OPERATIONS & PARTS MANUAL
SERIES
MODEL ST-45HRM
STRUCTURAL CONCRETE PUMP
(HATZ DIESEL ENGINE)
FINAL REVISION
Revision #4 (07/16/04)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
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HERE'S HOW TO GET HELP
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-537-3927
Email: mq@multiquip.com
Internet:www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
MAYCO PARTS
800-306-2926
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX:310-537-4259
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
FAX:310-631-5032
FAX:310-537-1173
WARRANTYDEPARTMENT
800-421-1244,EXT.279
310-537-3700,EXT.279
© COPYRIGHT 2004, MULTIQUIP INC.
Multiquip Inc, the MQ logo and the Mayco logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or
altered without written permission.All other trademarks are the property of thier respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and
should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the Mayco ST-45HRM w/ Hatz Diesel Engine. Illustrations, descriptions, references and technical data contained in this
manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change
specifications, design or the information published in this publication at any time without notice and without incurring any obligations.
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 3
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TABLE OF CONTENTS
PARTS ILLUSTRATIONS
MAYCO ST-45HRM
STRUCTURAL CONCRETE
PUMP
Explanation Of Code In Remarks Column ..............64
Suggested Spare Parts ...........................................65
Appendix — Recommended
Proposition 65 Warning .............................................2
Here’s how To Get Help.............................................3
Table of Contents ......................................................4
Parts Ordering Procedures ...................................... 5
Pump Specifications..................................................6
Engine Specifications ................................................7
Dimensions .............................................................. 8
Safety Message Alert Symbols .......................... 9-10
Rules for Safe Operation................................... 11-13
Operation and Safety Decals ............................ 14-15
Important Hand Signals ..........................................16
General Information .......................................... 17-18
How it Works............................................................19
Pump Components ........................................... 20-21
Control Box Components ........................................22
Engine Components ...............................................23
Operating Procedures....................................... 24-28
Inspection.......................................................... 29-31
Initial Start-Up Procedure ................................. 32-35
Towing Guidelines ............................................. 36-37
Trailer Safety Guidelines ................................... 38-40
Towing Information ............................................ 41-42
Wiring Diagram (Tail Lights)....................................43
Maintenance (Pump) ........................................ 44-52
Hydraulic Hose Connections............................. 54-56
Manifold Port Locations...........................................57
Appendix — Concrete Mix Information ............. 58-59
Appendix — Slump Test Procedure ........................60
Troubleshooting (Engine)........................................61
Troubleshooting (Hydraulic System) .......................62
Troubleshooting (Electrical System) .......................63
Troubleshooting (Brake System).............................64
Shotcrete System ............................... 66
Appendix — Recommended
Shotcrete Accessories........................ 68
Decal Placement ................................................70-71
Axle Assembly ....................................................74-75
Brakeline Assembly............................................76-77
Hopper Assembly...............................................78-79
Hopper Attachment Assembly ...........................80-81
Hopper Interior Assembly ..................................82-83
Shuttle Cylinder Assembly .................................84-85
Fuel and Hydraulic Tank Assembly ....................86-89
Front Cover Assembly........................................90-91
Heat Exchanger Assembly.................................92-93
Engine and Frame Assembly .............................94-96
Throttle and Water Filter Assembly....................96-97
Hydraulic Pump Assembly .................................98-99
Lubrication Pistons Assembly ........................100-101
Electrical System Assembly ...........................102-103
Accumulator Assembly...................................104-105
Manifold Assembly .........................................106-107
Remixer Control Assembly.............................108-109
Battery Assembly ...........................................110-111
Lubrication Panel ...........................................112-113
Taillight Assembly...........................................114-115
Control Box Interior Door Assembly...............116-117
Control Box Mounting Assembly ...................118-119
Control Box Assembly ...................................120-121
Control Box Door Wiring Diagram ......................... 122
Control Box Interior Wiring Diagram ..................... 123
Terminal Block Wiring Diagram ............................. 124
Control Box Electrical Schematic ...................125-126
Interconnect Hydraulic Control Box ...................... 127
Hydraulic Diagram ............................................... 128
Optional Radio Control.......................................... 129
NOTE
Specification and part
number are subject to
change without notice.
Terms and Conditions Of Sale — Parts ................ 130
Mayco Pump Warranty .......................................... 131
PAGE 4 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
❒
❒
❒
❒
❒
❒
Dealeraccountnumber
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to ship
“Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: mq@multiquip.com
Internet: www.multiquip.com
800-421-1244
FAX: 310-537-3927
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Standard
orders
Stock orders
PARTS DEPARTMENT
800-427-1244
310-537-3700
MAYCO PARTS
800-306-2926
310-537-3700
SERVICE DEPARTMENT
800-421-1244
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-421-1244, EXT. 279
310-537-3700, EXT. 279
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 800-672-7877
FAX: 310-637-3284
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-537-4259
FAX: 310-631-5032
FAX: 310-537-1173
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MULTIQUIP INC.
Direct TOLL-FREE access
to our Parts Department:
18910WILMINGTONAVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX:310-537-3927
Toll-free nationwide — 800-427-1244
E-MAIL:mq@multiquip.com
INTERNET:www.multiquip.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 5
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ST-45 PUMP — PUMP SPECIFICATIONS
Table 1. ST-45 Pump Specifications
Pumping Method
Pumping Rate
Reciprocating Piston
Up to 45 cu. yds. per hour*
1-1/2 in. minus (38mm)
Maximum Aggregate Size
Vertical Pumping Height
Horizontal Pumping Distance
Cylinder Lubrication Box Capacity
Hydraulic Fluid Capacity
Fuel Tank Capacity
Up to Excess of 250 ft. (76m)
1000 ft. (305m)*
7 Gallons (26.5 Liters)
58 Gallons (219 Liters)
20 Gallons (76 Liters)
Hopper Capacity
10 cu. ft. with optional fwd/rev remixer
3 in., 4 in., 5 in. dia.
(76.2mm, 101.6 mm, 127 mm)
Material Hose
Remote Control (25 ft. cable)
Dimensions
optional
See Page 16
Weight (with fluids)
Weight (dry/shipping)
Tire Size
4,206 lbs. (9,274 kg)
4,040 lbs. (8,908 kg)
7.35 in. x 14 in. (187 mm x 356 mm)
* Volume output will vary depending on mix design, slump, line size used and job site condititons
PAGE 6 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — ENGINE SPECIFICATIONS
Table 2. Engine Specifications
Model
HATZ 3M41 57HP DIESEL ENGINE
4.02 in. x 4.13 in.
(102 x 105 mm)
Bore X Stroke
Compression Ratio
Displacement
18.7
157 cu. (2,573 cc)
Lube Oil Capacity
Max/Min
9.1 qt. / 5.4 qt.
(8.6 L / 5.1 L)
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
562 lbs (255 kg)
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 7
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ST-45 PUMP — DIMENSIONS
TABLE 3. DIMENSIONS
REF.
DIMENSIONS
45 in. (114.3 cm.)
162 in. (411.5 cm.)
24 in. (61 cm.)
A
B
C
D
E
73 in. (185.4 cm.)
68 in. (172.2 cm.)
Figure 1. ST-45 Structural Concrete Pump Dimensions
PAGE 8 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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-45 Structural Concrete pump.
Refer to the engine manufacturers
instructions for data relative to its safe
operation.
Explosive Fuel
Before using this 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.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 9
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ST-45 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.
PAGE 10 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 ST-45 structural concrete ump:
■
NEVERtouchthehotexhaustmanifold,
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.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 11
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ST-45 PUMP — RULES FOR SAFE OPERATION
Transporting
■
■
■
ALWAYS remove the ignition key when leaving the pump
unattended.
■
ALWAYS shutdown engine before transporting the pump.
■
Tighten fuel tank cap securely and close fuel valve to prevent
fuel from spilling.
ALWAYS block the wheels on the unit when using on a
slope.
■
Drain fuel when transporting pump over long distances or
bad roads.
ALWAYS maintain this equipment in a safe operating
condition at all times.
Towing
■
■
ALWAYS stop the engine before servicing, adding fuel or oil.
■
■
■
■
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.
Tow only with a vehicle and hitch rated to pull a 5,000 lbs.
load.
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.
If unit is equipped with ball hitch coupler, use only 2" all steel
ball rated for minimum of 5,000 lbs. Use 1" hardened steel
pull pin, if not equipped with ball hitch.
■
■
■
■
■
DO NOT operate this equipment unless all guards and safety
devices are attached and in place.
■
This equipment shall not be towed or operated by individuals
who cannot read understand the signs, decals or operating
instructions.
CAUTION must be exercised while servicing this equipment.
Rotating and moving parts can cause injury if contacted.
Keep all inexperienced and unauthorized people away
from the equipment at all times.
■
■
■
■
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.
Before start-up, check the hopper and remove all foreign
matter and debris.
DO NOT use worn or damaged hose couplings, inspect all
hoses and couplings for wear.Replace any worn or defective
hose or couplings immediately.
