the pumping direction to forward and the right
most position sets the pumping direction to reverse.
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.
9. Pump Operation Switch– This 2 position switch controls
the operation of the pumping components and engine. The
center position allows the operation of the pump and
engine and the right most position allows only the engine
to operate.
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 counter-
clockwise to the “STOP“ position.
10. PressureTest Switch– Activates a self-diagnostic routine
which tests the pressure of the pumping system, which can
be read on the Pumping Pressure Gauge.
11. Pumping Control Switch – This 3-position switch controls
the pumping of the pump.The left most position is for use
with the remote control unit, the center position is for
normal pumping operation, and the right most position
(OFF) prevents pumping.
5. Battery Indicator Lamp– Indicates a low battery charge.
Replace or charge battery. NEVER operate the ST-45 when
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.
12. Cooling Fan Switch – If hydraulic oil temperature exeeds
23.9° C (75° F), set the pump operation switch to engine
and turn the cooling fan switch to the right most position to
activate cooling fan.
7. Air Filter Indicator Lamp – Indicates the engine air filter
is functioning properly. NEVER operate the ST-45 if this
lamp is off.
13. Remote Cable Connector – Insert the remote control input
cable into this connector.
PAGE 22 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— ENGINE COMPONENTS
Figure 9. Pump Control Box Components
INITIAL SERVICING
The pump's engine (Figure 9) must be checked for proper
lubrication and filled with fuel prior to operation. Refer to the
manufacturers Engine manual for instructions & details of operation
and servicing.
6. Air Filter/Cover – Prevents dirt and other debris from
entering the fuel system. Release the latches on the side of
the air filter cover to gain access to filter element.
7. Starter/Solenoid – This engine uses a 12 VDC , 2.7kW
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.
(3.7 HP) starter motor with solenoid.
8.
Front Oil Drain Plug – Remove this plug to drain engine
oil from the engine crankcase. For best results drain engine
oil when oil is warm.
2.
Dip Stick – Remove dipstick to determine if the engine oil
level is low. If low add oil as specified in Table 4.
9. V-Belt Cover – Remove this cover to gain access to theV-
belt.When replacing V-belt , use only recommended type
V-belt.
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.
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.
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.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 23
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ST-45HRM CE CONCRETE PUMP— OPERATING PROCEDURES
OPERATING SUGGESTIONS
C. Ifitisnecessarytowait10minutesormoreforanother
loadofconcrete,itiswisetostartthepumpandpump
6or8strokesevery5minutestopreventsettingofthe
mixinthesystem.Ifwaitingtimeisexcessive,itwould
bewisetowashoutthepumpandhosesandstartover
when the new truck arrives.
1. Awell-plannedlocationofthepumpandroutingofthehose
beforestartingapourmaysavesubsequentmovesthrough-
out the job.
2. Beforeconcreteisdischargedintothehopper,itissuggested
that 11-4-15.1liters(3to4gallons)ofwaterbesprayedinto
thehopper,followedbyapproximately18.9liters(5gallons)
of a creamy cement and water slurry (1/2 bag of cement to
18.9liters/5gallonsofwater).Thisprocedurelubricatesthe
hose and prevents separation and blockages in the hose.
D. When pumping stiff mixes and there is waiting time
between redi-mix trucks, it is advisable to add some
watertothelasthopperofmaterialand“handmix”to
ensure an easier start with the following load.
E. When the pumping job requires a stiffer mix, the
following method is suggested for starting: Take a
water hose with a nozzle on it and apply water with a
fine spray to the concrete as it comes down the redi-
mix chute into the pump hopper after the slurry
procedure is completed and you are ready to start
pumping.
Getting the concrete to flow through
the hose at the start of the pumping
cycle can be one of the most critical
operations of the pour. (Manually
operate the throttle when starting,
NOTREMOTELY)
Using this procedure will make it easier to pump
throughthecleanhose.Note:Oncetheconcretehas
reached the end of the hose, do not apply any more
water in this manner as this procedure is used for
startingonly.
CAUTION
If hoses or lines are blocked for any reason,
or if the lines are kinked when starting up or
during the pumping cycle, the pump
pressure could straighten out the kink or
force out the blockage. This rapid surge of
material could cause the lines to whip or
move in a manner that could cause injury to
personnel.
F. Hose sizing is very important: We strongly recom-
mendonharshmixes,verticalpushes,stiffconcrete,
shotcrete,longpushes,thata 6.35cm(2-1/2”)linebe
used as far as possible.The advantages of using the
6.35 cm (2 -1/2”) line are improved pumpability, less
pumping pressure and less wear on the pump.
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.
5. Followingthepumpoperation, properwashoutofallmate-
rials or “build-up” within the pump manifold and hoses will
prevent problems when starting the next job.
6. Athoroughinspectionofthedrivecomponentsandgreasing
ofallbearingsaftereachjobwillensureadequatelubrication
andservicetothepumpwhichisnormallyoperatinginwet,
grittyconditions.
4. Whenthepumpisstoppedforanyreasonduringapour;e.g.,
movinghose,waitingforredi-mixtruck,thefollowingsugges-
tionsareoffered:
A. Leave the hopper full of concrete at the time of
shutdown.Itisimportantnottolettheredi-mix driver
wash too much water into the hopper, as this could
cause separation of the concrete in the hopper.
Over-greasing any bearing on
yourMaycopumpwillnotdamage
thebearing.
B. Iftheshutdownperiodexceeds2to3minutes,turn
offtheenginesothevibrationdoesnotseparatethe
mixinthehopperwhichcancauseablockageinthe
manifold when the pump is started.
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ST-45HRM CE CONCRETE PUMP— OPERATING PROCEDURES
B. MBVR – air entraining, acts as a lubricant.
WARNING
C. Calcium Chloride – commonlyreferredtoasC.C.,is
Common sense tells us that if you drive a
truck into a brick wall, something is going to
used as an accelerator. When pumping a load with
calciumchloride, itisrecommendedthatyouwashout
be damaged.The same holds true with your
ifthewaitingtimebetweendeliverytrucksbecomestoo
concrete pump. If you repeatedly pull the
long.
throttle all the way out and try to force your
pump to push through blockages due to
D. Super Plasticizers – acts as an accelerator.The
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.
concrete will look very wet after the super plasticizer is
added, but will begin to set up very fast.Wash out
immediately if you do not have a truck waiting. Super
plasticizers are used mainly on commercial jobs.
E. RedLabel–actsasawaterretarderandanaccelerator.
Red label will be used mainly on commercial jobs.
WARNING
F. Fly Ash – is used to help increase the strength of the
concrete and decrease the cement content per yard.
This is one of the most common admixtures used.
It will be necessary at times to move your
pump from one job site location to another.
Before moving the pump, make sure to pump
the remaining concrete out of the hopper.
Moving the pump with a full hopper of
concrete can cause severe damage or
breakage of the axle and axle springs, excess
strain and pressure on the hub and bearing assembly.
All admixtures will be shown on the
redi-mix concrete ticket.Before start-
ing 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.
Pumping Tips
The effects of heat and excessive time on concrete:
10. Whenpumpinglongdistanceorpumpingstiffmixes,youcan
expectadropinvolumecomparedtoshorterlinesandwetter
mixes due to the change in valve efficiency or cavitation.
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:
11. Leakingmanifoldsealsorhosecouplinggasketswhichleak
watercancauseseparationandsubsequentjammingatthat
point.
8. Concrete starts setting by drying up through a chemical
reaction.Thecatalysttothisreactionisheat. Whenpumping
ahotload,itisimportanttorememberthatwhenyouhaveto
stoppumpingforanyreason,addwatertotheconcreteinthe
hopper and hand mix and move concrete in the hose every
5minutes.Iftheshutdowntimebecomestoolong,washout
immediately.
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.
Admixtures:
9. Remixtures that are designed into the concrete mix by the
redi-mixcompanyoranarchitecturalengineeringcompany.
This section lists common admixtures and a brief explana-
tionoftheirfunctions:
A. With the entire delivery system connected to the pump.
Except for the first hose. Pour 18.9 liters (5 gallons) of
water into the second hose and push in your clean out
ball and reconnect.This will help hold back the prime.
A. Pozzolith 300 – or the equivalent acts as a water
retarderandalubricant.Onaleanmix,longpushes,stiff
mixes, and vertical pushes, Pozzolith 300R helps
pumpability.
B. There are several things you can use for the prime. A
few examples are Cement and lime at a 50/50 mixture,
slick pac, bentonite clay.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 25
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ST-45HRM CE CONCRETE PUMP— OPERATING PROCEDURES
C. Mix the prime to the consistency of a smooth batter.
16. Theshuttletubeispluggedifvolumeatthedischargeendof
thehosestops,the hoseissoftandthehydraulicoilpressure
gauge reads 20.7 mPa (3000) psi or more.
D. Position the first ready-mix truck at the hopper. Check
the concrete.DO NOT discharge concrete into hopper
at this time.
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.
The bentonite is not compatible with
concrete. DO NOT pump it into the
forms. Discharge it out of the formed
area.
WARNING
E. Pour approximately two 18.9 liter (5 gallon) buckets of
prime into the first hose and connect it to the pump.
DO NOT open any of the
delivery system joint clamps.
F. 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.
“Reverse” Pumping Procedure
A. Switch the pump into reverse. With pump speed at a
medium-slow (approx. 12 strokes per min.) try to pull
the “pack” back into the hopper with 5 or 6 reverse
strokes.
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 18.9 liters (5 gallons)
of water per 7.62 meters (25 ft.) length, before adding it to
thesystem.
B. Remix the concrete in the hopper.
C. Switch the pump into forward. If it is still plugged, repeat
“Reversing” procedure three times.
Clearing Concrete Blockage
If concrete still does not move, proceed to the Shuttle Tube
Inspection Procedure.
13. Damaged hoses with internal restrictions can cause block-
ages.
Shuttle Tube Inspection Procedure
A. Stop the pump.Switch off the engine.
14. If a blockage occurs in a hose, walk the hose until you find
thepointoftrouble.Thehosewillbesoftimmediatelypastthe
blockage.Ifthishappensatthestart,disconnectthehoseat
the first coupling past the blockage.
B
The senior or most experienced operator must warn all
others to stand at least 6.1 meters (20 feet) away from
the machine and turn their heads to face away from the
pump.
15. Elevatethehoseatthatpointwiththeblockageareahanging
down. Using a hammer, you can pound the down-stream
edgeofthepackedareauntilitisfreetoflow.Shakeallofthe
sandandgravelouttotheendofthehose.Beforereconnect-
ing 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
Saftey glasses MUST be worn at all times
when operating the ST-45. Failure to fol-
low saftey guidlines can result in serious
injury.
CAUTION
C. The operator will position themself beside the reducing
elbow at the pump outlet. Wearing safety glasses,
slip the end of a pry bar (61 cm/24" length of reinforcing
steel rod) under the latch of the hose clamp and flip it
up.
Use extreme care! The hose line is under
pressure and can cause serious injury.
PAGE 26 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— OPERATING PROCEDURES
If, for any reason, the mix should set up in the system, the
following procedure (E through H) is suggested:
D. Carefully knock the end of the hose away from the
reducer.
E. Chip the concrete out of the reducer with the pry bar.
E. Disconnectthehosefromthepumpandwashthepump
outimmediately.
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.
F. Reconnect the hose and fill the hopper with water.
G. Reconnectthehoseandfillthehopperwithwater.DO
NOT try to push all the concrete out of all of the hose
lines at one time.
G. The senior operator may then remove the inspection
cover plate from the shuttle tube by using a long
extension wrench and the 61 cm (24-inch) pry bar.
Forexample:Ifyouhad 61meters(200ft.)ofsystemout,
youwoulddisconnecteachhose.Cleanitoutbypush-
ing water through the first hose off the pump, then
continueprogressingthroughallthehoses,untilallthe
systemisclean.
WARNING
Make sure the accumulator pressure gauge
reads ZERO psi. prior to performing any
maitinance or inspection.
H. Ifwaitingtimeisexcessive,itwouldbewisetowashout
thepumpandhosesandstartoverwhenthenewtruck
arrives.Thiscanbeavoidedbybeingobservanttothe
pump and system, also taking into consideration the
above factors (E through H) affecting the mix.
H. Chip the blockage out with the pry-bar.
I. Flush the shuttle tube with water.
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 5 cm x 10 cm x 15 cm (2”x 4”x 6”) be placed in the
hose before the start of pumping. Wet the sponge before
placing it in the hose.
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) affecting the concrete :
Thereasonforusingthewetspongeistokeeptheslurryfrom
running too far ahead of the concrete and so reducing the
possibility of separation. When the pump is stopped, the
materialcanflowslowlydown,duetogravity,andcausethe
hose to collapse.
A. How old is the concrete?
Whenpumpingisresumed,youcanexpectblockageatthe
point of hose collapse.To prevent this from happening, the
hosecanbe“kinkedoff”atthedischargeendwhenthepump
is stopped to prevent the gravity flow of the material in the
hose.
B. Isthereanaccelerator,calciumchloride,redlabel,etc.,
in the concrete?
C. Temperature of the day, 27° C (80° F), 32° C (90° F)?
D. Howmuchsystemyouhaveoutandhowstiffwasthemix
you were pumping?
The use of stiffer mixes when pumping down-hill will de-
creasegravityflowofthematerialinthehoseandwillassure
a smoother operation between the cam roller bearing and
camplate.Aswithanyjob, makesurethatthehoseandthe
couplings are in good workable shape.
When disconnecting hoses, use
EXTREME CAUTION! The hose is
under pressure!
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 27
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ST-45HRM CE CONCRETE PUMP— OPERATING PROCEDURES
19. VerticalPumping– Whenpumpingverticallyupthesideof
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
pumpingdistances.
a building, above 12.2 meters (40 feet), we would recom-
mend 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
bottomofthesteelline.
Theuseof63.5mm(2-1/2”)I.D.hoseintheseextremecases
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.
Usea7.62meter(25ft.)hose,orshortsection,offthepump;
andforthebalanceofthehorizontaldistancetothevertical
line, use steel pipe.This type of installation has been satis-
factory on many jobs being pumped in excess of 30 meters
(100 feet) high. Line pressures are always less using steel
pipe as compared to hose.
Ifexcessivepulsationexistsinthehose,itisadvisabletouse
burlaporsomemeansofwearprotectionunderthehoseat
pointswherethehosemaywearthroughtheoutercover;e.g.
overforms, steelorsharpcurbs.
Whenpumpingvertically,usingallhose,itisrecommended
nottogohigherthan7.62meters(50feet)withhose.Thehose
shouldbetiedoffatintervalsof3meters(10feet),ifpossible.
Specialattentionshouldbegivenwhentieingthehoseoffat
thetopasthehosewillhaveatendencytostretchwhenfilled
withconcrete.Thiswillincreasethepossibilityofablockage
at the point where the hose is tied off.To avoid this, a long
radiusof90degreeelbowisrecommended.Thesuggested
place to tie off is on the hose, under the clamp.
21. Snap-Joint – When using Snap-Joint couplings with gas-
ketstojoinhose, seethattheyarewashedcleanaftereach
job.Keepingthehoseendsclean(heavyduty)isveryimpor-
tantforthebestjobsetup.Athincoatofgreaseontherubber
gasket or dipping both coupling and gasket in water before
coupling the hose will make for easier installation.
22. NewPumps–Allnewpumpsare‘waterpressuretested”atthe
factoryThisprocedurepermitsathoroughinspectionofentire
drive system and valving under simulated full load conditions.
The pump owner can do the same by making an adapter to
coupletotheendofthedischargecone:e.g.,theuseofastandard
51mm(2-inch)pipecapwitha 9.5mm(3/8")drilledholeinthe
center, screwedontotheendofhingedconeorreduceratthe
pump.
It is strongly recommended that
steel pipe be used on all vertical
pumping for safety and conve-
nience.
Fillhopperwithwateraftermakingsurethatallsandandrock
have been removed from manifold. Operate pump at full
throttle and the 9.5 mm (3/8") diameter hole restriction will
createsufficientbackpressuretomakethoroughinspection
of all moving parts.
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ST-45HRM CE CONCRETE PUMP— INSPECTION
FUEL CHECK
CAUTION
5.
Read the fuel sight tube (Figure 10) on top of the fuel tank
to determine if the pump's engine fuel is low .
NEVER operate the pump
in a confined area or
enclosed area structure
that does not provide
ample free flow of air.
ALWAYS wear approved eye and hearing
protection before operating the pump .
NEVER place hands or feet inside the hopper. ALWAYS shut-
down the engine before performing any kind of maintenance on
the pump.
