Multiquip Heat Pump ST 45HRM CE User Manual

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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