DO NOT tow unit in excess of 45 MPH on highways..
Maintenance Safety
■
■
■
Keep hands out of the hopper when the engine is running.
■
NEVER lubricate components or attempt service on a running
pump .
DO NOT operate unit with the hood open.
■
ALWAYS allow the pump a proper amount of time to cool
DO NOT disconnect hose couplings or nozzle while under
pressure. Relieve pressure by manually activating pressure
relief valve at manifold.
before servicing.
■
■
Keep the pump in proper running condition.
■
■
■
■
Unauthorized equipment modifications will void all
warranties.
Fix damage to the pump immediately and always replace
broken parts.
Check all fasteners periodically for tightness. Also check
towing tongue bolt, lock nut and wheel lug nuts for wear.
■
■
Dispose of hazardous waste properly.Examples of potentially
hazardous waste are used motor oil, fuel and fuel filters.
Test the pump's ON/OFF switch.The purpose of this test is
to shut down the engine.
DO NOT use plastic containers to dispose of hazardous
waste.
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.
PAGE 12 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 13
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ST-45 PUMP — OPERATION AND SAFETY DECALS
Machine Safety Decals
The ST-45 structural concrete pump is equipped with a number of safety decals.These decals are provided for operator safety and
maintenance information. Figure 1 below illustrates these decals as they appear on the machine. Should any of these decals
become unreadable, replacements can be obtained from your dealer.
Figure 2. ST-45 Operation and Safety Decals
PAGE 14 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — OPERATION AND SAFETY DECALS
Figure 3. ST-45 Operation and Safety Decals
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 15
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ST-45 PUMP — IMPORTANT HAND SIGNALS
Figure 1 display's the basic hand signals commonly used in concrete pumping operations.
Figure 4 Operation Hand Signals
PAGE 16 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 24-28).
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 17
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ST-45 PUMP — GENERAL INFORMATION
5. The proper amount of water to make a workable slump and
plasticize the mix.
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.
In addition, the Mayco Structural Concrete ST-45 Pump can be
used to pump a large aggregate hard rock as follows:
1. Pea rock (1/2" minus) pump with mixes being as low as 30%
rock and 70% sand. (See page 44, for comments on cleaning
the pump.)
It is impossible to define a specific mix for each region that the
Model ST-45 be will working in.Therefore, the mixes on pages
58-59 will provide a basic guideline for establishing the proper
mix design for your area.
2. Shortening pea rock when used with an air compressor
and nozzle.(See back pages for recommended set-up.)
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.
3. “Mud Jacking”, high pressure grouting.
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:
500 lbs. of cement/cu yd for 2500 p.s.i. concrete after 28
days.
530 lbs. of cement/cu yd for 3000 p.s.i. concrete after 28
days.
600 lbs. of cement/cu yd for 4000 p.s.i. concrete after 28
days.
4. Admixture pump-aid if necessary.
PAGE 18 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 19
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ST-45 PUMP — PUMP COMPONENTS
PAGE 20 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — PUMP COMPONENTS
Figure 7 illustrates the location of the major components
for the ST-45 Structural Concrete Pump. The function of
each component is described below:
13. Lubrication Panel – This console allows for the remote
lubrication of components on the pump.
14. Rear Running Lights – ALWAYS check and make sure
both the right and left running lights are functioning correctly
before towing the pump.
1. Tow Hitch Coupler – Requires a 2-inch ball hitch or a
3-inch pintle. Capable of towing 5,000 lbs.
2.
Documentation Box – Contains engine and pump
operation, parts and maintenance information.
15. Accumulator – Stores hydraulic oil under pressure and
releases it to the shuttle cylinder and provides the
required pressure to activate the hydraulic system.
3. Hydraulic OilTank/Cap– Remove cap to add hydraulic
fluid. Fill with Shell Oil Tellus 68 or Mobil Oil DFE26 if
level is low.
16. Remixer Control Lever – Controls the forward/reverse
motion of the hopper remixer paddles.
4.
FuelTank/Cap – Fill with diesel fuel.Fuel tank (cell) holds
approximately 20 gallons (88 liters). DO NOT top off fuel.
Wipe up any spilled fuel immediately
17. Manifold – Aluminum block that controls the flow of
hydraulic pressure to the various hydraulic motors and other
components required to control the pump.
5. Battery –This unit uses a +12VDC type battery.ALWAYS
18. Hydraulic Pump – This unit incorporates an axial variable
use gloves and eye protection when handling the battery.
displacement hydraulic piston pump.
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.
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.
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..
8.
9.
Tires — This trailer uses two ST205-750 x14C type tires.
Tire inflation pressure is the most important factor in tire
life. Pressure should be checked to 50 psi 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.
20. StrokeVolume Control Dial – Turns CW/CCW to increase
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 page 22 for
components.
22. Tow End Jack Stand – Use this jack stand to level and
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.
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 1750
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 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.
12. Remixer Motor – Drives the remixer paddles inside
the hopper. The motor direction is controled by the
remixer control lever.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 21
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ST-45 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
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 inTable 4, page 30.
9. V-Belt Cover – Remove this cover to gain access to theV-
belt.When replacingV-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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 23
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ST-45 PUMP — OPERATING PROCEDURES
C. Ifitisnecessarytowait10minutesormoreforanother
loadofconcrete,itiswisetostartthepumpandpump
OPERATING SUGGESTIONS
1. Awell-plannedlocationofthepumpandroutingofthehose
beforestartingapourmaysavesubsequentmovesthrough-
out the job.
6or8strokesevery5minutestopreventsettingofthe
mixinthesystem.Ifwaitingtimeisexcessive,itwould
bewisetowashoutthepumpandhosesandstartover
when the new truck arrives.
2. Beforeconcreteisdischargedintothehopper,itissuggested
that 3 to 4 gallons of water be sprayed into the hopper,
followedbyapproximately5gallonsofacreamycementand
water slurry (1/2 bag of cement to 5 gallons of water).This
procedurelubricatesthehoseandpreventsseparationand
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
starting only.
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, long pushes, that a 2 -1/2” line be used as
faraspossible.Theadvantagesofusingthe2-1/2”line
areimprovedpumpability,lesspumpingpressureand
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.
PAGE 24 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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
used as an accelerator. When pumping a load with
calciumchloride, itisrecommendedthatyouwashout
ifthewaitingtimebetweendeliverytrucksbecomestoo
long.
truck into a brick wall, something is going to
be damaged.The same holds true with your
concrete pump. If you repeatedly pull the
throttle all the way out and try to force your
pump to push through blockages due to
D. Super Plasticizers – acts as an accelerator.The
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.
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.
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 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 25
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ST-45 PUMP — OPERATING PROCEDURES
C. Mix the prime to the consistency of a smooth batter.
16. Theshuttletubeispluggedifvolumeatthedischargeendof
thehosestops,the hoseissoftandthehydraulicoilpressure
gauge reads 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 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 5 gallons of
water per 25 foot length, before adding it to the system.
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 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 (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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — OPERATING PROCEDURES
D. Carefully knock the end of the hose away from the
If, for any reason, the mix should set up in the system, the
following procedure (E through H) is suggested:
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 24" pry bar.
Forexample:Ifyouhad200ft.ofsystemout,youwould
disconnect each hose. Clean it out by pushing water
through the first hose off the pump, then continue
progressing through all the hoses, until all the system
is clean.
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 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.
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.
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 :
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.
A. How old is the concrete?
B. Isthereanaccelerator,calciumchloride,redlabel,etc.,
in the concrete?
C. The temperature of the day, 80, 90, degrees?
The use of stiffer mixes when pumping down-hill will de-
creasegravityflowofthematerialinthehoseandwillassure
a smoother operation between the cam roller bearing and
cam plate.As with any job, make sure that the hose and the
couplings are in good workable shape.
D. Howmuchsystemyouhaveoutandhowstiffwasthemix
you were pumping?
When disconnecting hoses, use
19. VerticalPumping– Whenpumpingverticallyupthesideof
a building, above 40 feet, we would recommend the instal-
lationofsteelpipesecurelyfastenedatintervalsasnecessary
tosupportthepipe.Ninetydegree,longradiuspipesweeps
should be installed at the top and bottom of the steel line.
EXTREME CAUTION! The hose is
under pressure!
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 27
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ST-45 PUMP — OPERATING PROCEDURES
Use a 25 ft.hose, or short section, off the pump;and for the
entire drive system and valving under simulated full load
conditions.Thepumpownercandothesamebymakingan
adaptertocoupletotheendofthedischargecone:e.g.,the
use of a standard 2" pipe cap with a 3/8" drilled hole in the
center, screwed on to the end of hinged cone or reducer at
thepump.
balance of the horizontal distance to the vertical line, use
steel pipe.This type of installation has been satisfactory on
many jobs being pumped in excess of 100 feet high. Line
pressures are always less using steel pipe as compared to
hose.