NEVER operate the pumps's engine with the
engine hood or V-belt cover removed. The
possibility exists of hands, long hair, and
clothing becoming entangled with theV-belt,
causing injury and bodily harm.
Reference Figures 7 through 9 for
the location of any control or
component referenced in this section.
Figure 10. Fuel SightTube
Before Starting
6.
If fuel is low, remove fuel filler cap and fill with #2 diesel
fuel (Figure 11).
1. Read safety instructions at the begin-
ning of manual.
2. Cleantheentirepump,removingdirtanddust,particularly
the engine cooling air inlet, and air filter.
3. Check theairfilter for dirtanddust. Ifairfilterisdirty,replace
air filter with a new one as required.
4. Checkfasteningnutsandboltsfortightness.
CAUTION:
Handle fuel safely. Diesel fuel is highly
flammable and can be dangerous if
mishandled. DO NOT smoke while refueling.
DO NOT attempt to refuel mixer if the engine is
hot or running. ALWAYS allow engine to cool
before refueling.
Figure 11. Adding Diesel Fuel
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 29
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ST-45HRM CE CONCRETE PUMP— INSPECTION
ENGINE OIL CHECK
12 The oil listed inTable 4 is recommended to ensure better
engine performance. Use class CD or higher grade motor
oil.
7.
Remove the engine oil dipstick from its holder (Figure 12).
Figure 12. Engine Oil Dipstick
8. Make sure pump is placed on level ground.
9. Pull the engine oil dipstick (Figure 13) from its holder.
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
Figure 13. Engine Oil Dipstick
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.
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ST-45HRM CE CONCRETE PUMP— INSPECTION
14. If the hydraulic oil level is low, remove the cap just above the
16. Remove the cotter pin from the handle tee bolt eye, and
then pull the handle tee to release the stabilizer stand (Figure
17).
oil level sight glass (Figure 15) and add the correct amount
of hydraulic oil to bring the hydraulic oil level to a normal
safe operating level. (Use Shell oil Tellus 68 or Mobil oil
DFE26).
17. Position both rear stabilizers stands on firm (not loose) level
ground (Figure 18).
18. Align the hole on the stabilizer stand with the hole on the
frame body and insert handle tee bolt.
19. Insert the cotter pin into handle tee bolt eye to lock the
stabilizer stand.
Figure 15. Hydraulic Oil Filler Hole
REAR STABILIZER STAND
To reduce excessive vibration and rocking of the ST-45 Concrete
Pump, set the rear stabilizers as follows:
Figure 17. Rear Stablizer Stand
15. Locate both the left and right rear stabilizer stands
(Figure 16).
Figure 18. Rear Stablizer Stand Deployment
Figure 16. Locatiing Rear Stabilizer Stands
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 31
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ST-45HRM CE CONCRETE PUMP— INITIAL START-UP PROCEDURE
IGNITION SWITCH
STARTING
3. To start the engine, insert the key (Figure 20) into the ignition
CAUTION :
switch and turn the key to the ON position.
DO NOT attempt to operate this concrete
pump until the Safety, General Information
and Inspection sections have been read and
understood.
EMERGENCY STOP SWITCH
1. There are 2 emergency stop switches (Figure 19). One is
located on the the control box, the other is located on the
other side of the pump near the heat exchanger. Both are
provided for operator safety.In the event of an emergency,
press either stop switch to stop the engine.
Figure 20. Ignition Switch
4. Observe that the Air Filter and Oil Pressure status indicator
lights are “ON”(Figure 21).The Battery status indicator light
should be “OFF.”
Figure 19. Emergency Stop Switch
2. Turn both Emergency Stop switches counter-clockwise
(open).This will allow the engine to start.
Figure 21. Status Indicator Lights
If either one of the Emergency Stop
switches is in the “CLOSED” position
(stop), the engine will not start.To start
the engine, make sure that both
Emergency Stop switches are in the
“OPEN” position (fully extended).
A. Turn the key to the “START“ position and listen for the
engine to start.
B. In warm weather let engine warm-up for 5 minutes. In
cold weather let engine warm-up for 10 minutes.
C. The Air Filter, Oil Pressure and Battery indicator lights
(Figure 21) should all be “OFF”.
If any of the status indicator lights
referenced in the ignition section
(step 4) are “ON”, turn off the engine.
DO NOT continue to run the engine.
Place all switches on the Hydraulic
Control Box in the ”OFF” (up position).
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ST-45HRM CE CONCRETE PUMP— INITIAL START-UP PROCEDURE
8. While monitoring the tachometer,
(Figure 25) use the Engine
Throttle Control to set the engine
speed to 1500 RPM by following
steps 8A-8C.
CONTROL SWITCH
5. Turn the Pump Control switch (Figure 22) to
the “ON” position, a thumping sound
(cylinder stroke) should be heard. The
thumping sound represents the number of
strokes per minute (volume) of the pump.
Figure 25. Engine
Tachometer
A. Unlockthethrottlecable.Tounlockthethrottlecable, turn
the inner most knob counter clockwise (Figure 26.)
Figure 22. Pump Control Switch
UNLOCKING
KNOB
6. Turn the Volume Control (Figure 23), lock nut
counterclockwise (CCW) to release the volume control
knob.
UNLOCK
THROTTLE
ADJUSTMENT
KNOB (COARSE)
(PUSH/PULL)
LOCK
THROTTLE
ADJUSTMENT
KNOB (FINE)
(TURN CW/CCW)
Figure 26.Throttle Control Knob (Un-locking)
B. Push the outermost button, Figure 27 (coarse adjust-
ment) inward, then pull outward until engine RPM
reaches desired speed.
Figure 23. Volume Control
6. Use the volume control, to set the
pump volume to approximately 10
strokes per minute.Turning the
volume control clockwise (CW)
will decrease pump volume,and
counterclockwise (CCW) will
increase pump volume.
C. Turn the unlocking knob (figure 26) clockwise to lock
engine RPM in place.
PUSH-IN, THEN PULL
TO SET THROTTLE
(RPM’s)
Figure 24. Hydraulic Oil Temperature Gauge
7. Let the pump cycle until the hydraulic oil temperature
(Figure 24) is approximately 10°-15.6° C (50°- 60° F)
Use a wristwatch or stop watch to
determine the number of pump
strokes within 1 minute.
PUSH ALL THE WAY IN
TO IDLE ENGINE
Figure 27.Throttle Control Knob (RPM Adjust)
9. Turn the Control Off switch (Figure 22) to the “OFF“ position.
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ST-45HRM CE CONCRETE PUMP— INITIAL START-UP PROCEDURE
ENGINE SPEED
13. Make sure the Operation Pump/Engine
switch is in the “ENGINE“ position
(Figure 28), and that only the engine is
running.
10. Turn the Operation Pump/Engine switch
to the “ENGINE” position (Figure 28).
Figure 28. Operation Pump Engine
Switch
14. Turn the fan switch (Figure 30) to the “ON“
position and listen for fan to start.
Figure 30. Fan On/Off Switch
15. Turn the fan switch to the “OFF“ position and listen for fan
to stop. If machine exceeds 170°F or to cool the machine
down, turn the operation switch (Figure 28) back to the
“ENGINE“ position. Run engine at high RPM with cooling
fan on for 10 to 15 minutes.
The pump should not be cycling at this
time. Only the ENGINE should be
running.
PRESSURE TEST
11. While monitoring the tachometer
(Figure 25), use the Engine
Throttle Control to set the
engine speed to 2550 RPM
(maximum speed) using steps
8A-8C
16. The Pressure Test switch (Figure 31) is a
self-diagnostic test switch, that when
activated will test the pressure of the system.
This switch will be discussed in the
maintenance and troubleshooting section
of this manual.
12. The Accumulator Pressure
Gauge (Figure 29) should read
approximately 12.1 mPa (1,750
psi).
Figure 31. Pressure Test On/Off Switch
Figure 29. Accumulator Pressure Gauge
HOPPER REMIXER CONTROL
A. Located to the left of the Hydraulic Temperature gauge is
the Hopper Remixer Control lever (Figure 32).
COOLING FAN
This section is intended to make sure the fan is working properly.
Under normal conditions the fan should be turned on when the
hydraulic oil temperature begins to approach 23.9° C (75° F).
B. Turn the Operation Pump/Engine switch to the “ENGINE“
position (only the engine should be running).
CAUTION
If the hydraulic oil temperature exceeds
76.7° C (170° F), shut down the pump.
DO NOT continue to operate the pump.
Failure to shut down the pump will result in
severe damage to the pump.
Figure 32. Hopper Remixer Control Lever
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ST-45HRM CE CONCRETE PUMP— INITIAL START-UP PROCEDURE
C. Push the Hopper Remixer Control lever “DOWNWARD“
(Figure 32) and observe that the blades (Figure 33) inside
the hopper are turning in a clockwise direction (forward).
Figure 35. Handheld Remote Cable Unit
CYLINDER LUBRICATION BOX
Figure 33. Hopper Remixer Blades (Rotation)
WARNING
D. Push the Hopper Remixer Control lever“UPWARD“ (Figure
Before checking lubricaton level, stop the
32) and observe that the blades (Figure 33) inside the
engine and remove the engine starter key.
hopper are turning in a counter-clockwise direction
We recommend using soluble type oil (water
(reverse).
& oil mixture). The oil level should be
checked every day prior to pumping. The oil
level should be maintained at a height of 12.7
cm (5 inches) or about half the concrete
cylinder height.
OPTIONAL RADIO REMOTE CONTROL
14. The MAYCO ST-45 Concrete Pump has a remote control
feature that allows the pump to be remotely controlled. If
desired, the pump can be operated via a receiver/transmitter
method (Figure 34) or a hardwire method, which utilizes a
7.62 meter (25-ft.) extension cable. The manual remote
cord (Figure 35) should be installed under the main control
box.Contact your MAYCO/MULTIQUIP 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.
15. As the rubber piston cups naturally wear, fine cement
particles will accumulate in the box.Once the concrete paste
reaches a height of about 1.3 cm (1/2-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 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.
Figure 34. Handheld Receiver/Transmitter
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 35
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ST-45HRM CE CONCRETE PUMP—TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
ALWAYS wear safety glasses when
removing or installing force fitted
parts.Failure to comply may result in
serious injury.
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION
Lug Nut Torque Requirements
DO NOT attempt to repair or modify a wheel.
DO NOT install an inter-tube to correct a
leak through the rim. If
the rim is cracked, the
air pressure in the
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the fasteners
matched to the cone angle of the wheel. Proper procedure for
attachment of the wheels is as follows:
inter-tube may cause pieces of the rim to
explode (break-off) with great force and
can cause serious eye or bodily injury.
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 36. DO NOT
torquethewheellugnutsallthewaydown.Tighteneachlug
nut in 3 separate passes as defined by Tables 6 and 9.
TiresWear/Inflation
Tire inflation pressure is the most important
factor in tire life. Pressure should be
checked cold before operation. DO NOT
bleed air from tires when they are hot.
Check inflation pressure weekly during
use to insure the maximum tire life and
tread wear.
Table 6. Lug Nut Torque Requirements
Wheel Size
30.5 cm/12"
33.0 cm/13"
35.6 cm/14"
38.1 cm/15"
40.6 cm/16"
First Pass
N-m/FT-LBS
Second Pass
N-m/FT-LBS
Third Pass
N-m/FT-LBS
27.1-33.9/
(20-25)
47.4-54.2/
(35-40)
67.8-88.1/
(50-65)
Table 5 (Tire Wear Troubleshooting) will help
pinpoint the causes and solutions of tire wear
problems.
27.1-33.9/
(20-25)
47.4-54.2/
(35-40)
67.8-88.1/
(50-65)
27.1-33.9/
(20-25)
67.8-81.3/
(50-60)
122-162.7/
(90-120)
27.1-33.9/
(20-25)
67.8-81.3/
(50-60)
122-162.7/
(90-120)
27.1-33.9/
(20-25)
67.8-81.3/
(50-60)
122-162.7/
(90-120)
3. Afterfirstroaduse,retorquealllugnutsinsequence.Check
all wheel lug nuts periodically.
NEVER! use an pneumatic air gun
to tighten wheel lug nuts.
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ST-45HRM CE CONCRETE PUMP—TRAILER SAFETY GUIDELINES
Figure 36. Wheel Lug Nuts Tightening Sequence
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 37
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ST-45HRM CE CONCRETE PUMP —TOWING INFORMATION
RUNNING GEAR MANUFACTURERS
Broadway Industrial Estate, Hyde, Cheshire SK14 4QF
Telephone:0161 368 6414 Fax: 0161 367 8702
Email: enquiries@ meredithandeyre. co.uk
RECOMMENDED MAINTENANCE
& SERVICE INFORMATION
T CHASSIS
SUSPENSION AXLES
AUTO-REVERSE COUPLINGS
GENERAL TRAILER INFORMATION
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ST-45HRM CE CONCRETE PUMP—TOWING INFORMATION
1.0 GENERAL INFORMATION
1.3
TYRES AND WHEELS
Within the EC, tyres must be marked with a load index (LI) and
speed symbol, which designate the maximum carrying capacity
per tyre at the maximum speed. SeeTables 7 and 8.
In order to maintain the function and safety of your trailer, only
.
original parts of the manufacturers design must be used. Servicing
should only be undertaken by qualified personnel.
For trailer use, car tyres may be given a bonus loading of 5%
and commercial van tyres 10% due to the reduced speed limits
that apply to trailers (in the UK 97 kmh/60 mph). However, we
would generally recommend working within the load index
designation to allow for the possibility of operation over the
normal speed limitations.
1.1
TOWING LEVEL
Ideally, the trailer should be towed level (Figure 37) and not with
the draw bar leaning up or down excessively. Some countries
allow 4° from the level (approximately 100mm) but in others
it remains at the discretion of the user for safe operating conditions
TABLE 8. SPEED SYMBOLS
Speed Symbol
Max MPH
F
G
56
90
J
K
L
M
81
N
P
Q
R
50
80
62
68
75
87
93
100
160
106
170
Max KMH
100
110
120
130
140
150
Figure 37. Towing Level
1.2
CAPACITIES
The maximum tyre pressure marked on the tyre is usually
compatible with the load index and speed symbol. If in doubt,
For safety, warranty and legal reasons, DO NOT exceed the
maximum allowable fully laden mass.
check with the manufacturer or with us
.
On a trailer’s drawbar assembly, there may be 3 ore more labels/
stampings stating the maximum masses and other parameters.
It is important to be aware that the label or stamping stating the
lowest maximum gross mass overrules all others; generally the
label affixed to the body of the trailer by the trailer or plant
manufacturer states the actual maximum, as this will allow for
wheel and tyre capacities.
TABLE 7. TYRES LOAD INDEX
LI
Kg
LI
78
79
80
81
82
83
84
85
86
87
88
Kg
LI
Kg
580
LI
100
Kg
800
LI
111
Kg
1090
LI
Kg
LI
Kg
67 307
68 315
69 325
70 335
71 345
72 355
73 365
74 375
75 387
76 400
77 412
425 89
437 90
122
123
124
125
126
127
128
129
130
1500 133
1550 134
2060
2120
600
615
630
650
670
690
710
730
750
775
101
102
103
104
105
106
107
108
109
110
825
850
112
113
114
115
116
117
118
119
120
121
1120
1150
1180
1215
1250
1285
1320
1360
1400
1450
450
91
1600
1650
135 2180
136 2240
462 92
475 93
487 94
500 95
515 96
530 97
545 98
560 99
875
900
1700 137
2300
925
1750
1800
138 2360
139 2430
950
975
1850 140
2500
1000
1030
1060
1900
141 2575
142 2650
131 1950
132 2000
143
2725
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 39
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ST-45HRM CE CONCRETE PUMP—TOWING INFORMATION
1.4
CONNECTION TOTOWINGVEHICLE
2.0 ROUTINE CHECKS
First, check the compatibility of your 50mm Ball Coupling or
Towing Eye with theTowing Jaw/Ball connection on your vehicle.
Always fit the breakaway cable or safety chain in a loop, fastening
back on itself, to a substantial integral point on the towing vehicle.
Ensure that the effective length is as short as possible, but still
allows articulation (e.g. for cornering) without applying the brakes
or tension through the chains.
2.1
VISUAL INSPECTION
Regular visual inspections will usually identify accidental
damage if conducted systematically.
2.2
TYRE DAMAGE
It is dangerous to neglect tyre damage, and should a blister,
rupture or cut to be detected, exposing the casing, or the tyre
suffers a violent impact (e.g. against a curb) such that there is a
risk of internal damage, it is advisable to have the tyre examined
by ah specialist as soon as possible.
