1227058 - Mixer Seminar I Manual

Table of Contents Important Safety Information .......... ...................... ....................... ..................1 .......1

Rear Pedestal Specification Sheet ........... ...................... ...............42 ....42

Internal Flo-Fuse™ ........... ...................... ....................... ....................... ....................7 .........7

Fender Measurement ........... ....................... ....................... ...................... ............43 .43

Maintaining your Mixer Hydrostatic Pump and Motor System........................... System................ ...................... ....................... ....................... ....................... .............9 .9

Open Center Chute Block ........... ...................... ....................... ..................44 ......44

Gauge Installation Location .......... ..................... ....................... ...................15 .......15 Troubleshoot Troubl eshooting ing Your Mixer Hydro Hydrostati static c System .... ....17 17

Open Center Chute Valve Assembly HOLD POSITION ............ ....................... ...................... ....................... ....................45 ........45 Open Center Chute Valve Assembly RAISE POSITION ............ ....................... ...................... ....................... ..................46 ......46

How to use the Fault Logic Charts ............ ....................... ................23 .....23 Troubleshooting Hydraulic Pumps and Motors ..........24

Open Center Chute Valve Assembly LOWER POSITION ........... ....................... ....................... ....................... ................47 ....47

Diagram Action Steps ........... ...................... ...................... ....................... .............28 .28

Open Center Chute Valve Troubleshooting................48

Eaton Hydraulic Division, Eaton Hydrostatic Pump - Ball Guide .......... ...................... ....................... ...................... ....................... ....................... ..................30 .......30

Maintenance Periodic Inspection ........... ...................... .................49 ......49 Roller Adjustments

....................... ........... ....................... ...................... ................51 .....51

Control Valve - Old Style .......... ...................... ....................... ...................... ...........32 32 Universal Drive Shaft Shaft........... ....................... ....................... ...................... ................52 .....52 Control Valve - New Style S/N 0986 and higher ........33 Pump and Universal Alignment ........... ...................... .....................53 ..........53 Charge Pump Rotation Identification ............ ....................... ............34 .34 ZF Drum Drives ............ ....................... ....................... ....................... .....................54 ..........54 Valve Plate Rotation

...................... ........... ...................... ....................... ...............35 ...35 ZF Drum Drives .......... ..................... ....................... ....................... ...................... ..............55 ...55

Broken Pump Shaft ........... ...................... ...................... ....................... .................36 .....36 Fluid Power Equivalents ........... ...................... ....................... ......................56 ..........56 Hydrostatic Installation and Clean and Flush Procedures ........... ....................... ....................... ....................... ....................... ..................37 .......37 Recommendations for Hydraulic Fluid Specifications ..........................................................38

Common Abbreviations ........... ....................... ....................... ...................... ............57 .57 Index ........... ...................... ....................... ....................... ...................... ....................... ..................59 ......59

Mixer Oil Specs ........... ...................... ....................... ....................... ......................3 ...........39 9 Water Tank Measurement .......... ...................... ....................... ..................41 .......41

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Reserved

Table of Contents

i

Table of Contents Important Safety Information .......... ...................... ....................... ..................1 .......1

Rear Pedestal Specification Sheet ........... ...................... ...............42 ....42

Internal Flo-Fuse™ ........... ...................... ....................... ....................... ....................7 .........7

Fender Measurement ........... ....................... ....................... ...................... ............43 .43

Maintaining your Mixer Hydrostatic Pump and Motor System........................... System................ ...................... ....................... ....................... ....................... .............9 .9

Open Center Chute Block ........... ...................... ....................... ..................44 ......44

Gauge Installation Location .......... ..................... ....................... ...................15 .......15 Troubleshoot Troubl eshooting ing Your Mixer Hydro Hydrostati static c System .... ....17 17

Open Center Chute Valve Assembly HOLD POSITION ............ ....................... ...................... ....................... ....................45 ........45 Open Center Chute Valve Assembly RAISE POSITION ............ ....................... ...................... ....................... ..................46 ......46