Whenpumpingvertically,usingallhose,itisrecommended
not to go higher than 50 feet with hose.The hose should be
tied off at intervals of 10 feet, if possible. Special attention
shouldbegivenwhentieingthehoseoffatthetopasthehose
willhaveatendencytostretchwhenfilledwithconcrete.This
willincreasethepossibilityofablockageatthepointwhere
the hose is tied off.To avoid this, a long radius of 90 degree
elbowisrecommended.Thesuggestedplacetotieoffison
the hose, under the clamp.
Fillhopperwithwateraftermakingsurethatallsandandrock
have been removed from manifold. Operate pump at full
throttle and the 3/8" diameter hole restriction will create
sufficient back pressure to make thorough inspection of all
movingparts.
It is strongly recommended that
steel pipe be used on all vertical
pumping for safety and conve-
nience.
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.
Theuseof2-1/2”I.D.hoseintheseextremecasesreduces
linepressuresortheadditionofslightamountsofwatertothe
mix, if permissible, will permit easier pumping.The use of
certain pumping admixtures may help.
Ifexcessivepulsationexistsinthehose,itisadvisabletouse
burlaporsomemeansofwearprotectionunderthehoseat
pointswherethehosemaywearthroughtheoutercover;e.g.
overforms, steelorsharpcurbs.
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”at
thefactoryThisprocedurepermitsathoroughinspectionof
PAGE 28 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 make
while the engine is running. ALWAYS shut-down the engine
before performing any kind of maintenance service on the pump.
NEVER operate the pumps's engine with the
engine hood removed.The possibility exists of
hands, long hair, and clothing becoming
entangled with the V-belt, causing injury and
bodily harm.
See Figures 5 & 6 on pages 20-22 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 29
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ST-45 PUMP — INSPECTION
ENGINE OIL CHECK
12 The oil listed in Table 47 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/engine 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.
PAGE 30 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — INSPECTION
14. If the hydraulic oil level is low, remove the cap just above the
oil level sight glass (Figure 15) and add the correct amount
of hydraulic oil to bring the hydraulic oil level to a normal
safe operating level. (Use Shell oil Tellus 68 or Mobil oil
DFE26).
16. Remove the cotter pin from the handle tee bolt eye, and
then pull the handle tee to release the stabilizer stand
(Figure 17).
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 31
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ST-45 PUMP — INITIAL START-UP PROCEDURE
IGNITION SWITCH
Starting
3. To start the engine, insert the key (Figure 20) into the ignition
switch and turn the key to the ON position.
CAUTION :
DO NOT attempt to operate this concrete
pump until the Safety, General Information
and Inspection sections have been read
and understood.
EMERGENCY STOP SWITCH
1. Locate the Emergency Stop Switch (Figure 19) on the
Hydraulic Pump Control Box. Use this switch in the event of
a emergency.
Figure 20. Ignition Switch
4. Observe that the Batter,Air Filter and Oil Pressure status
indicator lights are “ON” (Figure 21).
OIL
AIR FILTER
BATTERY
PRESSURE
Figure 19. Emergency Stop Switch
2. Turn the Emergency Stop switch counter-clockwise (open).
This will allow the engine to start.
Figure 21. Status Indicator Lights
A. Turn the key to the “START“ position and listen for the
engine to start.
B. In warm weather let engine warm-up for 5 minutes. In
cold weather let engine warm-up for 10 minutes.
If the Emergency Stop switch is in the
“CLOSED” position (stop), engine will
not start. To start the engine, make
sure the Emergency Stop switch is in
the “OPEN” position (fully extended).
C. The Air Filter,Oil Pressure and Battery indicator lights
(Figure 21) should all be “OFF”.
The battery indicator light may remain
on if the engine is idling, or on some
models of the ST-45. Increasing the
engine RPM’s slightly should correct
the problem.
Place all switches on the Hydraulic
Control Box in the ”OFF” (up position).
CAUTION :
If any of the status indicator lights referenced
in the ignition section (step 4) remain “ON”,
turn off the engine and correct the problem.
DO NOT continue to run the equipment.
PAGE 32 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — INITIAL START-UP PROCEDURE
CONTROL SWITCH
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.
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. Unlock the throttle cable.To unlock the throttle cable, 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 50 to 60 degrees fahrenheit.
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 10) to the“OFF“ position.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 33
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ST-45 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
The pump should not be cycling at this
time. Only the ENGINE should be
running.
to stop. If machine exceeds 170°F or to cool the machine
down, turn the operation switch (Figure 28) back to the
“ENGINE“ position. Run engine at high RPM with cooling
fan on for 10 to 15 minutes.
PRESSURE TEST
11. While
monitoring
the
tachometer (Figure 25), use the
EngineThrottle 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 1750 pounds per
square inch (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 75 degrees
fahrenheit.
B. Turn the Operation Pump/Engine switch to the “ENGINE“
position (only the engine should be running).
CAUTION
If the hydraulic oil temperature exceeds 170
degrees fahrenheit, shut down the pump.
DO NOT continue to operate the pump.
Failure to shut down the pump will result in
severe damage to the pump.
Figure 32. Hopper Remixer Control Lever
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ST-45 PUMP — INITIAL START-UP PROCEDURE
C. Push the Hopper Remixer Control lever “DOWNWARD“
(Figure 31) and observe that the blades (Figure 33) inside
the hopper are turning in a clockwise direction (forward).
Figure 35. Handheld Remote Cable Unit
CYLINDER LUBRICATION BOX
Figure 33. Hopper Remixer Blades (Rotation)
WARNING
D. Push the Hopper Remixer Control lever“UPWARD“ (Figure
32) and observe that the blades (Figure 33) inside the
hopper are turning in a counter-clockwise direction
(reverse).
Before checking lubricaton level, stop the
engine and remove the engine starter key.
We recommend using soluble type oil (water
& oil mixture). The oil level should be
checked every day prior to pumping. The oil
level should be maintained at a height of 5
inches or about ½ the concrete cylinder
height.
OPTIONAL RADIO REMOTE CONTROL
14. The MAYCO ST-45 Concrete Pump has a remote control
feature that allows the pump to be remotely controlled. If
desired, the pump can be operated via a receiver/transmitter
method (Figure 34) or a hardwire method, which utilizes a
25-ft.extension cable.The manual remote cord (Figure 35)
should be installed under the main control box. Contact
your MAYCO representative for further information.
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 ½ inch from the bottom.The box
should be drained and cleaned.To clean, remove the drain
plug located at the bottom of the box.
Once the box is drained, start the 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 35
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ST-45 PUMP —TOWING GUIDELINES
Towing Safety Precautions
■
Check wheel mounting lug nuts with a torque wrench.
Torque wheel lug nuts as described in the "Lug NutTorque
Requirements",Table 7.
CAUTION
■
■
■
Make sure brakes are synchronized and functioning properly.
Check tightness of suspension hardware (nuts and bolts).
■
Check with your county or state safety
towing regulations department before
towing your concrete pump.
Avoid sudden stops and starts.This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
To reduce the possibility of an accident while transporting the
pump on public roads, always make sure that the trailer and
the towing vehicle are in good operating condition and both
units are mechanically sound.
■
■
■
Avoid sharp turns to prevent rolling.
Retract wheel stand when transporting.
DO NOT transport pump with fuel in the fuel tank.
The following list of suggestions should be used when towing
the pump:
CAUTION
If the trailer coupler is deformed replace
entire coupler. NEVER tow the pump with
a defective trailer coupler.There exist the
possibility of the trailer separating from the
towing vehicle.
■
Make sure that the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow the light tower's trailer with defective hitches, couplings,
chains etc.
PumpTrailerVehicle Connection
■
■
■
■
CHECK the tire air pressure on both the towing vehicle and
the trailer.Also check the tire tread wear on both vehicles.
1. Check the vehicle hitch ball, and trailer coupler for signs of
wear or damage. Replace any parts that are worn or
damaged before towing.
ALWAYS make sure the trailer section of the pump is
equipped with a "Safety Chain".
2. Use only the 2-inch ball diameter with a towing capability of
5,000 lbs. (2,268 kg) as indicated on the trailer's coupler.
Use of any other ball diameter will create an extremely
dangerous condition which can result in separation of the
coupler and ball or ball failure.
ALWAYS attach trailer's safety chain to frame of towing
vehicle.
ALWAYS make sure that the vehicle and trailer directional,
backup, brake, and trailer lights are connected properly and
are working properly.
3. Be sure the coupler is secured to the hitch ball and the lock
lever is down (locked).
■
Remember in most cases the maximum speed unless
otherwise posted for highway towing is 45 MPH, however
before towing your pump, check your local state, and county
vehicle towing requirements. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of terrain.
4. Attach safety chains as shown in Figure 36. Remember to
cross the safety chains.
5. After towing for about 50 miles recheck the entire towing
system for tightness.
■
■
Place chocked blocks underneath wheel to prevent rolling,
while parked.
Recommended Maintenance
1. Smear ball socket and clamp face with chassis grease.
Periodically oil pivot points and were surfaces of coupler
with SAE 30W motor oil.
Depending on soil conditions and location it may be
necessary to place support blocks underneath the trailer's
bumper to prevent tipping, while parked.