WARNING
2.3
WHEEL DAMAGE
We DO NOT recommend the use of safety
chains and a breakaway cable (Figures 38
and 39) at the same time.
Wheels damaged or distorted, or having wheel nut/bolt sea tings
cracked or deformed must not be repaired or used in service.
Warning: If the wheel is damaged, it is possible that the brake
drum, stub axle or complete axle may have been damaged, so
investigate further.
2.4
TOWING EYE, BALL HITCH & DRAWBAR
ATTACHMENT
Gripping the towing eye or ball in both hands, pull back and
forth, up and down, feeling for excessive movement. Replace
any parts that are bent or deformed in anyway. Check the
attachment of the coupling body to the drawbar and of the drawbar
to the trailer/machine.
Figure 38. Breakaway Cable
2.5
HAND BRAKE
Apply hand brake checking operation and effectiveness. If in
doubt re-adjust braking system (see section 3.2)
Figure 39. Safety Chains
It is legal to use safety chains up
to a maximum gross trailer mass
of 1500 kg.
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
3.0 BRAKING SYSTEM
3.1 WHEEL JACKING
If not already connected, connect the
Bowden (sheathed) cables to the
brakes.
On level ground, with the hand brake lever in the off position and
overrun coupling draw tube shaft fully extended forwards, secure
one wheel with wheel chocks.Position your jacking device behind
the opposite wheel, as near to a main longitudinal chassis
member as possible. Lift the wheel clear of the ground and secure
with suitable axle stands.
3.2
BRAKING SYSTEM ADJUSTMENT
Where the transmission rod and brake cables are already
connected, take the tension out of the system by winding back
the nuts on the rod behind the compensator.
It is now possible to begin the setup procedure:
3.3
WHEEL BRAKES
These can be adjusted by means of a 17mm, 19mm, or 24mm
AF Spanner (dependant on brake type) on the adjuster bolt head
at the rear of the brake back plate. Reference Figures 40A, B
and C.
Figure 40B. Connecting Sheated Cable
Adjuster Bolt
Figure 40A. Adjuster Bolt
Figure 40C. Connecting Sheated Cable
Rotate each wheel only in the forward direction of travel, whilst
tightening the bolt until the wheel locks.Then, gradually back off
the adjuster nut until the wheel can rotate forwards with just a
slight resistance/audible brushing of the brake drum on the brake
linings (this is best adjusted with the wheel and tyre fitted to the
brake drum).
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ST-45HRM CE CONCRETE PUMP — BRAKING SYSTEM
3.4 COUPLING ANDTRANSMISSION SYSTEM
Attach the opposite end of the outer cable to the anchor plate
(Figure 41E) on the axle or draw bar, using the nut provided.
Connect the inner cables to the compensator, locking the 2 plain
nuts together in front of the compensator for each cable. If not
already connected, attach the rear end of the brake rod to the
compensator center hole.
Figure 41C. Meredith & Eyre Handbrake Applied
COUPLINGS WITH HANDBRAKE MOUNTED ON COUPLING
BODY (FIGURES 41A-41E)
Spring Store now compressed
Use the plain nuts behind the compensator to adjust, until the
overrun output lever can be pulled rearwards by firm hand
pressure (not loose) a maximum of 14mm (16mm for adjustable
height models.) For knott couplings, there should not be any
movement
Maintain the compensator at 90° to the draw bar for even
distribution of force into each cable. Ensure the cables are not
“kinked” or damaged.
Figure 41D. Meredith & Eyre Handbrake After Automatic
Activation In the Reverse Mode
Spring Store now extended, handbrake will
feel less tensioned.
Figure 41A. Meredith & Eyre Fixed Height Coupling up
to 2500 kg GVM
Figure 41B. Meredith & Eyre Fixed Height Coupling up
to 2000 kg GVM
Figure 41E. Connecting Cables to Compensator
Handbrake Mounted On Coupling Body
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
With the handbrake fully off, check that the spring store’s overall
With these models, the brake transmission linkage runs through
the spring store, which must be set correctly to achieve automatic
operation tensioning of the system.
length is 185 to 190 mm and is not applying a force to the U
shaped guide on the side of the overrun lever.Adjusting is by the
nut at the front of the assembly.This procedure should only be
necessary when replacement parts have been fitted.
COUPLINGSWITH HANDBRAKE MOUNTED ON DRAW BAR
(FIGURES 41F-41J)
The setup for the higher capacity couplings is similar to the above,
with the exception of the setting of the handbrake spring store,
which is more powerful due to the higher transmission force
requirements for heavier trailers.
Figure 41I. Meredith & Eyre Fixed Height Coupling 2500
kg to 3500 kg GVM
Use the plain nuts behind the compensator to adjust, until the
overrun output lever can be pulled rearwards by firm hand
pressure to a maximum of 18mm (8mm for adjustable height
models).
Maintain the compensator at 90° to the drawbar for even
distribution of force into each cable. Ensure the cables are not
“kinked” or damaged.
Figure 41J. Meredith & Eyre Fixed Height Coupling
2200 kg to 3500 kg GVM
Figure 41F. Meredith & Eyre Fixed Height Coupling
2500 kg to 3500 kg GVM
Leave the handbrake and spring store connector loose while
setting the overrun system as previously described.Finally, pull
the spring store up to the hexagonal adaptor by sliding the spring
and bracket forward. Tighten the three locking nuts on the
connector.
Figure 41G. Meredith & Eyre Fixed Height Coupling
2200 kg to 3500 kg GVM
Figure 41H. Connecting Cables to Compensator
Handbrake Mounted On Drawbar
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 43
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ST-45HRM CE CONCRETE PUMP — BRAKING SYSTEM
3.5
BRAKE PARTS
KNOTT COUPLINGS
Brake shoes (Figure 42) are recommended to be replaced when
the lining thickness measures less than 2mm, as it is likely that
they will be worn out before the next service.
Please follow the adjustment instructions in section 3.5, but do
not allow for the rearward movement of the overrun output lever,
which is only required on Meredith & Eyre couplings. All knott
couplings (Figures 43A and 43B) operate in the same manner,
so the type of housing, cast A-frame, pressed steel A-frame, or
pressed steel square-tube, is irrelevant to the brake servicing.
Always replace both brake shoes together, regardless of the
lining thickness on the other shoe. It is further advised that brake
shoes should be ideally replaces as an axle set to avoid uneven
braking from side to side.
Adjuster
Figure 43A. Knott Cast Body Coupling
Sliding (Auto Reverse)
Expander
Brake Shoe
Figure 42. Auto Reverse Back Plate Assembly
(Right-Hand Knott 203 x 40)
Figure 43B. Knott Cast Body Coupling
Please note position of sliding shoe relative to
adjuster or expander.To function correctly the
brake must be assembled in this way.
Left hand brake is a mirror image.
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
4.0
4.1
ADJUSTABLE HEIGHT DRAW BARS
4.1
GREASING ADJUSTABLE JOINTS
There is a grease nipple at each joint pin position
HEIGHT ADJUSTMENT/TIGHTENING JOINTS
the principle of the joints is steel pegs engaging with mating
dimples (Figures 44A and 44B), which can be seen between the
joint plates.
4.2
CLEANING, INSPECTING & ASSEMBLY
Dismantled the joint pins and joints. Check the condition
and if serviceable clean, smear with grease and reassemble.
While securing the assemblies, the equipment should be “rocked”
as the joint pins are tightened to allow positive location.
When initially hand tight, they should be further tightened until
the next visible “R” pin hole lines up for the insertion of the pin.
For reference only, the actual torque figures if checked would be
approximately as follows:
■
■
■
■
TYPE A900 135-220 Nm
TYPE A1600 175-220 Nm
TYPE A2400 230-300 Nm
TYPE A3500 410-475 Nm
Figure 44A. Adjustable Height Draw Bar
Figure 44B. Adjustable Height Draw Bar
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 45
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ST-45HRM CE CONCRETE PUMP — BRAKING SYSTEM
The wheel bearings are greased on assembly at the factory and
should be re-greased at a minimum every 38,624 km (24,000
miles) or 2 years with axle grease “ELF Multi 2” or equivalent.
5.0
WHEEL HUB ASSEMBLIES
INSPECTION
5.1
Ensure the brake shoes (if braked) are clear of the drum with no
interference. Clean the hub to remove any road debris.
Use the service interval to inspect the bearings for wear/damage.
Replace the seal if necessary, lubricating the lip and bore, not
the outside diameter.
Rotate the hub slowly – there should be no roughness or
restriction.
WARNING
Rotate the hub rapidly – There should be no rumble, rattle or
high-pitched noises.
It is as important not to OVERPACK the hub
with grease, as it is to allow bearings to run
dry.
Rock the wheel while holding at the top and the bottom to detect
essential bearing endplay.The maximum movement should be
2mm, measured at the wheel rim.
REMOVAL OF HUB/BRAKE DRUM ASSEMBLY
If any clearance or free movement appears to emanate from the
suspension, check the axle housing for damage.
Remove the wheel, grease cap, split pin, slotted nut, and washer
and pull the drum off the stub axle.To avoid contamination, take
care not to drop the outer bearing cone onto the floor.
WHEEL HUB ASSEMBLIES WITH TAPER ROLLER
BEARINGS
5.4
WHEEL HUB ASSEMBLIES WITH UNIT BEARINGS
These hubs require no maintenance, however at intervals of
38,624 km (24,000 miles) or 12 months, the wheel hubs should
be checked for side play and the complete hub replaced if
necessary.
In order to re-set, remove the grease cap, split pin and set the
slotted nut. See Figure 45.
It is generally accepted that a finger tight slotted nut, will result in
a correct setting and running clearance for normal bearing life.
Always replace the split pin with a new one when setting is
complete and re-fit the grease cap.
WARNING
When refitting the hub, always fit a new nut
and tighten to a torque of 280Nm (206lbf.ft.)
5.5
WHEEL NUT / STUDTORQUE SETTINGS
TABLE 9. WHEEL NUT/ STUD TORQUE SETTINGS
Nm
Lbf.ft
Wheel Nuts
Min.
70
Max.
110
160
300
Min.
50
Max.
80
Wheel Nut 1/2 IN. UNF
Wheel Nut 5/8 IN. UNF
Wheel Nut M18 X 1.5
Wheel Studs
Figure 45. Grease Cap, Split Pin
and Slotted Nut Removal
135
245
100
180
120
220
WARNING
Wheel Stud M12 X 1.5
Wheel Stud M14 X 1.5
65
90
50
90
65
It is our experience that the majority of
bearing failures are the result of over-
tightening of the slotted nut or failure to
replace contaminated grease (e.g.: water
ingress – especially salt water).
120
150
110
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
6.0
OVERRUN COUPLING ASSEMBLY
Meredith & Eyre Couplings do not require for
the towing ball head or eye to be removed or
loosened when replacing
The coupling is greased on assembly, but will require periodic
maintenance to ensure a smooth operation of the braking system.
Meredith & Eyre Couplings do not require for the towing ball
head or eye to be removed or loosened when replacing a damper
Re-grease the shaft bearings via the grease nipples (Figure 46),
provided at 9,656 km (6,000 miles) or 6-month intervals. Also
ensure correct functioning of all pivots, levers, ratchets and the
spring store assembly.Grease all points of movement.
Knott Couplings have the damper attached to the rear bolt of the
towing head.These dampers in these couplings require a larger
amount of pre-compression when being fitted, so remove the
cast L. shaped bracket, which attaches the damper to the rear of
the couplings body and reassembly, this onto the new damper
before assembly onto the coupling body.
Nipples
7.0
STUB AXLE / BRAKE BACK PLATE
A number of Meredith & Eyre axles feature a removable stub
axle, as shown in Figure 48.This design is unique to Meredith &
Eyre and illustrated our desire to keep replacement costs as low
as possible.
Bellows
The large slotted nut on the back of the arm is torqued to 230Nm
(170 lbf.ft). Removing this nut will allow the stub axle to be
removed. When refitting, if the split pin cannot be fitted after
torque setting the slotted nut, tighten the nut further until the next
available hole is accessible
Figure 46. Meredith & Eyre Coupling with Bellows
and Shaft Nipples
The hydraulic damper (Figure 47) is sealed and maintenance
free but its operation should be checked if braking problems
occur.If the damper is to be removed, enclose it in a strong cloth
and do not stand directly in line as the damper contains oil and
gas under high pressure.
To remove, release the 2 bolts at either end. The damper will
need to be slightly pre-compressed to be fitted.This is normal,
and ensures that the braking system works efficiently and that
the trailer is towed on the drawtube, not on the damper as this
would lead to premature failure.
Figure 48. Meredith & Eyre Axle with
Removal Stub Axle
The removal of this assembly is only necessary when the stub
ale or brake back plate is to be replaced (e.g.: After an accident.)
Make a note of how these parts are fitted and the position of
thecable holder.
Damper
Overrun Lever
All other brakedrum components are accessed from the front via
thegrease cap.
Figure 47. Meredith & Eyre Coupling with Damper and
Overrun Output Lever
All other axles have a welded stub axle and brake back plate
assembly, which cannot be replaced.In the event of damage to
a stub axle, it is likely that the whole axle will need to be replaced.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 47
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Brake System Troubleshooting
(Table 10) information shown below. If the problem cannot be remedied, please leave the unit just as it is and consult our
company's business office or service plant.
TABLE 10. TRAILER BRAKES TROUBLESHOOTING
SYMPTOM
CAUSE
SOLUTION
Adjust brakes
Incorrect brake adjustment at wheel
Brake cable siezed
Braking is one-sided
Free off or replace
Replace lining
Brake lining contaminated with grease
Coupling damper is weak or ineffective
Replace coupling
Braking during mild
deceleration
Brakes over-adjusted
Adjust brakes
Brake cable sticking
Free off or replace cable
Adjust brakes
Brakes under-adjusted
Trailer Brakes snatch
when breaking
Coupling damper is weak or ineffective
Replace coupling
Check over full stroke,
lubricate if necessary
Drawtube sticking
Brake lining contaminated with grease
Replace brake lining
Failure of bond between brake lining
and brake shoe
Repair with new bonding
agent
Brake Judder
Distorted or cracked brake drum
Replace brake drum
Drums have rusty patches on
braking surface
Clean with abrasive paper
and wipe out
Brakes over-adjusted
Adjust brakes
Trailer brakes lock up
when reversing
Incompatibility between
coupling and brakes
Consult manufacturer(s)
Brakes under-adjusted
Adjust brakes
Brake lining contaminated with grease
Brake cables seized
Replace brake lining
Free off or replace
Replace brake linings
Adjust brakes
Trailer brakes
inoperative
Brake linings worn out
Brakes over-adjusted
Hot Brakes
Pull-off springs are stretched/broken
Brake cables seized
Replace pull-off springs
Replace brake cable
Adjust brakes
Brakes under-adjusted
Handbrake will not hol
on a slope
Incorrect setting of spring store
Adjust spring store
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ST-45HRM CE CONCRETE PUMP— BRAKING SYSTEM
TABLE 11. TORQUE FIGURES BY APPLICATION
Nm
Lbf.ft
Application
Fastern Size
MIN.
MAX.
MIN.
MAX.
70 / 80mm Drawbar to Axle
90 / 100mm Drawbar to Axle
Towing Eye Cross Bolts
3/8 in. UNF
M12
40
55
30
40
90
55
75
75
50
55
60
60
90
55
75
75
60
70
80
75
65
40
55
55
35
40
45
45
65
40
55
55
35
55
60
55
M10
Towing Eye Cross Bolts
M12
50mm Ball head Cross Bolts
M&E Coupling to 80mm Drawbar
M&E Coupling to 90mm Drawbar
M&E Coupling to 100mm Drawbar
Knott Coupling to Drawbar
M12
1/2 in. UNF
1/2 in. UNF
5/8 in. UNF
M12
TABLE 12. GENERAL TORQUE SETTINGS FOR GRADE 8.8
FASTENERS USED WITH SELF-LOCKING NUTS
Nm
Lbf.ft
Fastener Size
Min.
25
Max.
25
Min.
17
Max.
M8 x 1.25
M10 x 1.5
M12 x 1.75
M14 x 2.0
M16 x 2.0
17
35
50
50
35
90
90
65
65
130
200
130
200
97
97
150
150
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 49
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
TABLE 13. ST-45 MAINTENANCE CHECK SCHEDUAL
Daily
Hourly
Weekly Monthly
6-Months
Operational Hours
Engine Oil
Engine Air Filter
X
X
X
X
Fuel Filter
Hydraulic Oil Level
Lubrication Box
X
500 hrs.
X
X
Replace Hydraulic Oil
Clean Hydraulic Filters
Axle Crank
X
2100 hrs.