How to use the Fault Logic Charts ............ ....................... ................23 .....23 Troubleshooting Hydraulic Pumps and Motors ..........24

Open Center Chute Valve Assembly LOWER POSITION ........... ....................... ....................... ....................... ................47 ....47

Diagram Action Steps ........... ...................... ...................... ....................... .............28 .28

Open Center Chute Valve Troubleshooting................48

Eaton Hydraulic Division, Eaton Hydrostatic Pump - Ball Guide .......... ...................... ....................... ...................... ....................... ....................... ..................30 .......30

Maintenance Periodic Inspection ........... ...................... .................49 ......49 Roller Adjustments

....................... ........... ....................... ...................... ................51 .....51

Control Valve - Old Style .......... ...................... ....................... ...................... ...........32 32 Universal Drive Shaft Shaft........... ....................... ....................... ...................... ................52 .....52 Control Valve - New Style S/N 0986 and higher ........33 Pump and Universal Alignment ........... ...................... .....................53 ..........53 Charge Pump Rotation Identification ............ ....................... ............34 .34 ZF Drum Drives ............ ....................... ....................... ....................... .....................54 ..........54 Valve Plate Rotation

...................... ........... ...................... ....................... ...............35 ...35 ZF Drum Drives .......... ..................... ....................... ....................... ...................... ..............55 ...55

Broken Pump Shaft ........... ...................... ...................... ....................... .................36 .....36 Fluid Power Equivalents ........... ...................... ....................... ......................56 ..........56 Hydrostatic Installation and Clean and Flush Procedures ........... ....................... ....................... ....................... ....................... ..................37 .......37 Recommendations for Hydraulic Fluid Specifications ..........................................................38

Common Abbreviations ........... ....................... ....................... ...................... ............57 .57 Index ........... ...................... ....................... ....................... ...................... ....................... ..................59 ......59

Mixer Oil Specs ........... ...................... ....................... ....................... ......................3 ...........39 9 Water Tank Measurement .......... ...................... ....................... ..................41 .......41

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Reserved

Table of Contents

i

Important Safety Information IMPORTANT IMPORTAN T SAFETY SAFETY INFORMAT INFORMATION ION READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE OPERATING, REPAIRING, OR ADJUSTING YOUR MCNEILUS MCNEILUS MIXER. MIXER. THOSE WHO WHO USE AND MAINTAIN THIS EQUIPMENT MUST BE THOROUGHLY TRAINED AND FAMILIAR WITH THE PRODUCT. IF INCORRECTLY USED OR MAINTAINED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY.

Always keep this manual in a location where it is readily available for persons who operate or maintain the product. Additional copies of this manual are available from McNeilus Truck and Manufacturing; (507) 3746321 at no charge. Please contact McNeilus Truck and Manufacturing if you require additional manuals or if you have any questions concerning the information in this manual or this product. Some service operations may require special tools, equipment, equipm ent, or blocking blocking devices (such as the body hoist hoist or tailgate). If you require information on these items, please contact McNeilus Truck and Manufacturing at (507) 374-6321 before attempting these repairs and service operations. THESE SAFETY PROCEDURES ARE FOR YOUR OWN PROTECTION. DO NOT OPERATE OR REPAIR THIS EQUIPMENT UNTIL YOU HAVE READ THIS MANUAL AND UNDERSTAND ITS CONTENTS THOROUGHLY. PLEASE CALL MCNEILUS TRUCK AND MANUFACTURING AT (507) 374-6321 IF YOU REQUIRE ASSISTANCE! SHOULD AN OPERATOR OF THIS EQUIPMENT HAVE A READING OR LEARNING DISABILITY, DYSLEXIA, OR OTHER SUCH CONDITION, THEN HE OR SHE MUST BE ASSIGNED A MENTOR/TRAINER TO READ AND EXPLAIN TO SUCH INDIVIDUAL THE ENTIRE CONTENTS OF THIS MANUAL AS WELL AS THE SAFETY GUIDELINES, DANGER, CAUTION AND WARNING DECALS AND PLACARDS AFFIXED TO THIS UNIT. SUCH INDIVIDUAL SHOULD NOT BE ALLOWED TO OPERATE THIS EQUIPMENT UNTIL HE OR SHE THOROUGHLY UNDERSTANDS ALL OF THESE MATERIALS. MATERIALS. FAILURE TO TO DO SO CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH. SAFETY AND SAFE WORKING PROCEDURES MUST BE FOLLOWED AT ALL TIMES. OSHA LOCK OUT PROCEDURES MUST BE FOLLOWED WHEN MAINTAINING THIS EQUIPMENT. EQUIPMENT. IF YOU ARE