2. When parking or storing the concrete pump, keep the coupler
off the ground so dirt and other debris will not build up in the
ball socket.
■
Inflate tires to correct pressure, inspect tires for cuts, and
excessive wear.SeeTable 5 (Tire WearTroubleshooting).
PAGE 36 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP —TOWING GUIDELINES
Figure 36 shown below illustrates the typical towing
application that should be used when towing the pump.
Figure 36.Towing Applications
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 37
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ST-45 PUMP —TRAILER SAFETY GUIDELINES
8. WheelHub– Thewheelhubisconnectedtothetrailer'saxle.
Trailer Safety Precautions
9. TireRim– Tiresaremountedonatirerim.Thetirerimmust
CAUTION
match the size of the tire.
ALWAYS make sure that the trailer is in good
operating condition. Check the tires for
10. Lug Nuts – Used to secure the wheel to the wheel hub.
Alwaysuseatorquewrenchtotightendownthelugnuts.See
Table 7and Figure 38 for lug nut tightening and sequence.
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
11. Axle – This trailer employes a torsion bar type suspension,
which can support 3,500 lbs.
12. Electrical– Electricalconnectors(looms)areprovidedwith
the trailer so that brake lights and turn signal lights can be
connected to the towing vehicle. See Figure 43 for proper
wiringconnections.
This section is intended to provide the user with trailer service
and maintenance information. Remember periodic inspection of
the trailer will ensure safe towing of the equipment and will
prevent damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance
components of the trailer.The following trailer components will
be discussed in this section:
■
■
■
■
Tires
Lug Nut Torquing
Suspension
Electrical
The following list defines the major trailer components:
1. FrameLength–Thismeasurementisfromtheballhitchto
therearbumper(reflector).
3. FrameWidth–Thismeasurementisfromfendertofender.
4. Jack Stand – Trailer support device with maximum pound
requirement from the tongue of the trailer.
5. Coupler–Typeofhitchusedonthetrailerfortowing.Thisunit
employes a 2" ball.
6. TiresSize–Indicatesthediameterofthetireininches(10,
12,13,14,etc.),andthewidthinmillimeters(175,185, 205
etc.).The tirediametermustmatchthediameterofthetirerim.
This unit employes 7.35" X 14" tires.
7. TiresPly–Thetire ply(layers)numberisratedinletters;2-
ply, 4-ply, 6-ply, 8-ply, 10-ply etc.This unit employes 4-ply
tires.
PAGE 38 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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
Table 6. Suspension 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
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-50
inter-tube may cause pieces of the rim to
explode (break-off) with great force and
can cause serious eye or bodily injury.
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
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.
Suspension
The leaf suspension springs and associated components
(Figure 37) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqed suspension components
as detailed in Table 6.
Table 5 (Tire Wear Troubleshooting) will help
pinpoint the causes and solutions of tire wear
problems.
Figure 37. Major Suspension Components
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 39
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ST-45 PUMP —TRAILER SAFETY GUIDELINES
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the fasteners
matched to the cone angle of the wheel. Proper procedure for
attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 38. DO NOT
torquethewheellugnutsallthewaydown.Tighteneachlug
nut in 3 separate passes as defined byTable 7.
Table 7. Lug Nut Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
3. Afterfirstroaduse,retorquealllugnutsinsequence.Check
all wheel lug nuts periodically.
NEVER! use an pneumatic air gun
to tighten wheel lug nuts.
Figure 38. Wheel Lug NutsTightening Sequence
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ST-45 —TOWING INFORMATION
Towing Information
5. To make sure that the actuator is securely latched onto the
ball, extend the trailer tongue jack to the ground and lift the
truck and trailer combination 2" to 4". If the ball does not
disengage, the actuator is securely attached.
WARNING
6. Insert a padlock or bolt through the lock hole for added
protection.
Use jack stand to lift tongue.DO NOT lift by
hand as back injury could result.
7. Connect the break-away cable solidly to the bumper or frame
of the tow vehicle as near to the center as possible. The
cable must hang clear of the trailer tongue and be long
enough to permit short radius turns without pulling the
breakaway cable forward.
CAUTION
The ball capacity must be greater than or
equal to the trailer GVWR. Do not use a worn
hitch ball, it is unsafe and must be replaced.
USE 2" BALL ONLY
8. Make sure the breakaway cable is in a released position
with the indicator bead touching or resting against the cable
spring stop.(Figure 40).
Take care not to damage the actuator
when backing up the towing vehicle
for hook-up.
1. Position actuator ball socket above 2" ball.
2. Hold the release lever in the open position (Figure 39).
3. Lower the trailer tongue until the ball rests in the ball socket.
4. Close the release lever.
Figure 40. Trailer Hitch Release Handle
CAUTION
DO NOT use the breakaway cable as a
parking brake.
9. Cross the safety chains under the tongue and securely attach
them to the bumper or frame of the tow vehicle. Check with
local and state laws for proper compliance.
CAUTION
Figure 39. Trailer Hitch Release Lever
Safety chains must ALWAYS be used.
CAUTION
The release lever will close freely with finger
pressure when the ball is properly inserted
into ball socket. If the release lever does not
close freely, do not tow the pump. DO NOT
force the release handle into the closed
position.
Check the location of the breakaway
cable periodically during each trip. The
indicator should rest against the
spring stop.Accidental application will
cause the brakes to drag and heat up,
causing a failure.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 41
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ST-45 —TOWING INFORMATION
5. If the pump is to be uncoupled from the tow vehicle after
backing with the lever knob engaged, block all pump wheels
and pull forward slightly to take strain off of the actuator.
Uncouple the actuator by lifting the release handle and raising
the trailer tongue.Make sure the lever knob is in the “Towing
Position”when uncoupling from the trailer.
10. Retract the jack fully. Remove and store the caster, if
applicable.
11. Check for proper truck-trailer hook-up; the tow vehicle and
trailer should be level with a positive tongue load.For further
information, consult a dealer or Atwood Service Center.
12. The direction lever must be positioned in the “Towing
Position”(Figure 41).
CAUTION
Before towing the pump, always ensure that
the directional lever (Figure 41) has been
disengaged and is in the “Towing Position.”
Figure 41. Towing Hitch Direction Lever
13. Do not use the Atwood brake actuator with a sway controller,
unless prior Atwood Engineering approval of the sway
control system has been received.
14. You are now ready to tow your pump.
CAUTION
Avoid sharp turns.This could bend, create
extreme stress or fracture either the actuator
or trailer tongue.
BACKING UP
1. Refer to the previous steps 1 through 14 forTowing.
2. Before backing up a slope or through soft ground, pull the
trailer forward slightly to assure that the actuator socket is in
the fully forward position.
3. Move the directional lever on the side of the actuator
downward from the“TOWING”position along the curved slot
in the actuator frame to the“BACK-UP”position (Figure 41).
The slot has a notch at the bottom of its travel. Push the
directional lever down to engage the locking notch.
4. Back the trailer up.
PAGE 42 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — WIRING DIAGRAM (TAIL LIGHTS)
Figure 42. TrailerTail LightsWiring Diagram
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 43
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ST-45 PUMP — MAINTENANCE (PUMP)
TABLE 8. 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.
You will be required to put your hand in 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.
PAGE 44 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — MAINTENANCE (PUMP)
5. Add water to the hopper. Pump and flush clean the entire
hopper, shuttle tube and discharge elbow with water.
HYDRAULIC OIL SYSTEM MAINTENANCE
1.
When changing the hydraulic oil or topping off the reservoir,
use only the following type. (Reservoir capacity 58 gal.)
6. Scoop out 12 inches of concrete from the inboard end of the
delivery hose. “Cork screw” a 6" x 6" x 8" sponge into the end
of the first hose section. Reconnect the hose to the discharge
elbow.
Hydraulic oil: Shell Oil Tellius 68 or
Mobil DFE 26
Texaco Rand HDC
7. Fill hopper with water.Pump until sponge and clean water
come out the discharge end of the hose and line system.
The Mayco pump is equipped with an in-tank return hydraulic
filter with a 10 micron cleanable filter. The element has been
designed to remove all particles large enough to cause wear
and job break down. Under normal conditions, we recommend
replacement every 6 month.
8. When the Model ST-45 has been used to pump small
aggregate concrete (pea rock,
½" minus) 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,
page 26-27) and remove all remaining concrete.
WARNING
DO NOT mix oil brands!This may impair
quality.
9. When the Model ST-45 has been used to pump large
aggregate concrete (
step 8 once per week.
¾" to 1
½") follow the instructions in
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
NEVER use muriatic acid to clean the pump.
Acid will dissolve the chrome finish on
material cylinder bore and main hydraulic
cylinder rods.
Always run machine until oil temperature reaches a minimum of
50°F. before pumping. Damage to the main piston pump will
occur if the machine is cycled too fast before the oil temperature
reaches the minimum of 50°F.Cycle the machine at 6-8 strokes
per minute at approximately 1/3 throttle.