2 hrs
X
X
Grease Shuttle Tube Zerk Points
Grease Remix Bearing
Check System Pressure
Check Hardware for Tightness
Check Cutting Ware Ring
Check Trailer Brakes Function
Check Brake Lights
X
X
X
40 hrs.
40 hrs.
X
X
X
X
Check Tire Conditions
Inspect Saftey Devices / Decals
Check Wheel Bearings
Check Battery
X
X
X
Inspect Brake Lining
Visually Check for Oil Leaks
X
CLEANINGTHE PUMP AND DELIVERY SYSTEM
DANGER
Cleaning the pump is a very important operation as it determines
how the machine will pump the next time it is used.
At the end of every pour, or because of long delays during a
pour, the pump and delivery system must be thoroughly cleaned
by removing all concrete material.
If you are required to put your hand inside the concrete cylinders
or near the shuttle tube.You are at EXTREME RISK of injury or
AMPUTATION if the engine is running or if pressure is in the
hydraulic system.
1. Following the “Clearing Concrete Blockage” operating
procedure on page 26, ensure that there is no blockage in
the hose and line or in the shuttle tube (using the Shuttle
Tube Inspection Procedure, page 26-27). If a blockage
exists, clear it.
Prior to performing any maintenance on the pump, stop the engine
by turning off the ignition switch and remove the starter key.
Place a“DO NOT OPERATE”tag over the switch and disconnect
the battery.The pressure reading on the accumulator pressure
gauge MUST read ZERO. ALWAYS relieve the accumulator circuit
to zero pressure prior to performing any maintenance on the
pump.
2. Pump concrete until the opening of the concrete cylinder
intake in the hopper is visible.
3. Stop the pump.
4. Carefully disconnect the first hose joint at the shuttle tube
discharge elbow.
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
5. Add water to the hopper. Pump and flush clean the entire
HYDRAULIC OIL SYSTEM MAINTENANCE
hopper, shuttle tube and discharge elbow with water.
1.
When changing the hydraulic oil or topping off the reservoir,
use only the following type. (Reservoir capacity is 220 liters/
58 gal.)
6. Scoop out 30.5 cm (12-inches) of concrete from the inboard
end of the delivery hose. “Cork Screw” a 15 cm x 15 cm x 20
cm (6" x 6" x 8") sponge into the end of the first hose section.
Reconnect the hose to the discharge elbow.
Hydraulic oil: Shell OilTellius 68, Mobil DFE 26, Texaco Rand
HDC or equavalent.
7. Fill hopper with water. Pump until sponge and clean water
come out the discharge end of the hose and line system.
This Mayco.Multiquip pump is equipped with an in-tank return
hydraulic filter with a 10 micron cleanable filter.The element has
been designed to remove all particles large enough to cause
wear and job break down. Under normal conditions, we
rWecAomRmNenIdNreGplacement every 6 month.
8. When the Model ST-45 has been used to pump small
aggregate concrete (pea rock, 1.3 cm /1/2-inch or smaller)
or mixes with high fines content (60% or more sand) there
will be a tendency for hardened concrete to build up on the
inside surface of the shuttle tube.Therefore, at the end of
every such pour, after the pump and system have been
cleaned and the engine shut off, remove the shuttle tube
inspection plate (follow the Shuttle Tube Inspection
Procedure, pages 26-27) and remove all remaining
concrete.
DO NOT mix oil brands! This may impair
quality.
9. When the Model ST-45 has been used to pump large
aggregate concrete 1.9 -3.8 cm (3/4 to 1-1/2 inches) follow
the instructions in step 8 once per week.
The most important factor to keep in mind is the effect of cold
weather on the hydraulic oil. The viscosity (thickness) of the
hydraulic oil will be much heavier.
WARNING
Always run machine until oil temperature reaches a minimum of
10°C (50°F). before pumping. Damage to the main piston pump
will occur if the machine is cycled too fast before the oil temperature
reaches the minimum of 10°C (50°F). Cycle the machine at 6-8
strokes per minute at approximately 1/3 throttle.
NEVER use muriatic acid to clean the pump.
Acid will dissolve the chrome finish on
material cylinder bore and main hydraulic
cylinder rods.
In areas where the weather normally remains under 10°C
(50°F)., use Shell Oil Tellus – 46, or the equivalent.The above
steps must be followed or severe damage to the main axial piston
pump will be the end result.
Use only a 6.4 cm (2-½") diameter
clean-out hook when back-pumping
into redi-mix truck. Use a safety chain
to secure the clean-out hook to some
solid part of the mixer truck to prevent
hook from jumping off of the drum. Run
the pump at 6 strokes per minute
maximum speed.
2.
Lubrication: Grease daily/Hour
■
■
■
■
■
Main hydraulic cylinders
Remix bearings
Axle crank
- 2 Place
- 2 Place
- 1 Place
- 2 Place
- 3 Place
ENGINE (Hatz Model 3M41 57 HP Diesel)
Suttle cylinders
The ST-45 is equipped with a Model 3M41 57 HP diesel engine.
For information concerning the procedure in checking, removing,
cleaning, etc.of the various engine parts or any other information
on the engine not contained herein, refer to the engine
manufacturer’s instruction manual.
“S” tube outlet flange
GreaseType:
Lithium Based EP
Texaco Multitak 20
Lubriplate ED-2 or Equavalent
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 51
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
BRAKE SYSTEM
BATTERY MAINTENANCE
The brake system should be periodically checked. Look for fluid
leaks worn or cracked hoses. Check the reservoir for proper fluid
levels. Make sure that all links and pivots are kept lubricated.
SeeTable 13 for troubleshooting tips.
Mishandling of the battery shortens the service life of the battery
and adds to maintenance cost.When handling the battery do the
following:
z
Be careful not to let the battery electrolyte come in contact
with your body or clothing.
1. Keep all links and pivots lubricated to prevent rusting and
ensure ease of operation. Using SAE 30 oil or equavalent,
lubricate inside the release handle and inside the actuator
body.This can be reached from the underside of the actuator.
z
Always wear eye protection and rubber gloves, since
the battery contains sulfuric acid which burns skin and eats
through clothing.
Always check the battery terminals periodically to
ensure that they are in good condition.
z
z
z
Use wire brush or sand paper to clean the battery
terminals.
If equipped, lubricate the hitch ball with
conventional automotive grease or a
lubricant made for hitch balls.
Always check battery for cracks or any other damage.
If white pattern appears inside the battery or paste
has accumulated at the bottom, replace the battery.
2. Check for any leaks in the brake system. Periodic checks
should be made on all hoses to guard against cuts and worn
hoses which may cause failure (leaks, rupturing under
pressure, and collapsing). Replace defective hoses.
z
If the pump will not be in operation for a long period
of time, store in cool dry place and check the battery
charge level every month to maintain the performance
of the battery.
CAUTION
CAUTION :
Wear safety glasses or face
mask, protective clothes, and
rubber gloves when working
with battery.
DO NOT fill the master cylinder reservoir with
used brake fluid. DO NOT fill the reservoir
beyond 1.3 cm (1/2-inch) from top. DO
NOT overfill; brake fluid will damage paint.
3. Check the brake fluid level in the master cylinder reservoir.
Keep it filled to within 1.3 cm (1/2-inch) from the top of the
reservoir.
4. At the beginning of each year, inspect the brakes for excessive
wear, replace the linings if necessary.
z
Check the battery regularly and make sure that each
electrolyte level is to the bottom of the vent well
(Figure 49). If necessary add only distilled water in a
well-ventilated area.
Wheel bearings and seals should be
inspected and packed at this time.
Figure 49. Battery Electrolyte Levels
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
6.
On the control box, turn the pump control switch (Figure
22) and the test switch (Figure 31) to the “ON” position.
Using an allen wrench, adjust the main relief valve (Figure
45) to 24.13 mPa (3,500 PSI).The reading can be taken
from the pumping pressure gauge (Figure 52).
ST45 PRESSURE SETTING SEQUENCE
To set maximum pump pressure:
1.
With the engine turned “OFF”, loosen the 6.4 mm (1/4-
inch) hydraulic hose attached to the compensator valve
located on the top of the Main Delta Q Pump.
7.
Hold the main relief valve adjusting bolt with a wrench and
tighten the jam nut. Using the test switch, double check the
pressure reading to make sure the setting has not changed.
Figure 50. Compensator Valve
Figure 52. Pumping Pressure Gauge
2.
3.
Loosen the jam nut located on the end of the compensator
valve (Figure 50).
8.
9.
Turn the engine off and loosen the hose from the
compensator valve. Loosen the jam nut and turn the
compensator adjustment nut (Figure 50) counter-
Turn the compensator adjustment nut (Figure 50)
clockwise until tight.Tighten the 6.4 mm (1/4-inch) hose
leading to the compensator.
clockwise
½
turn. Tighten the 6.4 mm (1/4-inch) hydraulic
hose.
4.
5.
Start the engine and loosen the jam nut located on the
maximum relief valve cartridge (Figure 51).
Start engine and run at maximum RPM with volume control
at maximum volume (fully counter-clockwise). Turn the
pressure test switch (Figure 31) to the “ON” position.
The pumping pressure gauge should now read 22.75
mPa (3300 PSI). It may be necessary to repeat the above
steps to achieve the proper pressure settings. After the
adjustment, make sure the compensator valve jam nut is
locked tight.
Run the engine at maximum RPM (2,550) and turn the
volume control knob counter-clockwise to maximum
volume position (Figure 51).
MAXIMUM RELIEF
VALVE CARTRIDGE
JAM NUT
MAIN
RELIEF VALVE
VOLUME
CONTROL
Figure 51. Hydraulic Drive Pump Manifold
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 53
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
ST45 ACCUMULATOR CIRCUIT
CYLINDER LUBRICATION BOX
DANGER
CAUTION
Before checking lubrication level, stop the
engine and remove the ignition key.
Improper accumulator charging can result in an explosion
causing serious injury or death! NEVER use oxygen or
compressed air to charge the accumulator! Only qualified
personal should perform this procedure. Use only dry
nitrogen to charge the accumulator. Contact your Mayco
service department or your local Hydac representative for
proper charging procedure.
1. The lubrication level should be checked everyday prior to
pumping and maintained at a height of 12.7 cm (5 inches)
or about half the concrete cylinder height. We reccomend a
using a soluble type oil (water & oil mixture)
Important notice! During freezing
temperatures, completely drain the
Lubrication Box and cover the hopper
after each use. Frozen liquid will
restrict the piston travel and cause
damage to the pump.
The accumulator circuit has two functions in the hydraulic system.
■
The accumulator circuit furnishes the hydraulic pressure
to cycle the shuttle tube.
■
The accumulator circuit also furnishes the pilot pressure
necessary to activate the hydraulic system.
2. As the rubber piston cups naturally wear, fine cement
particles will accumulate in the box.Once the concrete paste
reaches a height of about ½ inch from the bottom of the box,
drain and clean the lubrication box.
The accumulator circuit is equipped with
a bladder type accumulator (Figure 54)
charged with 7.58 mPa (1,100 psi) of dry
nitrogen.Theaccumulatorstores3.78liters
(1 gallon) of hydraulic oil, which is, under
12.07 mPa (1,750 psi) of pressure.
CLEANINGTHE LUBRICATION BOX
1. Remove the top cover and the drain plug (Figure 53) located
at the bottom of the box and fully drain the inside of the box.
2. Once the box is drained, start the engine and stroke the
Figure 54. Accumulator
cylinder (keep hands out of box) ten to fifteen times.
When the pump cycles, a part of the stored oil is released to the
shuttle cylinder.This pressure release assures the shuttle tube
has enough force to shear the cylinder of concrete passing from
the concrete cylinder to the concrete delivery line during the
cycle phase.
3. While stroking, spray water inside of the box to thoroughly
clean out all contamination (Figure 53).
4. When the box is clean replace drain plug, add new
lubrication and install the top cover.
CHECKING ACCUMULATOR BLADDER PRESSURE
The normal accumulator charge pressure should be
approximately 7.58 mPa (1,100 psi).To check the accumulator
pressure:
1. Start the engine and stroke the pump. The accumulator
pressure gauge (Figure 29) should read 12.07 mPa (1,750
psi).
2. To determine the actual accumulator PSI, stop the engine
and observe the pressure gauge. As the PSI reading slowly
decreases, it will reach a point where there will be a sudden
drop in the PSI.The PSI reading should be taken just prior to
this sudden drop.If you do not read 1100 PSI, the accumulator
may require charging or bladder replacement.
Figure 53. Cleaning the Lubrication Box
PAGE 54 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
SETTING PRESSURE INTHE ACCUMULATOR CIRCUIT
4. Loosen the lock nut for the the accumulator circuit pilot
relief valve cartridge (Figure 57), located at port G4. Using
an allen wrench, turn the adjusting screw until pressure
gauge reads 13.44 mPa (1,950 psi) and tighten lock nut.
Turn the engine off and on several times to make the
pressure continues to read 13.44 mPa (1,950 psi).
1. Attach a 20.68 mPa (3,000 psi)test gauge (Mayco P/N
98016) to port G2 of the main manifold block (Figure 55).
PILOT RELIEF
VALVE CARTRIDGE
ADJUSTMENT
SCREW
LOCK NUT
Figure 57. Pilot Relief Valve Cartridge Adjustment
5. Turn the unloading valve cartridge adjusting screw
counter-clockwise until the pressure reaches 12.07 mPa
(1,750 psi) on the accumulator pressure gauge (Figure 29).
Start and stop the pump several times to make sure the
accumulator circuit pressure is holding at 12.07 mPa (1,750
psi).
Figure 55. Accumulator Circuit PressureTest Gauge
2. Loosen the lock nut on the unloading valve cartridge
(Figure 56) and using an allen wrench, turn the adjusting
screw clockwise until it is completely closed.
6. Tighten the lock nut on the unloading valve cartridge.Your
accumulator circuit pressure should now be properly
adjusted.
ADJUSTMENT
SCREW
UNLOADING
VALVE CARTRIDGE
LOCK NUT
Figure 56. UnloadingValve Cartridge Adjustment
3. Turn the pump control switch (Figure 22) to the “ON”
position and run engine at 2,550 RPM.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 55
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
CHANGINGTHE CONCRETE CYLINDER PISTON CUPS
6.
Remove the three 3/8 – 16 x 3” bolts (Lubrication Pistons
Assy, Item 20) from the piston.Remove the front faceplate
(Lubrication Pistons Assy, Item 19).
The Rubber piston cups will occasionally require replacement
depending on the following factors.
7.
Install two the 3/8’ 16x3” bolts (Lubrication Pistons Assy,
Item 20) back into the piston – do not tighten. Use the two
bolts as leverage to remove the rubber piston cup
(Lubrication Pistons Assy, Item 17) and rear components.
■
■
■
The fluid level and cleanliness of the lubrication box.
The size and type of aggregate.
The type of concrete being pumped.
It is time to replace the cups when increasingly large particles of
sand and cement pass into the lubrication box. Do not allow the
cups to become so worn that they begin to pass lubrication into
the material cylinders. If the liquid level of the lubrication box
becomes to low, the rubber cups will severely deform due to
excessive heat. Whenever replacement is due, both cylinder
cups should be replaced.
8.
9.
Obtain two 3/8 16x7” full thread studs (these studs will be
used to assist in assembly alignment) insert the two studs
into the piston adapter P/N 16460. Coat the concrete
cylinder with grease.
The new “O” ring (Lubrication Pistons Assy, Item 12) must
now be modified. Using a sharp knife cut four oil passage
grooves into the ring. the grooves should be placed at a
distance of 90o apart.The cut should be a v-shaped design,
1.49 mm (0.05 inches) deep and 4.0 mm (0.157 inches)
wide at the top.
WARNING
10. Install the “O” Ring P/N 14407 around the oiler plate
(Lubrication Pistons Assy, Item 13).Install the plate into the
concrete cylinder utilizing the studs for alignment.
11. Install the felt holder (Lubrication Pistons Assy, Item 14)
over the oiler plate.Install felt ring (Lubrication Pistons Assy,
Item 15) into felt holder. Install the bronze ring (Lubrication
ALWAYS relieve the accumulator circuit to ZERO pressure prior
to performing any maintenance on the pump.
CYLINDER CUP REPLACEMENT PROCEDURE
Felt ring must be saturated with 30 wt.
oil prior to installation.
1.
2.
3.
4.
5.
Remove the two hydraulic hoses (Hopper Assy., Item 34)
connected to the remix motor.Plug the ports with fittings(not
provided) to prevent hydraulic hose leakage.
Remove the hopper discharge nipple (Hopper Interior
Assembly, Item 21) and loosen sleeve seal. Inspect and
replace if wear is excessive.