© 3/98 McNeilus Truck and Manufacturing Manufacturing Co. All Rights Rights Reserved

UNFAMILIAR WITH THE OSHA LOCK OUT PROCEDURES OR ANY SAFETY REQUIREMENTS, PLEASE CONTACT MCNEILUS TRUCK AND MANUFACTURING AT (507) 374-6321 FOR ASSISTANCE.

! WARNING Anytime you are working on this equipment or its related systems, you must do the following: 1. Inform Inform the the truck truck driv driver er that that the the equip equipment ment is going to be repaired and locked out and that he must not attempt to start the truck. 2. Fol Follow low all all OSHA OSHA and Mixer Mixer Lock Lock Out Out proce procedure dures. s. Remove the keys from the truck’s ignition. 3. Plac Place e magneti magnetic c signs signs on both doo doors rs of the truck truck which read: “CAUTION - MAN WORKING ON MIXER - DO NOT START ENGINE” 4. Lo Lock ck out out sup suppli plies es are are availa availabl ble e from from McNei McNeilu lus s Truck and Manufacturin Manufacturing. g. Call (507) 374-6321 for assistance. READ, UNDERSTAND, AND FOLLOW THE SAFETY GUIDELINES, DANGERS, AND WARNINGS LISTED BELOW AND CONTAINED IN THIS MANUAL TO PROMOTE RELIABLE OPERATION AND PREVENT SERIOUS PERSONAL INJURY.

! WARNING Hydraulic hoses, fittings, and pipe must be inspected on a daily daily basis for leaks, cuts, abrasions, abrasions, damage, aging, improper clearance, and along the frame for hidden damage. If you find hoses with any such adverse conditions or damage, they must be replaced before before the mixer is returned to service! In any event, all hydraulic hoses must be replaced every two years. Failure to properly properly inspect inspect and maintain your mixer may result in serious personal injury.

! WARNING Hydraulic systems are hot. DO NOT TOUCH! Serious personal injury may result from hot oil. When you have completed working on the hydraulic systems, thoroughly clean any spilled oil from the equipment. Do not spill any hydraulic fluids on the ground. Clean any hydraulic fluids from your skin as soon as you have completed your maintenance maintenance and repairs. Dispose of used oil and filters as required by law.

Introduction and Safety Procedures Procedures

1

Important Safety Information ! WARNING Hydraulic systems operate under high pressure only experienced persons should attempt repairs or troubleshooting on hydraulic systems.

! WARNING Correct hoses, fittings, and adapters with the correct SAE rating must be used when replacing hoses to prevent possible serious injury. Always replace hoses, fittings, and adapters with replacements that have a proper, suitable working pressure rating. Replacement hoses must be of the correct length and must comply with the hose manufacturer’s installation guidelines and recommendations. Consult hose and fitting manufacturers for correct specifications or contact McNeilus Truck and Manufacturing at (507) 3746321. Hydraulic hoses have the SAE ratings marked on the hose to assist you in selecting the correct hose. Any replacement hydraulic hoses and fitting assemblies must be supplied by the same manufacturer. As an example: Brand “A” hose and brand “B” fitting will not normally be compatible. No “twist” is allowed in the hydraulic hoses. “Twist” may result in premature hose failure. Please contract McNeilus Truck and Manufacturing at (507) 374-6321 for assistance when required.