Use only a 2½" diameter clean-out
In areas where the weather normally remains under 50°F., use
Shell OilTellus – 46, or the equivalent.The above steps must be
followed or severe damage to the main axial piston pump will be
the end result.
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 57HP Diesel)
The ST-45 is equipped with a Model 3M41 57HP diesel engine.
For information concerning the procedure in checking, removing,
cleaning, etc.of the various engine parts or any other information
on the engine not contained herein, refer to the engine
manufacturer’s instruction manual.
Suttle cylinders
“S” tube outlet flange
GreaseType:
Lithium Based EP
Texaco Multitak 20
Lubriplate ED-2
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 45
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ST-45 PUMP — MAINTENANCE (PUMP)
BATTERY MAINTENANCE
BRAKE SYSTEM
The brake system should be periodically checked. Look for fluid
leaks worn or cracked hoses. Check the reservoir for proper fluid
levels.The Atwood surge brake should be checked for damage.
Make sure that all links and pivots are kept lubricated.
See Figure 16 for troubleshooting tips.
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, 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.
z
z
z
Always check the battery terminals periodically to
ensure that they are in good condition.
Use wire brush or sand paper to clean the battery
terminals.
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 :
DO NOT fill the master cylinder reservoir with
used brake fluid. DO NOT fill the reservoir
Wear safety glasses or face
mask, protective clothes, and
rubber gloves when working
with battery.
beyond
fluid will damage paint.
½" from top.DO NOT overfill;brake
3. Check the brake fluid level in the master cylinder reservoir.
Keep it filled to within
½" 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 43). If necessary add only distilled water in a
well-ventilated area.
Wheel bearings and seals should be
inspected and packed at this time.
Figure 43. Battery Electrolyte Levels
PAGE 46 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — MAINTENANCE (PUMP)
ST45 PRESSURE SETTING SEQUENCE
6.
On the electrical control panel, 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 3500 PSI.The reading can be taken
from the pumping pressure gauge (Figure 46).
To set maximum pump pressure:
1.
With the engine turned “OFF”, loosen the ¼” hydraulic
hose attached to the compensator valve located on
the top of the Main Delta Q Pump.
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 44. CompensatorValve
2.
3.
Loosen the jam nut located on the end of the compensator
Figure 46. Pumping Pressure Gauge
valve (Figure 44).
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 44) counter-
Turn the compensator adjustment nut (Figure 44)
clockwise until tight. Tighten the ¼” hose leading to the
compensator.
clockwise
½
turn. Tighten the
¼” hydraulic hose.
4.
5.
Start the engine and loosen the jam nut located on the
maximum relief valve cartridge (Figure 45).
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 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 (2550) and turn the
volume control knob counter-clockwise to maximum
volume position (Figure 45).
MAXIMUM RELIEF
VALVE CARTRIDGE
JAM NUT
MAIN
RELIEF VALVE
VOLUME
CONTROL
Figure 45. Hydraulic Drive Pump Manifold
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 47
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ST-45 PUMP — MAINTENANCE (PUMP)
ST45 ACCUMULATOR CIRCUIT
CYLINDER LUBRICATION BOX
DANGER
CAUTION
Before checking lubrication level, stop the
engine and remove the engine starter 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 5 inches or about ½
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 48)
charged with 1100 PSI of dry nitrogen.
The accumulator stores one gallon of
hydraulic oil, which is, under 1750 PSI
of pressure.
CLEANINGTHE LUBRICATION BOX
1. Remove the top cover and the drain plug (Figure 47) located
at the bottom of the box and fully drain the inside of the box.
2. Once the box is drained, start the engine and stroke the
Figure 48. Accumulator
cylinder (keep hands out of box) ten to fifteen times.
3. While stroking, spray water inside of the box to thoroughly
clean out all contamination (Figure 47).
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.
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 1100 PSI.To check the accumulator pressure:
1. Start the engine and stroke the pump. The accumulator
pressure gauge (Figure 29) should read 1750 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 47. Cleaning the Lubrication Box
PAGE 48 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — MAINTENANCE (PUMP)
SETTING PRESSURE INTHE ACCUMULATOR CIRCUIT
4. Loosen the lock nut for the the accumulator circuit pilot
relief valve cartridge (Figure 51), located at port G4.Using
an allen wrench, turn the adjusting screw until pressure
gauge reads 1950 PSI and tighten lock nut. Turn the engine
off and on several times to make the pressure continues to
read 1950 PSI.
1. Attach a 3000 PSI test gauge (Mayco P/N 98016) to port
G2 of the main manifold block (Figure 49).
3000 PSI
PRESSURE TEST GAUGE
P/N: 98016
PILOT RELIEF
VALVE CARTRIDGE
ADJUSTMENT
SCREW
LOCK NUT
Figure 51. Pilot Relief Valve Cartridge Adjustment
5. Turn the unloading valve cartridge adjusting screw
counter-clockwise until the pressure reaches 1750 PSI
on the accumulator pressure gauge (Figure 29).Start and
stop the pump several times to make sure the accumulator
circuit pressure is holding at 1750 PSI.
Figure 49. Accumulator Circuit PressureTest Gauge
2. Loosen the lock nut on the unloading valve cartridge
(Figure 50) and using an allen wrench, turn the adjusting
screw clockwise until it is completely closed.
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 50. UnloadingValve Cartridge Adjustment
3. Turn the pump control switch (Figure 22) to the “ON”
position and run engine at 2550 RPM.
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 49
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ST-45 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,
0.059” deep and 0.157”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
Pistons Assy, Item 16)
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.
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.
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.
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).
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 55 ft.
lbs. each.
Remove ignition key and disconnect battery.
Think safety! Check the hydraulic gauges (Figure 29) on
panel and make sure accumulator pressure reads zero.
One piston should be in the fully discharged position at the
end of the concrete cylinder.
PAGE 50 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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.
2.
Install the two cylinder “O” rings (Hopper Interior Assy,
Item 10).
Using silicon sealant, coat the circumference of the concrete
cylinders, the back of the wear plate and around the five
bolt holes. Next, install the wear plate and the five bolts.
The bolts must all be equally snugged and tightened to
100 foot pounds each.
Wear 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 theWear
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 suttle tube to the nun-plate and remove
shuttle tube (Hopper Interior Assy, Item 41).
Using two small pry bars remove the rubber energizer ring
(Hopper Interior Assy, Item 13B), steel insert ring (Hopper
Interior Assy, Item A) and wear ring (Hopper Interior Assy,
Item 13).
The energizer ring and wear ring
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 51
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ST-45 PUMP — MAINTENANCE (PUMP)
WHEEL BEARINGS
EXTENDED STORAGE INSTRUCTIONS
After every 6 months of operation inspect the wheel bearings.
Once a year, or when required, disassemble the wheel hubs
remove the old grease and repack the bearings forcing grease
between rollers, cone and cage with a good grade of high speed
wheel bearing greases (never use grease heavier than 265
A.S.T.M.penetration“No.2.”).
The following preventative maintenance is recommended for
extended periods of storage.
1. Check brake system for proper fluid level in master cylinder
and bleed all lines.
2. Lubricate all links and pivots to prevent any rusting.
3. Remove wheel and drum assemblies and spray a good anti-
corrosion compound (CRC formula 5-56) under rubber boot
on forward end of brake wheel cylinder.Avoid spraying drum
and brake lining.
1. Fill the wheel hub with grease to the inside diameter of the
outer races and also fill the hub grease cap.
2. Reassemble the hub and mount the wheel.Then tighten the
adjusting nut, at the same time turn the wheel in both
directions, until there is a slight bind to be sure all the bearing
surfaces are in contact.
4. Grease all bearings and reinstall wheel and drum
assemblies.
5. Make sure breakaway cable is fully released.
3. Back off the adjusting nut 1/6 to 1/4 turn or to the nearest
locking hole or sufficiently to allow the wheel to rotate freely
within limits of .001” to .010” end play. Lock the nut at this
position.
6. After extended storage, refer to the Maintenance Steps listed
above to insure that the trailer is ready for towing.
4. Install the cotter pin and dust cap, and tighten all hardware.
PAGE 52 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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NOTE PAGE
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 53
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ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS
Figure 53 is provided to show the hydraulic hose connections
on the ST-45 for reference when performing inspections and
maintenance on the pump.
FRONT OF MACHINE
M
N
REMIXER
CONTROL
MANIFOLD
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 53. Hydrauilc Hose Connections
PAGE 54 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS
Figure 53. Hydrauilc Hose Connections (Continued)
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 55
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ST-45 PUMP — HYDRAULIC HOSE CONNECTIONS
Figure 53. Hydrauilc Hose Connections (Continued)
PAGE 56 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 — MANIFOLD PORT LOCATIONS
Figure 54 is provided to show the locations and names for
the two manifold block ports on the ST-45 for reference when
peforming maintenance on the pump.
Figure 54. Manifold Ports
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 57
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APPENDIX — ST-45 PUMP CONCRETE MIX INFORMATION
The following information has been extracted from actual testing laboratory reports.The purpose of this printing is only to help create
a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete
mixes.These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock ratio can be adjusted (65% sand
35% rock) and pumpability should be excellent.