Pistons Assy, Item 16)
12. Using silicon sealant place a small bead of sealant
material on the front of the rubber piston cup and the rear of
the face plate. Install over alignment studs and into concrete
cylinders.
Remove the two tie rod nuts (Hopper Attachment, Item 19)
and the four eyebolt nuts (Hopper Attachment, Item 22)
securing the hopper to the pump frame.
Using an approved lifting device, remove the hopper
(Hopper Assy, Item 1) using extreme care not to damage
the hopper seal (Hopper Assy, Item 2).
13. Insert one 3/8” 16x3”bolt into the open bolt hole, remove
the alignment studs one at a time and install the remaining
3/8” 16x3” bolts.
Start the engine and turn on the pressure test switch (Figure
31). Cycle pump in reverse until hydraulic system obtains
maximum pressure, then turn pump and engine off.
Before installing 3/8” bolt, coat the back
of bolt heads with silicon sealant.
Torque all three bolts equal at 74.56
N-m (55 ft. lbs.) each.
Remove ignition key and disconnect battery.
Think safety! Check the hydraulic gauges (Figure 29) on
pump and make sure accumulator pressure reads zero.
One piston should be in the fully discharged position at the
end of the concrete cylinder.
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
CHANGINGTHEWEAR PLATE AND RING
Wear Plate Installation
Due to the swinging motion of the Nun-plate and the abrasive
nature of concrete, it is normal for the cutting ring to wear on the
side that shears through the concrete inside the hopper. If the
wear ring and wear plate do not fully seat against each other the
concrete slurry will pump into the hopper.This condition can be
easily observed by the sudden change of the level of concrete
inside the hopper during each stroke.
1.
Install the two cylinder “O” rings (Hopper Interior Assy,
Item 10).
2.
Using silicon sealant, coat the circumference of the concrete
cylinders, the back of the wear plate and around the five
bolt holes. Next, install the wear plate and the five bolts.
The bolts must all be equally snugged and tightened to (
136-N-m (100 ft. lbs) each.
Wear Plate and Ring Replacement Procedure
Wear Ring installation
1.
2.
3.
4.
5.
Remove the two hydraulic hoses (Hopper Assy., Item 34)
connected to the remix motor.Plug the ports with fittings(not
provided) to prevent hydraulic hose leakage.
1.
Install the wear ring (Hopper Interior Assy, Item 13) into the
nun plate.
2.
Install the steel insert ring (Hopper Interior Assy, Item A)
inside of the rubber energizer ring (Hopper Interior Assy,
Item 13B).
Remove the hopper discharge nipple (Hopper Interior
Assembly, Item 21) and loosen sleeve seal. Inspect and
replace if wear is excessive.
3.
Install the energizer ring assembly into the nun-plate.
Remove the two tie rod nuts (Hopper Attachment, Item 19)
and the four eyebolt nuts (Hopper Attachment, Item 22)
securing the hopper to the pump frame.
After installing the above mentioned components the machine
can be re-assembled by reversing steps 1 through 5 of the Wear
Plate and Ring Replacement Procedure.
Using an approved lifting device, remove the hopper
(Hopper Assy, Item 1) using extreme care not to damage
the hopper seal (Hopper Assy, Item 2).
Remove the four 1/2” 1-¼ “ bolts (Hopper Interior Assy,
Item 43) that hold the shuttle tube to the nun-plate and
remove shuttle tube (Hopper Interior Assy, Item 41).
Using two small pry bars remove the rubber energizer ring
(Hopper Interior Assy, Item 13B), steel insert ring (Hopper
Interior Assy, Item A) and wear ring (Hopper Interior Assy,
Item 13).
The energizer ring and wear ring will
normally have concrete contamination
holding them in position. It will be
required to chip some of the concrete
loose to better expose the energizer
ring.
6.
Clean out all concrete build up in and around the nun-
plate area with a wire brush.
7.
Inspect the wear components for indications of wear.
The wear plate (Hopper Interior Assy, Item 52) has two
wear surfaces. If it becomes necessary to replace, the plate
can be reversed to the opposite side to expose a new flat
surface. To replace or reverse the plate, remove the five
allen head counter sink bolts.Then remove the two cylinder
“O” rings and clean the entire back surface.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 57
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ST-45HRM CE CONCRETE PUMP— MAINTENANCE (PUMP)
EXTENDED STORAGE INSTRUCTIONS
EMERGENCY STOP SWITCH FUNCTIONALTEST
The following preventative maintenance is recommended for
extended periods of storage.
There are 2 emergency stop switches on the ST-45 concrete
pump. Follow the procedure below to test the switches to make
sure that they are both working correctly.
1. Check brake system for proper fluid level in master cylinder
and bleed all lines.
1. Start the pump as outlined in the start-up procedure.
2. Let the engine run for a few minutes.
2. Lubricate all links and pivots to prevent any rusting.
3. Remove wheel and drum assemblies and spray a good anti-
corrosion compound (CRC formula 5-56) under rubber boot
on forward end of brake wheel cylinder.Avoid spraying drum
and brake lining.
3. While the engine is running, press the RED emergency stop
pushbutton switch on the control box.
4. Verify that the engine has STOPPED. If the engine has
stopped it can be determined that the emergency stop circuit
is functioning correctly.
4. Grease all bearings and reinstall wheel and drum
assemblies.
5. If the engine continues to run after the emergency stop switch
has been activated, turn the ignition switch key to the OFF
position and correct the problem using the wiring diagrams
provided in the manual.
5. Make sure breakaway cable is fully released.
6. After extended storage, refer to the Maintenance Steps listed
above to insure that the trailer is ready for towing.
6. Pull and turn clockwise the emergency stop switch on the
control box.This will allow the engine to be started again.
7. Repeat steps 1 through 5 for the RED emergency stop switch
on the other side of the pump, located near the heat
exchanger.
PROXIMITY SWITCH FUNCTIONALTEST
There is one proximity switch located near the hopper grate.The
purpose of this switch is to stop the engine in the event the grate
is lifted during operation of the pump.
Follow the procedure below to test the proximity switch to make
sure it is working correctly.
1. Remove the two U-clamps that secure the hopper grate to
the hopper.This will allow the grate to be lifted.
1. Start the pump as outlined in the start-up procedure.
2. Let the engine run for a few minutes.
3. While the engine is running, lift the splash plate, then the
hopper GRATE.
4. Verify that the engine has STOPPED. If the engine has
stopped it can be determined that the grate engine stop circuit
(proximity switch) is functioning correctly.
5. If the engine continues to run after the grate has been lifted ,
turn the ignition switch key to the OFF position and correct
the problem using the wiring diagrams provided in the
manual.
6. Re-install the two U-clamps that secure the hopper grate to
the hopper.
PAGE 58 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HYDRAULIC HOSE CONNECTIONS
Figure 58 is provided to show the hydraulic hose connections
on the ST-45 for reference when performing inspections and
maintenance on the pump.
FRONT OF MACHINE
M
N
REMIXER
MANIFOLD
CONTROL
I
J
L
M
K
L
O
FRONT OF MACHINE
HEAT EXCHANGER
LUBRICATION
PISTONS
N
P
HYDRAULIC
DRIVE PUMP
O
J
I
K
P
FRONT OF MACHINE
NOTES
HOSES SHADED FOR
VISUAL CLARITY.
Figure 58. Hydrauilc Hose Connections
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 59
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ST-45HRM CE CONCRETE PUMP— HYDRAULIC HOSE CONNECTIONS
Figure 58. Hydrauilc Hose Connections (Continued)
PAGE 60 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HYDRAULIC HOSE CONNECTIONS
Figure 58. Hydrauilc Hose Connections (Continued)
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 61
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ST-45HRM CE — MANIFOLD PORT LOCATIONS
Figure 59 is provided to show the locations and names for
the two manifold block ports on the ST-45 for reference when
peforming maintenance on the pump.
Figure 59. Manifold Ports
PAGE 62 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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NOTE PAGE
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 63
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APPENDIX — ST-45HRM CE CONCRETE PUMPCONCRETE MIX
INFORMATION
The following information has been extracted from actual testing laboratory reports.The purpose of this printing is only to help create
a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete
mixes.These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock ratio can be adjusted (65% sand
35% rock) and pumpability should be excellent.
EXAMPLE #1 (A CaliforniaTest Lab.Report)
JOB: Building Foundations (Water Project)
Sacks per cu./yd.
6.5 designed for 2,500 lbs. in 28 days
Sacks per cu./meter.
Liters/Gallons per sack
Washed Sand-#200 wash
Organic matter-OK
8.5 designed for 1,134 kg. in 28 days
26.9/7.1
1.3
Specific gravity (SSD)
Sand-2.58;Pea Gravel-2.60
Sieve analysis-percent passing
Material
1.5” 1”
3/4”
3/8”
100
100
100
#4
#8
#16
#30
#50
#100
4.0
#200
1.1
W.C.Sand
Pea Gravel
% Comb.
99.7
3.0
66
79.1
60.4
36.5
14.3
51
39
23
9
3
1.0
3.81 cm =1.5 in.
2.54 cm = 1.0 in.
1.90 cm = 0.75 in.
.952 cm = 0.375
DESIGN FOR ONEYARD OF CONCRETE (SATURATED & SURFACE DRY):
Absolute volume of aggregate in one cu. yard:
Specific gravity of aggregates in one cu. yard:
503 liters (17.78 cu. ft.)
2.58
Weight of aggregates in one cu. yard batch: 1,293 kg. (2,850 lbs.)
%
BATCH
1800
1000
1
SPEC.GRAVITY
ABS.VOL.
W.C.Sand
65
35
2.58
2.60
327 liters (11.56 cu. ft)
176 liters (6.22 cu ft.)
PEA GRAVEL
WATER 174 liters/46 gal.
CEMENT 6.5 Sack/cu yd
CEMENT 8.5 Sack/cu meter
TOTAL
611
611
27.00
ADMIXTURE:
SLUMP
None
10.2 cm (4-inches)
REMARKS
This mix designed for pumping
NOTE:
Due to the availability of well-graded sand as shown in the above sieve analysis,
this mix pumped very successfully.
PAGE 64 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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APPENDIX — ST-45HRM CE CONCRETE PUMP CONCRETE MIX
INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 65
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APPENDIX — ST-45HRM CE CONCRETE PUMP SLUMPTEST
1. To obtain a representative sample (concrete), take several
Figure 60-B. Slump
Test (2/3 Full)
samples at three or more regular intervals throughout the
dischargeofthemixerortruck.DONOTtakesamplesatthe
beginning or end of the discharge.
2. Dampen the inside of the cone and place it on a smooth,
moist,nonabsorbent,levelsurfacelargeenoughtoaccom-
modate both the slumped concrete and the slump cone.
Stand on the “foot pieces” throughout the test procedure to
hold the cone firmly in place.
2/3 FULL
3. Fillthecone1/3fullbyvolume (Figure60-A)androd25times
with a 1.3 cm x 61 cm (1/2” diameter x 24” length) bullet-
pointed steel rod. (This is a specific requirement which will
producenon-standardresultsunlessfollowedexactly.)Dis-
tribute rodding evenly over the entire cross section of the
sample.
Figure 60-C. SlumpTest
(Full-Overflow)
4. Fillconeanother1/3 (Figure60-B)whichwillmakethecone
2/3fullbyvolume.Rodthissecondlayer25timeswiththerod
penetrating into, but not through, the first layer. Distribute
rodding evenly over the entire cross section of the layer.
FULL
(OVERFLOW)
5. Fill cone to overflowing (Figure 60-C). Rod this layer 25
times with rod penetrating into but not through, the second
layer.Distributeroddingevenlyovertheentirecrosssection
ofthislayer.
Figure 60-D. SlumpTest
(Removing Excess Concrete)
6. Removetheexcessconcrete(Figure60-D)fromthetopofthe
cone, using the tamping rod as a screed.
7. Lifttheconevertically(Figure60-E)withaslowevenmotion.
DONOTjartheconcreteortilttheconeduringthisprocess.
( Invert the withdrawn cone, and place it next to, but not
touchingtheslumpedconcrete.
Figure 60-E. SlumpTest
(Cone Invert)
8. Lay a straight edge (Figure 60-F) across the top of the
slumpedcone.Measuretheamountofslumpininchesfrom
the bottom of the straight edge to the top of the slumped
concrete at a point over the original center of the base .The
slump operation must be complete in a maxi
BULLET POINTED
STEEL ROD
Figure 60-F. SlumpTest
(Measurement)
1/3 FULL
1/2 DIAMETER
24 INCHES LONG
FOOT
PIECE
Figure 60-A. SlumpTest (1/3 Full)
PAGE 66 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the EngineTroubleshooting (Table 14) information
shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult
our company's business office or service plant.
TABLE 14. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
Speed control lever is in "STOP" position?
No fuel reaching injection pump?
Defective fuel pump?
SOLUTION
Set speed control lever to "START" position.
Add fuel. Check entire fuel system.
Replace fuel pump.
Fuel filter clogged?
Replace fuel filter and clean tank.
Replace or repair fuel line.
Faulty fuel supply line?
Engine will not start or start is
delayed, although engine can
be turned over.
Check piston, cylinder and valves. Adjust or
repair per engine repair manual.
Compression too low?
Repair or replace injector in accordance with
engine repair manual.
Fuel injector not working correctly?
Oil pressure too low?
Check engine oil pressure.
Comply with cold starting instructions and
proper oil viscosity.
Low starting temperature limit exceeded
Check whether clear (not turbid) fuel emerges
from the fuel line (detach from injection
pump). If the fuel is turbid or separated, warm
up the engine or drain the complete fuel
supply system. Refuel with winter grade diesel
fuel.
Fuel separates has inadequate resistance to
low temperatures?
At low temperatures engine will
not start.
Refill engine crankcase with correct type of oil
for winter environment.
Engine oil too thick?
Throttle lever in STOP position?
Fuel filter blocked?
Reposition throttle lever to RUN position.
Replace fuel filter.
Engine fires but stops soon as
starter is switched off.
Fuel supply blocked?
Fuel tank empty?
Check the entire fuel system.
Add fuel.
Engine stops by itself during
normal operation.
Fuel filter blocked?
Replace fuel filter.
Fuel tank empty?
Replace fuel filter.
Fuel filter clogged?
Replace fuel filter.
Low engine power, output and
speed.
Fuel tank venting is inadequate?
Ensure that tank is adequately vented.
See engine manual for corrective action.
Speed control lever does not remain in
selected position?
Engine oil level too full?
Air filter blocked?
Correct engine oil level?
Clean or replace air filter.
Adjust valves per engine specification.
See engine manual.
Low engine power output and
low speed, black exhaust
smoke.
Incorrect valve clearances?
Malfunction at injector?
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ST-45HRM CE CONCRETE PUMP—TROUBLESHOOTING (HYDRAULIC
SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Hydraulic System Troubleshooting
(Table 15) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 15. HYDRAULIC SYSTEM TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Check TB1 terminal #17. If this terminal is energized when the
pump is turned on, the pump will not cycle because the
compensator is dumping controll pressure to the accumulator tank.
Check K-3 relay and replace if necessary.
Delta "Q" compensator not de-energized
when pump is energized?
Volume control not turned open?
Hydraulic oil level low?
Turm volume control valve counter-clockwise to open.
Fill resevouir to proper level.
No hydraulic oil flow from axial piston
pump.
Restricted suction screen?
Main pressure relief valve open
Clean suction screen.
Remove cartridge. Clean and reset. Replace cartridge if
ncessisary.
This emergency cycle switch, located in the control box, can be
used to determine which switch is faulty. Determine malfunctioning
proximity switch and replace.
Proximity switch is not sending a signal?
Pilot cycle valve malfunction?
Turn on pump switch. Check TB1 terminal #35 and #36 to
determine if current is flowing to valve. Check detents in valve for
proper operation.
Drive cylinders will not cycle
K-4 relay faulty?
Check the proximity switch enclosure.
Main cycle valve(manifold) faulty?
Check spool or centering springs. Replace or repair as necessary.
Accumulator pressure drops to zero
on every cycle
Low nitrogen charge in accumulator
bladder?
Re-charge accumulator bladder with nitrogen to 7.58 mPa (1,100
PSI.)
Accumulator pressure is below 12.1
mPa (1750 PSI.)
Unloading valve setting too low?
Adjust unloading valve until 12.1 mPa (1,750 PSI) is reached.
Check solinoid and cartridge. Replace if necessary
Accumulator pressure is not
discharging when switch is turned off
Cartridge at port 4-D on manifold block
is not working?