EXAMPLE #1 (A CaliforniaTest Lab.Report)
JOB:Building Foundations (Water Project)
Sacks per cu./yd.
6.5 designed for 2,500 lbs. in 28 days
Gallons per sack
7.1
1.3
Washed Sand-#200 wash
Organic matter-OK
Specific gravity (SSD)
Sand-2.58;Pea Gravel-2.60
Sieve analysis-percent passing
Material
1.5” 1”
3/4”
3/8”
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
DESIGN FOR ONEYARD OF CONCRETE (SATURATED & SURFACE DRY):
Absolute volume of aggregate in one cu. yard:
Specific gravity of aggregates in one cu. yard:
Weight of aggregates in one cu. yard batch: 2850 lbs.
17.78 cu. ft.
2.58
%
BATCH
1800
1000
1
SPEC.GRAVITY
ABS.VOL.
11.56
W.C.Sand
PEA GRAVEL
WATER 46 gal.
CEMENT 6.5 sk.
TOTAL
65
35
2.58
2.60
6.22
611
27.00
ADMIXTURE:
SLUMP
None
4”
REMARKS
NOTE:
This mix designed for pumping
Due to the availability of well-graded sand as shown in the above sieve analysis,
this mix pumped very successfully.
PAGE 58 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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APPENDIX — ST-45 PUMP CONCRETE MIX INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 59
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APPENDIX — ST-45 PUMP SLUMPTEST PROCEDURE
1. To obtain a representative sample (concrete), take sev-
Figure 41-B. Slump
Test (2/3 Full)
eralsamplesatthreeormoreregularintervalsthroughout
thedischargeofthemixerortruck.DONOTtakesamples
at the beginning or end of the discharge.
2. Dampentheinsideoftheconeandplaceitonasmooth,
moist, nonabsorbent, level surface large enough to ac-
commodate 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. Fill the cone 1/3 full by volume (Figure 41-A) and rod 25
timeswitha1/2”diax24”lg.bullet-pointedsteelrod.(This
is a specific requirement which will produce non-stan-
dard results unless followed exactly.) Distribute rodding
evenly over the entire cross section of the sample.
Figure 41-C. SlumpTest
(Full-Overflow)
4. Fill cone another 1/3 (Figure 41-B) which will make the
cone 2/3 full by volume. Rod this second layer 25 times
withtherodpenetratinginto,butnotthrough,thefirstlayer.
Distributeroddingevenlyovertheentirecrosssectionof
thelayer.
FULL
(OVERFLOW)
5. Fill cone to overflowing (Figure 41-C). Rod this layer 25
timeswithrodpenetratingintobutnotthrough,thesecond
layer. Distribute rodding evenly over the entire cross
sectionofthislayer.
Figure 41-D. SlumpTest
(Removing Excess Concrete)
6. Removetheexcessconcrete(Figure41-D)fromthetop
of the cone, using the tamping rod as a screed.
7. Lift the cone vertically (Figure 41-E) with a slow even
motion.DONOTjartheconcreteortilttheconeduringthis
process.(Invertthewithdrawncone,andplaceitnextto,
but not touching the slumped concrete.
Figure 41-E. SlumpTest
(Cone Invert)
8. Lay a straight edge (Figure 41-F) across the top of the
slumped cone. Measure the amount of slump in inches
from the bottom of the straight edge to the top of the
slumpedconcreteatapointovertheoriginalcenterofthe
base .The slump operation must be complete in a maxi
BULLET POINTED
STEEL ROD
Figure 41-F. SlumpTest
(Measurement)
1/3 FULL
1/2 DIAMETER
24 INCHES LONG
FOOT
PIECE
Figure 41-A. SlumpTest (1/3 Full)
PAGE 60 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the EngineTroubleshooting (Table 9) information
shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult
our company's business office or service plant.
TABLE 9. 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?
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 61
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ST-45 PUMP —TROUBLESHOOTING (HYDRAULIC SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Hydraulic System Troubleshooting
(Table 10) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 10. 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.
Re-charge accumulator bladder with nitrogen to 1100 PSI.
Adjust unloading valve until 1750 PSI is reached.
Accumulator pressure drops to zero
on every cycle
Low nitrogen charge in accumulator
bladder?
Accumulator pressure is below 1750
PSI.
Unloading valve setting too low?
Accumulator pressure is not
discharging when switch is turned off
Cartridge at port 4-D on manifold block
is not working?
Check solinoid and cartridge. Replace if necessary
PAGE 62 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP —TROUBLESHOOTING (ELECTRICAL SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Electrical System Troubleshooting
(Table 11) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 11. 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 63
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ST-45 PUMP —TROUBLESHOOTING (BRAKE SYSTEM)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, please take a remedial action following the diagnosis based on the Brake System Troubleshooting
(Table 11) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit
just as it is and consult our company's business office or service plant.
TABLE 12. BRAKE SYSTEM TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Overheated wheel bearing?
Replace wheel bearing and pack with grease.
Low brake fluid?
Fill and bleed brake system.
Brakes squeak, chatter or chuck.
Siezed acutator master cylinder?
Brake shoe noise?
Replace/Rebuild master cylinder.
Inspect drums. Adjust shoes or replace if necessary.
Check and replace wheel cylinder and bleed brake system.
Fill with dot approved brake fluid and bleed brake system.
Replace complete actuator unit.
Replace brake line.
Leaking wheel cylinder?
Low brake fluid level?
Brake actuator frame damage?
Brake line being pinched?
Seized actuator?
Brakes overheah, fail to operate, pull
to the side, or function poorly
Replace or rebuild actuator.
Broken return spring?
Brakes improperly adjusted?
Replace spring.
Check adjustment.
Break-away cable might be pulled. Determine cause and correct.
Pry up on cable until indicator bead touches or rests against cable
spring stop. This will fully release the frame brakes and prevent
drag.
Break-away cable system
partially activated?
PAGE 64 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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NOTE PAGE
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 65
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ST-45 PUMP — EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial number
range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model number
or model number variant.
Items Found In the“Items Number”Column
All parts with same symbol in the number column, , #, +, %,
*
or <, belong to the same assembly or kit
If more than one of the same
reference number is listed, the last
one listed indicates newest (or
latest) part available.
The contents of this catalog are
subject to change without notice.
PAGE 66 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 — SUGGESTED SPARE PARTS
ST-45 STRUCTURAL CONCRETE PUMP
ST-45 STRUCTURAL 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
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
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 .......... 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 67
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APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
10
AIR COMPRESSOR
(125 TO 250 CFM)
1/2 STANDARD
AIR HOSE
1
3/4 STANDARD
AIR HOSE
2
10
4
3
6
3
6
9
3
11
OR
8
7
13
15 14
Figure 39. Shotcrete System
PAGE 68 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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APPENDIX — ST-45 PUMP RECOMMENDED 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
NOZZLE TIP, 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 69
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APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE 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 70 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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APPENDIX — ST-45 PUMP RECOMMENDED SHOTCRETE 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/AIR VIBRATOR MOUNTING
AIR VIBRATOR
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
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 71
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ST-45 PUMP — DECAL PLACEMENT
DECAL PLACEMENT
PAGE 72 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — DECAL PLACEMENT
DECAL PLACEMENT
NO.
1
2
PART NO.
511709
EM97082
34536
PART NAME
QTY.
1
2
REMARKS
DECAL, 800-30-MAYCO
DECAL, ST-45
DECAL, OWNERS MANUAL
3
1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
EM97070
EM97070
EM93000
EM98022
EM696
EM97072
TBD
DECAL, ACCUMULATOR PRESSURE
DECAL, PUMPING PRESSURE DECAL
DECAL, CAUTION - GREASE 2 HOURS
DECAL, WARNING - CHECK MANUAL
DECAL, CAUTION - TOWING DECAL
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
1
1
4
1
1
2
1
1
1
1
1
1
1
1
1
2
EM985
EM97071
EM97084
EM955
EM97083
TBD
EM965
TBD
DECAL,VOLUME CONTROL
DECAL, SHUTTLE TUBE DANGER
DECAL, MAYCO
EM1023
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 73
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AXLE ASSY.
AXLE ASSY.
ST-45 PUMP — AXLE ASSY.
PAGE 74 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — AXLE ASSY.
AXLE ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
2
2
4
8
8
4
2
4
4
2
2
2
2
10
10
10
2
REMARKS
EM25611
EM16608
EM16607
EM16605
EM923347
EM16612
EM16609
EM166081
EM966259
EM16612
EM16611
EM16612
EM16610
EM166141
EM492451
0166A
AXLE
LEAF SPRING
SADDLE, SPRING
U BOLT WITH NUTS AND WASHERS
9/16”LOCKWASHER
9/16” LOCK NUT
LINK SHACKLE L1A
BUSHING, PLASTIC
SHACKLE BOLT
LOCK NUT
BOLT
LOCK NUT
DRUM, BRAKE
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
BRAKE ASSY.
BOLT, 3/8”- 24 X 1 HEX HEAD
3/8”LOCKWASHER
NUT 3/8”- 24
15 INCH TIRE AND WHEEL
COTTER PIN
LUG NUT, CHROME
CAP, 15” CHROME
FENDER RIGHT-SIDE
FENDER LEFT-SIDE
BOLT, HHC 1/2- 13 X 3/4
WASHER LOCK 1/2"
EM492574
EM26615
EM924006
EM26519
EM26520
EM511418
EM513087
981635
2
12
2
1
1
8
8
6109180
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 75
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SUSPENSION FRENOS ASSY.
BREAKLINE ASSY.
ST-45 PUMP — BRAKELINE ASSY.
PAGE 76 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — BRAKELINE ASSY.
BREAKLINE ASSY.
NO.
1
2
3
4
5
6
PART NO.
TBD
TBD
EM16602
TBD
EM166021
EM16116
PART NAME
QTY.
REMARKS
NUT
2
2
1
1
1
1
LOCK WASHER
SURGE BRAKE ACTUATOR
BOLT
ACTUATOR COVER
BRAKE LINE KIT
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 77
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HOPPER ASSY.
HOPPER ASSY.
ST-45 PUMP — HOPPER ASSY.
PAGE 78 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — HOPPER ASSY.
HOPPER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM25174
EM16184
EM25863
EM23305
EM963610
0166A
EM25301
EM963610
0166A
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
CAPSCREW
LOCK WASHER 3/8”
SHAFT, DRIVE END
CAPSCREW
LOCK WASHER 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
LOCKWASHER
ALLEN SCREW
MOTOR COUPLING
HOSE
505719
EM963692
6109180
506203
EM708601
EM50417
EM708602
492378
0166A
492465
512791
EM25483
2
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 79
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TANQUE TRANSMISIONHATZ 57HP ASSSY.T-45 PUMP — HOPPER ATTACHMENT ASSY.
HOPPER ATTACHMENT ASSY.
PAGE 80 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 81
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ST-45 PUMP — HOPPER INTERIOR ASSY.
HOPPER INTERIOR ASSY.
PAGE 82 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 AXEL 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, COUNTERSUCK 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 83
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ST-45 PUMP — SHUTTLE CYLINDER ASSY.
SHUTTLE CYLINDER ASSY.
PAGE 84 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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” FLAT WASHER
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 85
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REAR HOOD ASSY
ST-45 PUMP — FUEL AND HYDRAULICTANK CONNECTIONS ASSY.
FUEL AND HYDRAULIC TANK CONNECTIONS ASSY
PAGE 86 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — FUEL AND HYDRAULICTANK CONNECTIONS 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 87
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REAR HOOD ASSY.
ST-45 PUMP — FUEL AND HYDRAULICTANK ASSY. (CONTINUED)
FUEL AND HYDRAULIC TANK ASSY. (CONTINUED)
PAGE 88 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — FUEL AND HYDRAULICTANK ASSY. (CONTINUED)
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 89
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FRONT COVER ASSY.
FRONT COVER ASSY.
ST-45 PUMP — FRONT COVER ASSY.
PAGE 90 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — FRONT COVER ASSY.
FRONT COVER ASSY.
NO.
7
8
PART NO.
EM963003
EM923057
2101402
EM510271
29057
EM969079
4384102
510687
PART NAME
QTY.
19
23
15
1
1
4
REMARKS
BOLT 1/4” NC X 3/4”
WASHER, FLAT 1/4”
WASHER, LOCK 1/4” DIAMETER
COVER, FRONT
9
10
14
17
18
19
DOCUMENT BOX
NUT LOCK NYLON 1/4”
CAP, AIR INTAKE
1
1
COVER, TOP
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 91
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RADIATOR ASSY.
ST-45 PUMP — HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
PAGE 92 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — HEAT EXCHANGER ASSY.
HEAT EXCHANGER ASSY.
NO.
PART NO.
EM509802
EM963610
3019892
PART NAME
GUARD, HEAT EXCHANGER
BOLT 3/8”
QTY.
1
4
6
4
1
1
4
4
4
1
6
6
6
1
1
1
1
1
2
1
1
1
1
1
REMARKS
1
2
3
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
COVER
BOLT 1/4” NC X 3/4”
WASHER, FLAT 1/4”
WASHER, LOCK 1/4”
FITTING, HYDRAULIC
TEE, FITTING
ELBOW
HOSE
CLAMP
WASHER LOCK 7/16”
TEE, FITTING
FITTING
NUT
HOSE, HYDRAULIC
HOSE, HYDRAULIC
HOSE, HYDRAULIC
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
EM25498
EM25566
EM509401
EM509400
EM98048
EM492625
EM509344
EM509345
EM509402
EM509378
EM510984
EM509374
1
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 93
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ENGINE AND FRAME ASSY
ENGINE AND FRAME ASSY
ST-45 PUMP — ENGINE AND FRAME ASSY.
PAGE 94 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — ENGINE AND FRAME ASSY.
ENGINE AND FRAME ASSY
NO.
1
2
3
4
PART NO.
TBD
020310080
EM23118
EM01005
TBD
PART NAME
QTY.
4
4
4
2
REMARKS
NUT
NUT
SHOCK MOUNT
CONNECTOR LINK, CHAIN
NUT
5
4
6
7
8
9
10
11
29
30
31
32
35
36
37
509405
503117
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
TAG, IDENTIFICATION
RIVET
1
2
2
1
1
1
2
2
2
2
1
2
3019092
EM969013
508776
EM25610
EM70186
EM745
EM744
EM20732
EM942
491744
EM60701
HATZ DIESEL ENGINE 57HP
1
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 95
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THROTTLE AND WATER FILTER ASSY.
ST-45 PUMP —THROTTLE ANDWATER FILTER ASSY.
THROTTLE AND WATER FILTER ASSY.
PAGE 96 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 NYLON 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 97
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HYDRAULIC PUMP ASSY.
HYDRAULIC PUMP ASSY.
ST-45 PUMP — HYDRAULIC PUMP ASSY.
PAGE 98 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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
0166A
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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 99
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LUBRICATION PISTONS ASSY.
LUBRICATION PISTONS ASSY.
ST-45 PUMP — LUBRICATION PISTONS ASSY.
PAGE 100 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 101
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SISTEMA ELECTRICO HATZ ASSY.
ELECTRICAL SYSTEM ASSY.
ST-45 PUMP — ELECTRICAL SYSTEM ASSY.
PAGE 102 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 103
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MANIFOLD ACUMULADOR ASSY.
ACCUMULATOR ASSY.
ST-45 PUMP — ACCUMULATOR ASSY.
PAGE 104 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 105
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ST-45 PUMP — MANIFOLD ASSY.
MANIFOLD ASSY.
PAGE 106 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — MANIFOLD ASSY.
MANIFOLD ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM97000
EM963610
3019092
0166A
EM25462
EM98018
EM25429
EM98015
TBD
PART NAME
QTY.
1
4
4
4
1
3
2
2
REMARKS
MANIFOLD ASSY.
BOLT 3/8”
WASHER, FLAT 3/8”
WASHER, LOCK 3/8” DIAMETER
STRAIGHT CONNECTOR 12- 16F5X
TEST PORT
ADAPTOR, ELBOW 6801- 04- 04
TEST PORT
9
ADAPTOR, ELBOW
1
10
11
12
13
15
20
21
22
23
24
25
26
27
28
TBD
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 CONTROLVALVE
PILOT VALVE
1
4
1
1
2
1
1
8
4
4
1
1
1
1
EM25498
EM509352
EM509353
EM25462
EM509398
EM97010
EM50932
EM196
EM508804
EM97011
EM97002
EM97013
EM97008
DIRECTIONAL CONTROLVALVE
CARTRIDGE, UNLOADING VALVE
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 107
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ST-45 PUMP — REMIXER CONTROL ASSY.
REMIXER CONTROL ASSY.
PAGE 108 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 109
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ST-45 PUMP — BATTERY ASSY.
BATTERY ASSY
PAGE 110 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — BATTERY ASSY.
BATTERY ASSY
NO.
1
2
3
4
5
6
7
PART NO.
492561
PART NAME
QTY.
REMARKS
NUT, HEX 1/4” X 20
1/4” FLAT WASHER
1/4”LOCKWASHER
BATTERY HOLDER FRAME
CABLE, BATTERY NEGATIVE
CABLE, BATTERY POSITIVE
BATTERY
2
2
2
1
1
1
1
EM923057
EM492622
EM25708
EM16707
EM509105
EM16738
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 111
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ST-45 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. (1.5 m)
B ................................................. AXLE CRANK GREASE POINT....................................... 34 in. (1.1 m)
C................................................. SWING AXLE BUSHING GREASE POINT...................... 26 in. (.85 m)
PAGE 112 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 113
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TAILLIGHT ASSY
TAILLIGHT ASSY.
ST-45 PUMP —TAILLIGHT ASSY.