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ST-45HRM CE CONCRETE PUMP—TROUBLESHOOTING (ELECTRICAL
SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Electrical System Troubleshooting
(Table 16) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 16. ELECTRICAL SYSTEM TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
If the hydraulic system is in a maximum pressure condition, pull
the toggle on the emergency cycle switch (located inside the
control box) towards you. If the pump cycles, replace the proximity
switch at the lubrication box. If the pump cycles when you push
the toggle down, replace the proximity switch on the towing end of
the pump.
After completion of a pumping stroke,
pumping pressure gauge indicates
high pressure and cycle stops.
Proximity switch is not emitting a radio
frequency?
Use a hot jumper wire. Connect (jumper wire) to terminals #35
and #36 on terminal block #1. When contact is made between
these two terminals and the pump cycles. This would indicate that
you have a faulty K-4 relay.
Emergency cycle switch does not
cycle pump
Faulty K-4 relay?
Check fuse box in control panel. Replace blown fuses.
Check fuse link below engine solenoid, next to batter.
Starter switch is activated and pump
does not start
Faulty fuses?
Hatz engine will not continue to run
after key is released
Check D1 diode in control box. Replace if needed with 6 amp
diode P/N EGG5815 or equivalent.
D-1 diode has failed?
No power to TB-5, conductor #3?
Hatz engine will not start
Check and replace K1 relay if necessary
Check and replace K-2 relay if necessary
No power to magnet valve start/stop?
Engine runs, but no current travels to
circuits #32-47
Faulty K-2 relay?
K-6 relay not completing the circuit?
Open circuit at TB1-24?
When pump is turned on, engine
RPM's will not increase
Check and replace K-6 relay if necessary
The pump will not reverse when
operated by remote control
K-5 relay failure?
Check and replace K-5 relay if necessary
Check and replace sending unit if necessary
Engine oil pressure light will not
de-activate
Oil pressure sending unit failure?
Faulty D-2 diode?
Replace with diode 1U404-C
Battery charge light wont de-activate
Alternator not charging battery?
Check and repair/replace alternator unit.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 69
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APPENDIX — ST-45HRM CE SHOTCRETE SYSTEM
SHOTCRETE SYSTEM
Figure 39. Shotcrete System
PAGE 70 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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APPENDIX — ST-45HRM CE SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
NO.
1
PART NO.
EM28904
PART NAME
COUPLING, 3” H-D “CF”
QTY. REMARKS
2
EM23946
EM28903
EM28005DD
EM28061
EM24849
EM28001DD
EM23815D
EM28902
EM23101
TBD
ELBOW, 3"x90°
3
COUPLING, 2.5” H-D w/GASKET & PIN
REDUCER, 3”x2.5”x36” H-D ENDS
PIPE, 2.5”x120w x 10’ H-D
HOSE, 2.5”x2”x36” H-D
4
5
6
7
REDUCER, 2.5”x2”x36” H-D
REDUCER, 2.5”x2” w/AIRVIBRATOR
COUPLING, 2” H-D w/GASKET & PIN
AIR VIBRATOR ASSY.
8
9
10
11
12
13
14
15
2”x2” ELBOW
EM24841
EM23808D
EM23806
EM23807
HOSE, 2”x25’ H-D w/ENDS
NOZZLE ASSEMBLY, 2” H-D
NOZZLETIP, RUBBER 1-3/8”
NOZZLE TIP, RUBBER 1.25”
General recommendations
■
If the site will permit, use steel pipe from the pump to the
pool perimeter.It will reduce line pressures which is highly
recommended.
■
■
The vibrator on the reducer by the pool improves pumpability.
Turn both air vibrators off whenever the pump is stopped to
prevent separation of mix.
■
■
The air vibrators are low consumption (4.2 scfm).
Leave the air on at the nozzle when the pump is stopped to
prevent clogging of air the hoses in the air insert.
■
Use item #11 (steel elbow) at the edge of the pool to prevent
collapse of the rubber hose, which can cause blockage.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 71
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APPENDIX — ST-45HRM CE CONCRETE PUMP ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
Figure 40. Shotcrete System Accessories
Use a 1-3/8" rubber nozzle tip for a wide spray pattern. Use a 1-1/4" rubber nozzle tip for a narrow
spray pattern. DO NOT INSTALLTHE NOZZLE ATTHE END OFTHE HOSE UNTILTHE FIRST
MATERIAL HAS PASSEDTHROUGHTHE ENTIRE HOSE LENGTH.
Disassemble and clean the nozzle assembly thoroughly after each job.Grease all threads before
re-assembly.DO NOT close the air valve when pumping is stopped as a continued air flow keeps
the air passages clean.
PAGE 72 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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APPENDIX — ST-45HRM CE CONCRETE PUMP ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
NO.
1
2
3
4
5
6
7
8
PART NO.
EM26107
EM23101
EM132
EM23407
EM23408
EM23411
EM912073
EM23409
EM923346
EM406
EM23818
EM24841
EM23845
EM23802
EM23803
EM20816
EM23804
EM23805
EM23806
EM23807
EM911076
PART NAME
QTY.
REMARKS
HOPPER SCREEN .......................1............. W/AIRVIBRATOR MOUNTING
AIRVIBRATOR
BOLT, 1/2-13X2
AIR HOSE
BUSHING
VALVE
NIPPLE
COUPLING
WASHER, 1/2 LOCK
NUT, HEX 1/2-13
2"X25' GROOVED HOSE
2"X25' RAISED HOSE
2"X50' GROOVED HOSE
VIC ADAPTER / EM23802D H.D
GUN BODY
“O” RING
AIR INSERT
NOZZLE CLAMP
NOZZLE TIP, 1-3/8", SHORT
NOZZLE TIP, 1-1/4", LONG
STREET ELBOW
1
2
1
1
1
2
1
2
2
9
10
11
11
11
12
1
1
1
1
1
1
1
1
*
13
*
14
*
15
*
16
*
17
*
18
*
19
20
*
AIR HOSE..................................................... NOT SUPPLIED BY MAYCO
NOZZLE ASSEMBLY ................... 1 ............. INCLUDES ITEMS W/
21
EM23808
*
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 73
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ST-45HRM CE PUMP— EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial number
range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model number
or model number variant.
Items Found In the “Items Number”Column
All parts with same symbol in the number column, , #, +, %,
*
or <, belong to the same assembly or kit.
If more than one of the same
reference number is listed, the last
one listed indicates newest (or
latest) part available.
The contents of this catalog are
subject to change without notice.
PAGE 74 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE — SUGGESTED SPARE PARTS
ST-45HRM CE CONCRETE PUMP
ST-45HRM CE CONCRETE PUMP
3 Units
1 Units
Qty.
P/N
Description
Qty.
P/N
Description
1 .......... EM16459 .............. PIN
1 .......... EM16462 .............. FELT HOLDER
4 .......... EM98050 .............. PISTON CUP, ORANGE
4 .......... EM16493 .............. FELT RING
2 .......... EM18801 .............. CONCRETE CYLINDER
2 .......... EM16462 .............. FELT HOLDER
6 .......... EM98050 .............. PISTON CUP, ORANGE
8 .......... EM16493 .............. FELT RING
1 .......... EM98033 .............. OIL PLATE
2 .......... EM14408 .............. BRONZE RING
2 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE )
1 .......... EM98021 .............. WEAR RING
2 .......... EM16816-1 ........... ENERGIZER RING
1 .......... EM16816-2 ........... INSERT RING
2 .......... EM98065 .............. SLEEVE SEAL
1 .......... EM98022 .............. WEAR PLATE
2 .......... EM97024 .............. SWITCH, PROXIMITY
1 .......... EM50417 .............. CUP
1 .......... EM20709-1 ........... SOLENOID
2 .......... EM97050 .............. RELAY
1 .......... EM97048 .............. RELAY
1 .......... EM97036 .............. SWITCH, PUMP CONTROL
1 .......... EM97045 .............. SWITCH, OPERATION PUMP/ENG
1 .......... EM98065 .............. RUBBER RING
2 .......... EN98033 .............. OIL PLATE
2 .......... EM14408 .............. BRONZE RING
4 .......... EM16145 .............. BUSHING, SWING AXLE (BRONZE )
3 .......... EM98021 .............. WEAR RING
4 .......... EM16816-1 ........... ENERGIZER RING
2 .......... EM16816-2 ........... INSERT RING
4 .......... EM98065 .............. SLEEVE SEAL
2 .......... EM98022 .............. WEAR PLATE
4 .......... EM97024 .............. SWITCH, PROXIMITY
3 .......... EM50417 .............. CUP
2 .......... EM20709-1 ........... SOLENOID
4 .......... EM97050 .............. RELAY
2 .......... EM97048 .............. RELAY
2 .......... EM97021 .............. SOLENOID
2 .......... EM97036 .............. SWITCH, PUMP CONTROL
2 .......... EM97045 .............. SWITCH, OPERATION PUMP/ENG
1 .......... EM98065 .............. RUBBER RING
Part numbers on this Suggested
Spare Parts List may supercede or
replace the P/N shown in the text
pages of this book.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 75
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ST-45HRM CE CONCRETE PUMP— DECAL PLACEMENT
DECAL PLACEMENT
PAGE 76 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— DECAL PLACEMENT
DECAL PLACEMENT
NO.
1
2
3
4
5
6
7
8
PART NO.
511709
EM97082
34536
EM97070
EM97070
EM93000
EM98022
EM995
EM97072
TBD
EM985
EM97071
EM97084
EM955
EM97083
TBD
PART NAME
QTY.
1
2
1
1
1
4
1
1
2
1
1
1
1
1
1
1
REMARKS
DECAL, 800-30-MAYCO
DECAL, ST-45
DECAL, OWNERS MANUAL
DECAL, ACCUMULATOR PRESSURE
DECAL, PUMPING PRESSURE DECAL
DECAL, CAUTION - GREASE 2 HOURS
DECAL, LUBRICATION BOX
DECAL, DIESEL FUEL ONLY
DECAL, CAUTION - OP. INSTRUCTIONS
DECAL, HOPPER REXMIXER
DECAL, HYDRAULIC OIL
DECAL, CAUTION - MINIMUM OIL LEVEL
DECAL, MAINTENANCE
DECAL, CAUTION - REFER TO MANUAL
DECAL, WARNING - ACCUM. SAFETY
DECAL, REMOTE OUTLET
DECAL,VOLUME CONTROL
DECAL, SHUTTLE TUBE DANGER
DECAL, MAYCO
DECAL, TOWING VEHICLE
NAMEPLATE .................................................1 ..........CONTACT MQ PARTS DEPT.
HELMENT, HAND & FOOT (ISO BLUE)
DECAL, CE-04
DECAL, READ
DECAL, NOISE LEVEL
DECAL, HOT PARTS
DECAL, ACC. CHARGE
DECAL, DANGER AMPUTATION
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
EM965
TBD
EM1023
DCL305
1
1
2
1
36999
DCL306
35137
DCL303
M91010000
DCL304
DCL301
1
1
1
1
1
1
2
All decals are considered safety
related. Immediately replace any
decal that becomes worn or diffi-
cult to read.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 77
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ST-45HRM CE CONCRETE PUMP— SAFETY GRIDS ASSY.
SAFETY GRIDS ASSY.
PAGE 78 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— SAFETY GRIDS ASSY.
SAFETY GRIDS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM98201
EM98202
EM963003
2101402
EM923057
EM98203
EM959179
0161 D
PART NAME
QTY.
REMARKS
GRID, SHUTTLE CYL. 22.5” X 9.0 X 14.5”
GRID, BLADE SHAFT 4.5” X 4.5”
BOLT 1/4” NC X 3/4”
1
1
5
5
5
2
3
6
6
6
WASHER, LOCK 1/4” MED
WASHER, FLAT 1/4”
GRID SUPPORT BRACKET
NUT, NYLOCK 1/4-20
BOLT, HEX 5/16”-18 X 3/4”
WASHER, LOCK 5/16” MED
WASHER, FLAT SAE 5/16”
9
10
EM923343
EM923023
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 79
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ST-45HRM CE CONCRETE PUMP— HUB AND DRUM ASSY.
HUB AND DRUM ASSY.
PAGE 80 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HUB AND DRUM ASSY.
HUB AND DRUM ASSY.
NO.
1
2
PART NO.
109221
302261
PART NAME
QTY.
1
1
REMARKS
STUB AXLE
BRAKE
3
4
4A
5
5A
6
DPSM639010
368A
362A
501349
501310
1053 08
1061 07
1” UNF
OIL SEAL
1
1
1
1
1
1
2
2
INNER BEARING CONE 2”
INNER BEARING CUP 2”
OUTER BEARING CONE
OUTER BEARING CUP
LOAD WASHER 1”T5 HP
GREASE CAP
7
8
SLOTTED NUT, 1”UNF
9
3/16” X 1-1/2
1026 15
1026 19
1026 20
1027 07
1027 10
1027 15 & 16
1162
COTTER PIN 3/16” X 1-1/2
WHEEL STUD 1/2” UNF PRESS IN
WHEEL STUD 5/8” UNF PRESS IN
WHEEL STUD M18 X 1.5 PRESS IN
WHEEL LUG NUTS 1/2 UNF 60 CON
WHEEL LUG NUTS 5/8” UNF 80 CON
WHEEL LUG NUTS M18 X 1.5 16 MM RAD
HUB AND DRUM ASSY.
2
8
8
8
8
8
8
2
10
10
10
11
11
11
13
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 81
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ST-45HRM CE CONCRETE PUMP— BRAKE COMPONENTS ASSY.
BRAKE COMPONENTS ASSY.
PAGE 82 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— BRAKE COMPONENTS ASSY.
BRAKE COMPONENTS ASSY.
NO.
1
2
3
4
PART NO.
33623
44856
45439
35212
45488
42860
43123-1
PART NAME
QTY.
REMARKS
HALF SHELL
1
1
1
1
1
1
1
1
EYELET
READJUSTABLE WEDGE
ADJUSTER SHOE POST
BOLT
SPRING BUCKLE
EXPANDER
SHOE BRACKET ONLY (NO LINING)
SLIDING SHOE.................................................. 1 .............INCLUDES ITEMS W/
6
7
8
9
*
10
25455.03
24929.03
42861.03
44445
44444
44443
*
11
12
FIXED SHOE
1
2
2
1
1
SHOE STEADY SPRING (CONICAL)
SPRING (REVERSE SHOE)
SPRING
13
14
15
*
SPRING
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 83
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ST-45HRM CE CONCRETE PUMP—TOWING COUPLER ASSY.
TOWING COUPLER ASSY.
PAGE 84 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP—TOWING COUPLER ASSY.
TOWING COUPLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
87003909
98702694
56000594
TBD
69004692
87003909
98857593
69001494
EM300R56501
PART NAME
QTY.
REMARKS
BRAKE LEVER ASSY.
ENERGY STORE
BREAK-AWAY CABLE
BODY ASSY.
1
1
1
1
1
1
BELLOWS
DAMPER
DRAW TUBE W/STOP RING.............................. 1 .............INCLUDES ITEM W/
STOP RING
COUPLING HEAD
*
1
1
9
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 85
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HOPPER ASSY.
HOPPER ASSY.
ST-45HRM CE CONCRETE PUMP— HOPPER ASSY.
PAGE 86 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HOPPER ASSY.
HOPPER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM25174
EM16184
EM25863
EM23305
EM963610
0166 A
EM25301
EM963610
0166 A
EM916001
EM18137
EM18138
EM181361
EM621
EM18135
6109180
EM492397
EM916001
EM50141
EM501411
EM25425
EM750
PART NAME
QTY.
1
1
1
1
4
4
1
4
4
1
4
16
4
4
2
8
8
1
1
1
1
1
1
2
2
2
1
1
1
4
4
4
1
REMARKS
HOPPER ASSY.
HOPPER SEAL 3/8” X 1/2
REMIXER, SHAFT
SHAFT, ADAPTOR
CAP SCREW
WASHER, LOCK 3/8”
SHAFT, DRIVE END
CAP SCREW
WASHER, LOCK 3/8”
GREASE FITTING
SHAFT GASKET
SPACER
9
10
11
12
13
14
15
16
17
18
19
20
22
23
23
24
25
26
27
28
29
30
31
32
33
34
SPACER PLATE
1/2”WILLIAMS WASHER
BEARING FLANGE
LOCK WASHER 1/2”
BOLT, HEX 1/2”- 13 X 2 1/2”
GREASE FITTING
MOUNT, REMIX MOTOR
MOTOR MOUNT PLATE
MOTOR, HYDRAULIC REMIX
KEY 1/4” X 3/8” X 1
KEY 1/4” SQ.
CAPSCREW 1/2” X 13 X 1 1/2”
LOCK WASHER 1/2”
FITTING
PISTON CUP HOLDER
PISTON CUP
HANDLE
BOLT
WASHER, LOCK 3/8”
ALLEN SCREW
MOTOR COUPLING
HOSE
505719
EM963692
6109180
506203
EM708601
EM50417
EM708602
492378
0166 A
492465
512791
EM25483
2
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 87
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TANQUE TRANSMISSION HATZ 57HP ASSY.
ST-45HRM CE CONCRETE PUMP— HOPPER ATTACHMENT ASSY.
HOPPER ATTACHMENT ASSY.
PAGE 88 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HOPPER ATTACHMENT ASSY.
HOPPER ATTACHMENT ASSY.
NO.
1
2
3
4
PART NO.
EM70134-1
EM16159
EM491686
EM70134-2
EM505723
EM16166
EM505728
EM14165
EM619
EM968446
EM505121
EM968446
505123
PART NAME
QTY.
1
1
2
1
1
2
6
4
4
4
4
4
REMARKS
SPLASH PLATE
HINGE PIN
COTTER PIN 1/8” x 1-3/4”
SPLASH PLATE PIN
COTTER PIN 5/32” x 1-1/2”
ROD TIE, 1”- 8 NC X 28
NUT, HEX 1” NC
EYE BOLT
WILLIAMS WASHER 3/4”
NUT, HEX 3/4”
5
18
19
20
21
22
23
24
25
26
27
BOLT, HEX
NUT, HEX 3/4”
BOLT 1/2” N/C X 2.1/2”
BOLT 1/2” N/C X 2.1/2”....................................... 2 .............REPLACES 492558
NUT, HEX 1/2” X 13
2
EM968446
6109160
3
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 89
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ST-45HRM CE CONCRETE PUMP— HOPPER INTERIOR ASSY.
HOPPER INTERIOR ASSY.
PAGE 90 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HOPPER INTERIOR ASSY.
HOPPER INTERIOR ASSY.
NO.
1
PART NO.
EM16145
EM284
PART NAME
QTY.
1
1
1
1
1
1
1
1
4
1
4
4
1
1
1
3
6
6
1
1
4
1
4
1
1
4
4
1
1
2
2
2
1
2
REMARKS
SWING AXLE BUSHING
1- 14 X 5 STUD GR8
O- RING
9
10
11
12
13
13A
13B
14
16
17
18
19
20
21
22
23
24
41
42
43
44
45
47
48
49
50
51
52
53
54
55
56
57
EM16175
EM16170
EM16176
EM98022
EM16816-2
EM16816-1
EM98039
EM16804
EM104
EM923348
EM25803
EM98065
512215
EM491701
EM210
EM6109180
EM16811
EM25843
EM492393
491719
EM923348
EM20816
EM16802
EM963102
6109180
EM16188
EM295
EM969023
EM265
EM295
SHUTTLE AXLE RING SEAL
O- RING
WEAR RING, HARD FACED
RING, INSERT STEEL
RING, ENERGIZED RUBBER
BEVELED RING
DISCHARGE SLEEVE
BOLT 1/2- 13 X 5
5/8” LOCKWASHER
DISCHARGE PLATE BEARING
SEAL
DISCHARGE NIPPLE
GREASE FITTING
BOLT, HEX 1/2” NC X 3 1/4 G5
1/2” LOCKWASHER
SHUTTLE TUBE
NUN PLATE
BOLT, HEX HEAD 1/2” NC X 1 1/4
PIN
5/8 LOCK WASHER
O- RING
INSPECTION PLATE
CAP SCREW, HEX BOLT
1/2” LOCKWASHER
HOPPER SCREEN
BOLT, COUNTERSUNK 3/4-10 X 2
NUT LOCK 5/8”
BOLT, FLAT HEAD 5/8”- 11 X 3”
BOLT, FLAT HEAD 3/4”- 10 X 2”
BOLT, HEX SOC 1/2”- 13 X 3”
“O” RING
EM264
EM16190
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 91
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ST-45HRM CE CONCRETE PUMP— SHUTTLE CYLINDER ASSY.
SHUTTLE CYLINDER ASSY.
PAGE 92 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— SHUTTLE CYLINDER ASSY.
SHUTTLE CYLINDER ASSY.
NO.
1
PART NO.
EM16145
510684
EM16169
EM25236
EM505490
EM16814
EM458
EM417
EM254549
492397
492600
6109180
492584
EM505490
EM25500
EM509372
EM25459
EM509373
EM25434
EM254542
EM717
PART NAME
QTY.
REMARKS
SWING AXLE BUSHING
GREASE FITTING
THRUSTWASHER
SHUTTLE CRANK, SPLINED SHAFT
GREASE FITTING
TENSIONER
1
2
3
1
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
4
5
6
7
NUT 1- 14
8
NUT FLEX LOCK
PIVOT BRACKET
BOLT, HEX 1/2”- 13 X 2 1/2”
1/2” FLATWASHER
1/2” LOCKWASHER
1/2” LOCK NUT
FITTING
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
FITTING
HOSE
FITTING
HOSE
SHUTTLE CYLINDER
CLEVIS PIN 3/4” ................................................ 1 ............ BOTTOM OF ITEM 36
COTTER PIN
FEMALE CLEVIS
2
2
EM254541
EM26126
CLEVIS PIN ....................................................... 1 .............TOP OF ITEM 36
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 93
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REAR HOOD ASSY
ST-45HRM CE CONCRETE PUMP— FUEL AND HYDRAULICTANK ASSY.
FUEL AND HYDRAULIC TANK CONNECTIONS ASSY
PAGE 94 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— FUEL AND HYDRAULICTANK ASSY.
FUEL AND HYDRAULIC TANK CONNECTIONS ASSY
NO.
5
6
7
8
PART NO.
EM963610
3019092
EM969013
EM25169
EM251191
EM25184
492364
EM923343
EM16478
EM16517
EM18436
EM50424
EM50466
EM27441
EM635
PART NAME
QTY.
2
2
2
2
1
1
20
20
1
1
1
1
1
1
4
1
4
1
4
4
1
1
1
1
1
1
1
6
1
1
8
8
1
REMARKS
BOLT 3/8”
WASHER FLAT 3/8”
NUT LOCK 3/8”
GASKET, RUBBER
TANK COVER PLATE
RESEVOIR GASKET
BOLT HHC 5/16” X 18 X 1”
WASHER LOCK 5/16” DIAMETER
SIGHT GAUGE, HYDRAULIC OIL
BUSHING 912 X 2 RED, REMOVER
ELBOW, 90 DEGREE MALE
STRAINER, 2.5 SUCTION
O- RING
ELBOW
LOCK 1/2” HI COLLAR
HOSE
CLAM 2”
ELBOW
BOLT 1/2” UNC X 1- 1/2”
LOCK 1/2”
O-RING
GAUGE 3000 PSI
ADAPTER 4- 4- GTX- S
GAUGE 5000 PSI
ELBOW
9
10
11
12
13
24
25
26
27
28
29
31
32
33
34
35
36
43
44
45
46
47
49
50
51
52
53
54
55
57
58
60
61
62
EM509437
EM26471
EM27442
EM963692
EM635
509436
EM90766
EM25523
EM97067
EM491396
EM16414
EM16477
492267
511010
511012
492357
2101402
EM25217
20426
508827
EM20421
509517
VALVE NEEDLE
CAP HYDRAULIC OIL TANK
BOLT, ALLEN 3/16” DIAMETER
COVER PLATE
GASKET
BOLT HHC 1/4”- 20 X 12
WASHER LOCK 1/4” DIAMETER
FUEL FILLER CAP- BR
90° FITTING
HOSE, FUEL GAUGE
FITTING, BALL END CNTRL, CABLE
HOSE
1
1
1
1
509516
HOSE
1
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 95
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REAR HOOD ASSY.
ST-45HRM CE CONCRETE PUMP— FUEL AND HYDRAULICTANK ASSY.
FUEL AND HYDRAULICTANK ASSY. (CONTINUED)
PAGE 96 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— FUEL AND HYDRAULICTANK ASSY.
FUEL AND HYDRAULIC TANK ASSY.(CONTINUED)
NO.
1
2
PART NO.
509772
509786
PART NAME
QTY.
1
1
REMARKS
RESERVOIR, FUEL AND HYDRAULIC OIL
ELBOW, SUCTION
ELBOW
3
510591
1
4
491164
EM18447
509369
491237
506094
16512
EM963610
0166A
16433
16516
EM16513
510674
509794
EM509795
510675
EM510676
EM509371
20426
512769
506208
20426
EM20763
EM165121
SUCTION NIPPLE 3/4”
PLUG 3/4” PIPE SQ H
ADAPTER 1/2- FF- S
GATE VALVE 1/2” NPT FEMALE VALVE
PLUG 1/2” NPT GALVANIZED
RETURN FILTER ASSY.
CAP SCREW
WASHER, LOCK 3/8” DIAMETER
ELBOW
TUBE
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
14
15
16
17
18
19
20
21
22
23
37
38
39
40
41
42
61
62
63
64
68
69
DEFUSER
NIPPLE 1-1/4” x 2-1/2”
COUPLING GALV 1 1/4”
ELBOW, 1- 1/4 PIPE/ 1- 1/4 JIC
HOSE
ELBOW
HOSE
FITTING
HOSE, FUEL
CLAMP, HOSE
FITTING
FILTER, FUEL
RETURN FILTER ELEMENT
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 97
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FRONT COVER ASSY.
FRONT COVER ASSY.
ST-45HRM CE CONCRETE PUMP— FRONT COVER ASSY.
PAGE 98 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— FRONT COVER ASSY.
FRONT COVER ASSY.
NO.
7
8
PART NO.
EM963003
EM923057
2101402
PART NAME
QTY.
19
23
REMARKS
BOLT 1/4” NC X 3/4”
WASHER, FLAT 1/4”
WASHER, LOCK 1/4” DIAMETER
9
15
10
14
17
18
19
EM510271
29057
EM969079
EM97063
510687
COVER, FRONT ................................................ 1 .............SAFETY ITEM
DOCUMENT BOX
NUT LOCK NYLOC 1/4”
1
4
EMERGENCY STOP SWITCH .......................... 1 .............SAFETY ITEM
COVER, TOP...................................................... 1 .............SAFETY ITEM
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 99
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ST-45HRM CE CONCRETE PUMP— HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
PAGE 100 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
NO.
1
2
PART NO.
EM509802
EM963610
3019892
PART NAME
GUARD, HEAT EXCHANGER
BOLT 3/8”
WASHER, FLAT 3/8”
NUT, LOCK 3/8”
GASKET, RUBBER
HEAT EXCHANGER
SCREW HHC 5/16” X 18 X 1”
WASHER, FLAT 5/16”
NUT, NYLON 5/16”- 18
QTY.
REMARKS
1
4
6
4
1
1
4
4
4
3
4
5
6
7
EM969013
EM25171
EM98049
492364
8
9
EM923023
2105164
10
11
12
13
14
15
16
17
18
20
21
22
23
24
25
26
EM509805
EM963003
EM923057
2101402
COVER ............................................................... 1 .............SAFETY ITEM
BOLT 1/4” NC X 3/4”
WASHER, FLAT 1/4”
WASHER, LOCK 1/4”
FITTING, HYDRAULIC
TEE, FITTING
ELBOW
6
6
6
1
1
1
1
1
2
1
1
1
1
1
1
EM25498
EM25566
EM509401
EM509400
EM98048
EM492625
EM509344
EM509345
EM509402
EM509378
EM510984
EM509374
HOSE
CLAMP
WASHER LOCK 7/16”
TEE, FITTING
FITTING
NUT
HOSE, HYDRAULIC
HOSE, HYDRAULIC
HOSE, HYDRAULIC
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 101
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ST-45HRM CE CONCRETE PUMP— ENGINE AND FRAME ASSY.
ENGINE AND FRAME ASSY
PAGE 102 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— ENGINE AND FRAME ASSY.
ENGINE AND FRAME ASSY
NO.
1
2
3
4
6
7
8
9
10
11
29
30
31
32
35
36
37
PART NO.
020310080
030210250
EM23118
EM01005
509405
PART NAME
QTY.
8
8
4
2
1
2
2
1
1
1
2
2
2
2
1
2
REMARKS
NUT
WASHER, LOCK
SHOCK MOUNT
CONNECTOR LINK, CHAIN
FRAME, MAIN
BOLT, HEX 3/8”
WASHER 3/8”
NUT, NYLOC
RUBBER PAD
JACK STAND, FRONT
JACK STAND, REAR
PIN
CLEVIS PIN 1/2” X 4”
CONNECTOR
503117
3019092
EM969013
508776
EM25610
EM70186
EM745
EM744
EM20732
EM942
TAG, IDENTIFICATION
RIVET
HATZ DIESEL ENGINE 57HP
491744
EM60701
1
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 103
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ST-45HRM CE CONCRETE PUMP—THROTTLE ANDWATER FILTER ASSY.
THROTTLE AND WATER FILTER ASSY.
PAGE 104 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP—THROTTLE ANDWATER FILTER ASSY.
THROTTLE AND WATER FILTER ASSY.
NO.
29
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
61
PART NO.
EM509414
EM969013
EM509510
EM959119
492357
EM959179
EM207091
EM968435
EM26315
EM963003
2101402
EM923057
492561
510229
EM501102
EM491089
492364
2105164
510732
EM510733
510725
EM510731
EM509449
EM269
EM16747
EM963003
2101402
EM20426
506208
PART NAME
QTY.
1
1
1
1
1
1
1
2
1
4
4
4
4
1
1
1
1
2
1
1
1
1
1
2
1
3
3
4
2
1
REMARKS
BRACKET
NUT LOCK 3/8”
SPRING
CLEVIS YOKE 1/4- 28
SCREW HHC 1/4”- 20 X 12
NUT LOCK NYLOC 1/4”
KIT, SOLENOID W/BRACKET
NUT 1/4”- 20” HEX
SAFETY LINK ASSEMBLY
BOLT 1/4” NC X 3/4”
WASHER, LOCK 1/4” DIAMETER
WASHER, FLAT 1/4”
NUT, HEX 1/4”- 20
CABLE THROTTLE ASSY.
BUSHING, LOCK
BOLT
SCREW HHC 5/16” X 18 X 1”
NUT NYLON 5/16- 18
HOSE CLAMP
HOSE
CLAMP
CAP, RAIN
BRACKET
M10 X 30MM SOC HDCS
FILTER ASSY, WATER SEPERATOR
BOLT 1/4” NC X 3/4”
WASHER, LOCK 1/4” DIAMETER
FITTING
CLAMP
HOSE, FUEL
512790
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 105
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ST-45HRM CE CONCRETE PUMP— HYDRAULIC PUMP ASSY.
HYDRAULIC PUMP ASSY.
PAGE 106 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— HYDRAULIC PUMP ASSY.
HYDRAULIC PUMP ASSY.
NO.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
22
23
24
25
26
28
60
61
63
64
65
PART NO.
EM16306
EM146
EM16303
EM16302
EM16741
EM162
EM98025
EM510902
EM635
PART NAME
QTY.
1
6
1
1
1
10
1
2
2
2
1
1
1
1
1
4
1
1
1
2
2
1
1
1
1
1
1
1
1
REMARKS
COUPLING, ENGINE
BOLT 12 MM X 1” ALLEN HEAD
COUPLING, CHAIN
COUPLING, PUMP
COVER, ENGINE
BOLT 10 X 25MM SOC. HEAD
PUMP, PISTON
SCREW
WASHER, LOCK 1/2”
WASHER, FLAT 1/2” DIAMETER
FITTING 8C5 X- S
ELBOW 6801- 04- 04
HOSE
492600
EM25507
EM25429
EM509366
EM505533
EM97001
EM509341
EM25497
EM25429
EM97002
EM963610
0166 A
EM25498
EM16524
506195
509637
509370
O- RING
MANIFOLD ASSY.
BOLT, ALLEN 3/8”- 16 X 5”
FILTTING
ELBOW 6801- 04- 04
PUMP, DUAL GEAR
CAP SCREW
WASHER, LOCK 3/8” DIAMETER
FITTING - ADAPTOR
FITTING, 90°
FITTING, 90°
HOSE
HOSE
HOSE
510984
509374
509371
HOSE
HOSE
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 107
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ST-45HRM CE CONCRETE PUMP— LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
PAGE 108 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
510749
EM507895
492378
3019092
0166A
510755
PART NAME
LUBRICATION BOX
PLUG
QTY.