PAGE 114 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP —TAILLIGHT ASSY.
TAILLIGHT ASSY.
NO.
2
3
4
5
6
7
8
PART NO.
EM26536
EM265361
492364
EM923343
492553
PART NAME
QTY.
REMARKS
TAIL LIGHT ASSY.
TAIL LIGHT BRACKET
SCREW, HHC 5/16” X 18- 1
5/16”LOCKWASHER
NUT, HEX 5/16”
2
2
4
4
4
1
1
EM256072
EM256071
SOCKET, FEMALE
PLUG, MALE
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 115
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ST-45 PUMP — CONTROL BOX INTERIOR DOOR ASSY.
CONTROL BOX INTERIOR DOOR ASSY.
PAGE 116 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — CONTROL 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
RELAY , SMALL
RELAY, LARGE
SOLENOID, 12 VOLT
FUSE, 15 AMP
DIODE, 6 AMP
QTY.
2
1
3
6
1
19
1
REMARKS
DIODE
SWITCH, EMERGENCY CYCLE
NUT
4
9
10
12
TBD
EM97068
EM97049
CONNECTOR
REMOTE CONTROL RECEPTACLE
BASE, SOCKET
4
1
1
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 117
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ST-45 PUMP — CONTROL BOX MOUNTING ASSY.
CONTROL BOX MOUNTING ASSY.
PAGE 118 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — CONTROL BOX MOUNTING ASSY.
CONTROL BOX MOUNTING ASSY.
NO.
35
36
PART NO.
492366
EM510703
PART NAME
SCREW HHC 5/16-18x1-1/2
SHOCK MOUNT
QTY.
4
4
REMARKS
37
38
39
40
2105164
EM503112
3019092
NUT 3/8 IN.
4
2
4
2
REPLACES 492582
BOLT HHC 3/8-16x2-3/4
FLAT WASHER
NUT
REPLACES 492598
REPLACES 492583
EM969013
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 119
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ST-45 PUMP — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 120 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 121
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ST-45 PUMP — CONTROL BOX DOORWIRING DIAGRAM
PAGE 122 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — CONTROL BOX INTERIORWIRING DIAGRAM
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 123
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ST-45 PUMP —TERMINAL BLOCKWIRING DIAGRAM
PAGE 124 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 PUMP — CONTROL BOX ELECTRICAL SCHEMATIC
FUSE LINK
K2
TB1-11
RED 51
FU2
15A 15A
RED 30
+
12 VDC
BATTERY
FU 4
FU1
FU3
15A
START
K1
RUN
START
OFF
3
TB1-10
TB1-1
BLK 44
4
D4
RUN
K2
[0]
GND INSIDE BOX
DURING INSTALL
BLK 45
BLK 39
1
2
D5
HI THROTTLE
SOL
SW1
K6
A1
TB1-24
TB1-25
TB1-4
B+
[22]
W
D7
K1
BLK 22
WHT 0
D
S
ALT
D+
G
G
TACH
[1]
RED 1
TB1-2
30
[3]
[7]
RED 3
TB1-5
TB1-6
TB2-3 D1 (6AMP) TB2-2
BLK 7
STRTR
SOL
D3 TB2-1
WHT 0
BATTERY
TB2-4
D2
[2]
BLK 2
TB1-3
TB1-8
R
PL3
0
7
3
OIL PRESS
[4]
BLK 4
R
PL2
AIR FILTER
MAGNET
VALVE
START-STOP
[17]
BLK 17
TB1-7
R
PL1
EXTERNAL HATZ ENGINE
AND BATTERY WIRES
PUMP ENGINE
K3
BLK 53
2
BLK 55
K6
12
9
4
1
D18
SW3
HYD PRESS
COMPENSATOR
K3
D6
D8
BLK 52
TB1-16
TB1-17
1
K3
K4
6. SPARE TERMINALS
TB1-9, TB1-21,TB1-30 AND TB31
9
5
3
2
K3
K4
5. HATZ ENGINE (DIESEL) WIRES
ARE IN [ ] BRACKETS.
BLK 35
BLK 36
TB1-18
A
B
10 11
12
8
A2
PILOT
VALVE
SOL
O O O O
5
4. TB1 = SYSTEM INTERCONNECT
TERMINAL STRIP
TB1-19
TB1-20
BLK 34
+
-
HOUR
METER
K4
TB2 = DIODE INTERCONNECT
TERMINAL STRIP
3
4
3. UNUSED REF DESIG:.
TB1-9, TB1-21,TB1-30, TB31,
AND WIRE NO. 57
K4
PROX SW
BLK
D9
TB1-26
TB1-27
TB1-28
ENGINE
SIDE
SW
10
9
BLU
BLK 34
BRN
BLK 40
K4
2. LAST USED REF DESIG:
D21, WIRE NO.57
5
6
8
7
TB2-6
TB2-7
D10
1. WIRE COLOR CODE:
RED = +12 VDC
BLK 42
TB2-5
BLK 34
TB1-29
BLK
BLU
WHT = 12 VDC GROUND (GND)
BLK = ALL OTHERS
K4
BRN
D11
BLK 32
PROX SW
WHT 0
SHEET 1 OF 2
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 125
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ST-45 PUMP — CONTROL BOX ELECTRICAL SCHEMATIC
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
PAGE 126 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 — INTERCONNECT HYDRAULIC CONTROL BOX
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
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 127
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ST-45 — HYDRAULIC DIAGRAM
Part ID
1
Description
MAIN PUMP 3000 PSI
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
2
SECONDARY PUMP, ACCUMULATOR & REMIXER
FLOW CONTROL BLOCK ASSEMBLY
FLOW CONTROL
3
3A
3B
4
RELIEF VALVE, FLOW CONTROL
MAIN MANIFOLD ASSEMBLY
MAIN VALVE
4A
4B
4C
4D
4E
4F
4G
4H
5
SHUTTLE VALVE
PILOT VALVE
ACCUMULATOR CIRCUIT DUMP VALVE
UNLOADING VALVE
CHECK VALVE
RELIEF, ACCUMULATOR CIRCUIT
TEST VALVE
ACCUMULATOR
6
PROXIMITY SWITCH
6A
7
CONDUCTOR CABLE, PROXIMITY SWITCH
DIRECTIONAL VALVE, REMIXER
MOTOR, REMIXER
8
9
SHUTTLE CYLINDER
10
11
MAIN CYLINDER
HEAT EXCHANGER
PAGE 128 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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ST-45 — OPTIONAL RADIO CONTROL
MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 129
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TERMS AND CONDITIONS OF SALE — PARTS
Effective:October 1, 2002
PAYMENTTERMS
5. Parts must be in new and resalable Rebatesforpricedeclinesandaddedcharges
condition,intheoriginalMultiquippack- forpriceincreaseswillnotbemadeforstockon
age (if any), and with Multiquip part handatthetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
numbersclearlymarked.
Multiquip reserves the right to quote and sell
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: directtoGovernmentagencies,andtoOriginal
EquipmentManufactureraccountswhouseour
productsasintegralpartsoftheirownproducts.
price book and shows as being
a. Obsolete parts.(If an item is in the
replaced by another item, it is SPECIALEXPEDITINGSERVICE
obsolete.)
A$35.00surchargewillbeaddedtotheinvoice
b. Any parts with a limited shelf life for special handling including bus shipments,
(such as gaskets, seals, “O” rings, insuredparcelpostorincaseswhereMultiquip
and other rubber parts) that were mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
purchased more than six months
priortothereturndate.
LIMITATIONSOFSELLER’SLIABILITY
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
RETURNEDGOODSPOLICY
d. Special order items.
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
LIMITATIONOFWARRANTIES
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
Nowarranties,expressorimplied,aremadein
connectionwiththesaleofpartsortradeacces-
soriesnorastoanyenginenotmanufacturedby
Multiquip.Suchwarrantiesmadeinconnection
with the sale of new, complete units are made
exclusively by a statement of warranty
packagedwithsuchunits,andMultiquipneither
assumesnotauthorizesanypersontoassume
foritanyotherobligationorliabilitywhateverin
connection with the sale of its products.Apart
fromsuchwrittenstatementofwarranty,there
arenowarranties,express,impliedorstatutory,
which extend beyond the description of the
productsonthefacehereof.
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 130 — MAYCO ST-45HRM PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04)
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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 PUMP — OPERATION & PARTS MANUAL — REV. #4 (07/16/04) — PAGE 131
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OPERATIONS & PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-537-3927
Email: mq@multiquip.com
Internet:www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
MAYCO PARTS
800-306-2926
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX:310-537-4259
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
FAX:310-631-5032
FAX:310-537-1173
WARRANTYDEPARTMENT
800-421-1244,EXT.279
310-537-3700,EXT.279
Your Local Dealer is:
MULTIQUIP INC.
18910WILMINGTONAVE.
CARSON, CALIFORNIA 90746
800-421-1244 • 310-537-3700
FAX:310-537-3927
E-mail:mq@multiquip.com
Internet:multiquip.com
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