1
1
6
6
6
1
2
4
8
8
8
2
2
2
2
2
2
6
2
6
2
2
2
8
8
8
1
2
2
8
2
2
1
2
1
2
4
2
REMARKS
BOLT G5 HHCS
WASHER, FLAT 3/8”
WASHER, LOCK3/8” DIAMETER
COVER, LUBRICATION BOX
CYLINDER, CONCRETE
RETAINER, CYLINDER
CAP SCREW
WASHER LOCK 3/8” DIAMETER
WASHER FLAT 3/8”
O- RING, OILER PLATE
OILER PLATE
FELT HOLDER
RING, FELT
RING, BRONZE
CUP, PISTON- ORANGE
PISTON CUP SPACER
FACE PLATE
BOLT, HEX HEAD 3/8 NC x 3-1/4 IN GS
O- RING
EM80801
EM25110
EM963610
EM0166A
3019092
EM14407
EM98033
EM16462
EM16493
EM14408
EM98050
EM16465
EM16464
510265
EM16174
EM50425
EM274351
EM492451
3019092
EM50443
510516
EM97024
EM97025
504505
EM25497
EM491701
510515
EM25497
EM25474
EM16454
505723
9
10
11
12
13
14
15
16
17
18
19
20
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
44
45
FLANGE, RING
SEAL LUBE BOX
BOLT 3/8”- 24 X 1” HEX HEAD
WASHER, FLAT 3/8”
SEAL, OIL BOX
CYLINDER, DRIVE
SWITCH PROXIMITY
CABLE PROXIMITY SWITCH
WRAP TIE
FITTING, 90°
FITTING, GREASE
CYLINDER, SLAVE
FITTING, 90°
HOSE, HYDRAULIC
PIN, WRIST
PIN, COTTER
HOSE, HYDRAULIC
EM509511
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 109
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SISTEMA ELECTRICO HATZ ASSY.
ST-45HRM CE CONCRETE PUMP— ELECTRICAL SYSTEM ASSY.
ELECTRICAL SYSTEM ASSY.
PAGE 110 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— ELECTRICAL SYSTEM ASSY.
ELECTRICAL SYSTEM ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
512759
491028
491030
EM256073
512760
512761
505303
508437
512762
512763
EM98066
508632
508259
512764
504984
512800
512801
512802
512803
508259
512804
491894
512805
512806
512807
EM97025
508632
508238
505501
PART NAME
CABLE HARNESS
CABLE WRAP
QTY.
REMARKS
1
5
5
5
5
1
2
2
CABLE WRAP
CONNECTOR BOOT II
CONDUCTOR CABLES
SHIELD, CABLE
TERMINAL CONNECTION
TERMINAL CONNECTOR
WIRE, HEAT EXCHANGER ............................... 1 ............. WHITE
WIRE, HEAT EXCHANGER ............................... 1 ............. BLUE
HOLDER, FUSE
FUSE 25 AMP
CONNECTOR
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
28
29
30
1
1
2
WIRE - 1.5M ....................................................... 1 ............. RED
TERMINAL CONNECTOR 3.8”
STARTER CONDUCTOR CABLE
SHIELD, CABLE
WIRE, PUMP ...................................................... 1 ............. BLUE
PUMP WIRE
CONNECTOR
PUMP CONDUCTOR CABLES
TERMINAL CONNECTOR .................................. 2 ............. BLUE
CABLE, SOLENOID ........................................... 1 ............. RED
CABLE, SOLENOID ........................................... 1 ............. WHITE
CABLE, SOLENOID CONDUCTOR
CABLE, PROXIMITY SWITCH
FUSE 25 AMPS
1
1
1
1
2
1
1
2
1
1
2
BLOCK FUSE
FUSE TERMINAL
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 111
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ST-45HRM CE CONCRETE PUMP— ACCUMULATOR ASSY.
ACCUMULATOR ASSY.
PAGE 112 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— ACCUMULATOR ASSY.
ACCUMULATOR ASSY.
NO.
34
35
36
37
38
39
40
42
43
PART NO.
EM97015
EM97016
EM9603055
3019092
PART NAME
QTY.
REMARKS
ACCUMULATOR 1 GALLON
BRACKET, ACCUMULATOR
HHCS 3/8” DIAMETER
WASHER, FLAT 3/8”
WASHER, LOCK 3/8” DIAMETER
FITTING
1
1
2
2
2
1
1
1
1
0166A
EM509425
EM509353
EM98009
509372
ELBOW
ACCUMULATOR REPAIR KIT
HOSE, ACCUMULATOR
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 113
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ST-45HRM CE CONCRETE PUMP— MANIFOLD ASSY.
MANIFOLD ASSY.
PAGE 114 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— MANIFOLD ASSY.
MANIFOLD ASSY.
NO.
1
2
PART NO.
EM97000
EM963610
3019092
PART NAME
QTY.
1
4
REMARKS
MANIFOLD ASSY.
BOLT 3/8”
WASHER, FLAT 3/8”
3
4
4
5
6
7
8
9
10
11
12
13
15
20
21
22
23
24
25
26
27
28
0166 A
WASHER, LOCK 3/8” DIAMETER
STRAIGHT CONNECTOR 12- 16F5X
TEST PORT
ADAPTOR, ELBOW 6801- 04- 04
TEST PORT
ADAPTOR, ELBOW
PLUG
FITTING, HYDRAULIC
ADAPTOR, ELBOW
ADAPTOR, ELBOW
STRAIGHT CONNECTOR 12- 16F5X
ADAPTER
CARTRIDGE, PILOT RELIEF
SOCKET HEAD 3/8”-NCx2.5”
SOCKET HEAD 1/4”-NCx2.25”
SOCKET HEAD 10-NCx2”
DIRECTIONAL CONTROL VALVE
PILOT VALVE
4
1
3
2
2
1
1
4
1
1
2
1
1
8
4
4
EM25462
EM98018
EM25429
EM98015
EM25429
EM98006
EM25498
EM509352
EM509353
EM25462
EM509398
EM97010
EM50932
EM196
EM508804
EM97011
EM97002
EM97013
EM97008
1
1
1
1
DIRECTIONAL CONTROL VALVE
CARTRIDGE, UNLOADING VALVE
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 115
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ST-45HRM CE CONCRETE PUMP— REMIXER CONTROL ASSY.
REMIXER CONTROL ASSY.
PAGE 116 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— REMIXER CONTROL ASSY.
REMIXER CONTROL ASSY.
NO.
22
23
24
25
26
27
28
30
32
33
PART NO.
EM97017
EM218
EM923343
492553
EM25507
EM512655
506195
EM25563
EM98012
EM98015
PART NAME
QTY.
REMARKS
VALVE REMIX W/LEVER
BOLT 5/16”- 18 X 2, 1/2HXHDCS
WASHER, LOCK 5/16” DIAMETER
NUT, HEX 5/16” DIAMETER- NC
FITTING, 90°
1
2
2
2
1
2
2
1
1
1
ADAPTER
FITTING, 90°
TEE, CUSTOM
ADAPTER GAUGE
COUPLING, TEST PORT
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 117
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ST-45HRM CE CONCRETE PUMP— BATTERY ASSY.
BATTERY ASSY
PAGE 118 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— BATTERY ASSY.
BATTERY ASSY
NO.
1
2
3
4
PART NO.
34506
6109100
EM16738
EM16707
EM509105
PART NAME
QTY.
REMARKS
BATTERY BOX
1
1
1
1
1
BATTERY HOLD-DOWN STRAP
BATTERY
CABLE, BATTERY NEGATIVE
CABLE, BATTERY POSITIVE
5
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 119
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ST-45HRM CE CONCRETE PUMP— LUBRICATION PANEL
GREASE POINTS
Grease daily, two or three hots
of #2 multipurpose automotive
grease. Over greasing any
NOTE
bearing will not damage the
machine.ALWAYS grease
before and after pump
operation.
POSITION
LOCATION
LENGTH OF LINES
A ................................................. PIVOT BRACKET GREASE POINT ................................. 41 in. (1.04 m)
B ................................................. AXLE CRANK GREASE POINT....................................... 34 in. (.86 m)
C................................................. SWING AXLE BUSHING GREASE POINT...................... 26 in. (.66 m)
PAGE 120 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— LUBRICATION PANEL
GREASE POINTS
NO.
1
2
3
4
5
6
PART NO.
EM491701
EM208812
EM510684
EM510486
EM510487
TBD
PART NAME
QTY.
REMARKS
GREASE FITTING
CONNECTOIR
CONNECTOR
3
2
3
1
1
1
HOSE, PLASTIC
HOSE, PLASTIC
HOSE, STEEL
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 121
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ST-45HRM CE CONCRETE PUMP— CONTRL. BOX INTERIOR DOOR ASSY.
CONTROL BOX INTERIOR DOOR ASSY.
PAGE 122 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— CONTRL. BOX INTERIOR DOOR ASSY.
CONTROL BOX INTERIOR DOOR ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM97050
EM97048
EM97027
EM97078
EM98001
EM98002
EM40711
TBD
PART NAME
QTY.
2
1
3
6
1
19
1
REMARKS
RELAY , SMALL
RELAY, LARGE
SOLENOID, 12VOLT
FUSE, 15 AMP
DIODE, 6 AMP
DIODE
SWITCH, EMERGENCY CYCLE
NUT
4
9
TBD
CONNECTOR
4
1
1
1
10
12
13
EM97068
EM97049
52016
REMOTE CONTROL RECEPTACLE
BASE, SOCKET
RELAY
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 123
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX MOUNTING ASSY.
CONTROL BOX MOUNTING ASSY.
PAGE 124 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX MOUNTING ASSY.
CONTROL BOX MOUNTING ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
35
36
37
38
39
40
492366
EM510703
2105164
EM503112
3019092
EM969013
SCREW HHC 5/16-18x1-1/2
SHOCK MOUNT
NUT 3/8 IN. .......................................................4...............REPLACES 492582
BOLT HHC 3/8-16x2-3/4
FLAT WASHER..................................................4...............REPLACES 492598
NUT ...................................................................2...............REPLACES 492583
4
4
2
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 125
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 126 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM25704
EM97063
EM97039
EM97041
EM97062
EM97028K
EM97028
EM97030
EM97036
EM97045
EM97032
EM97073
EM98039
PART NAME
QTY.
1
1
3
3
1
1
1
1
1
1
2
1
REMARKS
TACHOMETER
EMERGENCY STOP SWITCH
LENS, BATTERY, OIL FILTER, AIR FILTER
CONTACT BLOCK
HOUR METER
KEY, IGNITION
IGNITION SWITCH W/ KEY
DIRECTIONAL CONTROL SWITCH
PUMP CONTROL SWITCH
OPERATION PUMP/ENGINE SWITCH
SWITCH, FAN CONTROL, TEST FUNCTION
CONTROL BOX ASSY, COMPLETE
PANEL, FACE
9
10
11
12
13
1
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 127
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX DOORWIRING
PAGE 128 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX INTERIORWIRING
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 129
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ST-45HRM CE CONCRETE PUMP—TERMINAL BLOCKWIRING DIAGRAM
PAGE 130 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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NOTE PAGE
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 131
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX ELECT. DIAGRAM
PAGE 132 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX ELECT. DIAGRAM
BLK 32
WHT
TB1-12
+
FAN
OFF
ON
MOTOR
TEST
SOL
BLK 31
4
3
SW5
TB1-13
D13
TB1-14
TB1-15
UNLOAD
SOL
BLK 32
BLK 33
PRESS TEST
D14
D15
OFF
ON
PRESS
TEST
SOL
3
4
SW2
TB1-16
TB1-22
K5
9
5
8
K5
BLK 38
12
REV
SOL
DIRECTION
FWD
CONTROL
OFF
D12
REV
ON
REM
TB1-23
BLK 32
BLK 37
4
3
2
1
SW4
TB2-8
D17
OPERATION
PUMP ENG
3
3
4
4
BLK 57
TB2-9
BLK 50
13
14
BLK 41
K3
D16
K5
2
1
SW6
SW3
D19
(REFER TO LOCATION B7)
TB2-10
13
14
REMOTE CONTROL
D20
J1
REV
ON
FWD
WHT
BLK 49
GRN 56
BLK 48
GRN
BLK
PUMP
0FF
SHEET 2 OF 2
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 133
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ST-45HRM CE CONCRETE PUMP— CONTROL BOX ELECT. DIAGRAM
EXISTING HATZ ENGINE
WIRING
MAYCO WIRING
TB1
14
33
17
52
2
3
4
5
6
7
9
10
11
30
12
31
13
15
33
16
20
36
21
22
0
23
38
1
8
18
35
19
[0]
[0]
[0]
[1]
[2]
[22]
[3]
[0]
0
0
0
0
0
0
D+
B+
W
2
ALT
AIR
FILT
SW
ENG
OIL
PRES
SW
STRTR
B
A
SOL
50
COOL
FAN
MOTOR
PRESS
TEST
SOL
HYD
PRESS
COMP
UNLOAD
SOL
PILOT
VALVE
SOL
PILOT
VALVE
SOL
1
0
3
7
TB1
FUSE
LINK
GROUND TERMINAL
BUS BAR
ACS SUPPLIED
28
24
39
25
26
27
29
30
31
42
40
34
0
0
0
34
BRN
MAGNETIC VALVE
START - STOP
10 GA RED
PROX SWITCH
ROD -BACK SIDE
PROX SWITCH HEAD -
FRONT SIDE (ENG -SIDE)
HI THROTTLE
SOL
A3
A4
1500
500
2500
3000
3
1000
4000
5000
10 GA WHITE
0
LHA
0
LHA
ACCUMULATOR
PRESSURE GUAGE
PUMPING
PRESSURE GUAGE
0-3000 PSI
0-5000 PSI
BULKHEAD
FITTINGS
NOTES:
1. HATZ ENGINE WIRES ARE IN [ ] BRACKETS
2. ALL MAYCO WIRES ARE CONNECTED TO TB1
3. GROUND WIRE SUPPLIED WITH CONTROL
PANEL. CONNECTION MADE INSIDE PANEL
TO MOUNTING HARDWARE. SCAPE PAINT
TO ENSURE GROUND INTEGRITY.
HYD LINE FROM
PUMP PRESS
HYD LINE FROM
ACCUM PRESS
PAGE 134 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE— HYDRAULIC DIAGRAM
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 135
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ST-45HRM CE— OPTIONAL RADIO CONTROL
PAGE 136 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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ST-45HRM CE—TAIL LIGHTSWIRING DIAGRAM
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 137
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TERMS AND CONDITIONS OF SALE — PARTS
Effective:October 1, 2002
PAYMENTTERMS
5. Parts must be in new and resalable
condition,intheoriginalMultiquippack-
age (if any), and with Multiquip part
numbersclearlymarked.
Rebatesforpricedeclinesandaddedcharges
forpriceincreaseswillnotbemadeforstock
onhandatthetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
Multiquipreservestherighttoquoteandsell
directtoGovernmentagencies,andtoOrigi-
nal Equipment Manufacturer accounts who
useourproductsasintegralpartsoftheirown
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifest has been obtained from the carrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
a. Obsolete parts.(If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
priortothereturndate.
A$35.00surchargewillbeaddedtotheinvoice
forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
turedbyMultiquip.Suchwarrantiesmadein
connectionwiththesaleofnew,completeunits
aremadeexclusivelybyastatementofwar-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnotauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification,pending
instructions. If a reply is not received
within five days, the material will be
returnedtothesenderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. Incaseswhereanitemisaccepted,for
which the original purchase document
cannotbedetermined,thepricewillbe
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cific date and all orders received on or after
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All that date will be billed at the revised price.
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 138 — MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04)
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MAYCO PUMPWARRANTY
Mechanical Drive Models
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 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.
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 its performance,
nor to normal service or maintenance or where blockages have
developed within the pump manifold or placing line or which
has been operated in any other manner not recommended by
the Manufacturer.Due to the abrasive nature of concrete, Mayco
does not cover natural component wear.
This warranty 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 OFTHE FAILURE OF ANY PUMP
OR PART TO OPERATE PROPERLY, INCLUDING ANY
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
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 OFTHE FAILURE OF ANY PUMP
OR PART TO OPERATE PROPERLY, INCLUDING ANY
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
MAYCO ST-45HRM CE PUMP — OPERATION & PARTS MANUAL — REV. #0 (02/23/04) — PAGE 139
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OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS/SERVICE/WARRANTY
LANCASHIRE, OL7 OLT
UNITED KINGDOM (UK) CALL:
PHONE: 161-339-2223
FAX:
161-339-3226
MULTIQUIP (UK)
HANOVER MILL
FITZROY STREET
ASHTON-UNDER-LYNE
LANCASHIRE, OL7 OTL
UNITED KINGDOM
PH. 0161-339-2223
FAX. 0161-339-3226
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