! WARNING Never remove hydraulic lines, fittings, and adapters until all pressure has been relieved from the hydraulic system. Contact McNeilus Truck and Manufacturing at (507) 374-6321 for assistance if required.

! WARNING Hydraulic components can be heavy. Use caution while lifting these components. Serious personal injury can be avoided with proper handling of the components.

! WARNING Any hydraulic pipe which is replaced must conform to SAE J1065 specifications. If incorrect hydraulic pipe is installed, the hydraulic system may fail. Damage or leaking pipes must be replaced before the mixer is returned to service. Please contact McNeilus Truck and Manufacturing at (507) 374-6321 for assistance.

2

Introduction and Safety Procedures

! WARNING Do not heat hydraulic pipe. The carbon content of this steel tube is such that if heated for bending, and either water or air quenched, the pipe may lose its ductility and thereby be subject to failure under high pressure or hydraulic shock conditions. Damaged or leaking pipes must be replaced before the mixer is returned to service. Please contact McNeilus Truck and Manufacturing at (507) 374-6321 if you require assistance or have questions.

! WARNING All hydraulic pressures must be relieved from the hydraulic system prior to removing any components from the system to prevent oil from spraying or functions and systems from falling. Call McNeilus Truck and Manufacturing at (507) 374-6321 for information concerning relieving the hydraulic pressures.

! WARNING Increasing hydraulic pressure beyond the recommendations may result in serious damage to the mixer or serious personal injury. If you have questions concerning hydraulic pressures or testing procedures, please contact McNeilus Truck and Manufacturing at (507) 374-6321 before attempting the test procedures or making adjustments.

! WARNING When performing hydraulic test procedures, use the proper hydraulic gauges. Installing an incorrect test gauge could result in serious injury if the gauge fails. Use properly rated hydraulic hoses to allow the test gauge to be read away from moving parts and functions. Contact McNeilus Truck and Manufacturing at (507) 374-6321 for assistance.

! WARNING Use the proper tools and equipment when servicing the hydraulic system. Use only the McNeilus charging kit when recharging the accumulator. Call McNeilus Truck and Manufacturing at (507) 374-6321 for assistance, if required.

! WARNING Never operate the hydraulic system if a leak is present.

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Important Safety Information ! WARNING Never enter under the chassis unless the mixer is in the Lockout mode. Remember to follow the Lockout procedures when working under the truck

! WARNING When working on the mixer, the wheels must be blocked, the parking brake on, Lock Out procedures in effect, and the keys out of the truck’s ignition.

! WARNING The mixer must not be modified in any way without authorization from McNeilus Truck and Manufacturing. Modifications may not comply with safety standards, including ANSI safety standards, and may result in serious personal injury. Please contact McNeilus Truck and Manufacturing at (507) 374-6321 if you require assistance.

! WARNING When using the emergency jumper procedure to rotate the drum on a disabled mixer the following must be observed: Before removing the hydraulic motor from the mixer drive on both the operating and disabled mixer, be sure the drum has been allowed to turn freely so that it is balanced with no forces transmitted to the hydraulic motor

! WARNING Daily inspection should be performed on the mixer. This includes proper operation of the controls, hydraulics lock out systems, electrical systems, lighting system including turn signals, back up alarm, brake lights, clearance lights, head lamps, tail lamps, safety equipment, and work lights. The truck’s air system must operate properly and have no leaks. Water and moisture should be drained from the truck’s air system daily. Call McNeilus Truck and Manufacturing at (507) 374-6321 for assistance.

! WARNING Do not wear watches, rings, and jewelry while operating or working with this equipment or its electrical and mechanical systems. These items can be hazardous and can cause serious and painful injuries if they come into contact with electrical wires, moving parts, or hydraulic equipment.


! WARNING Use slower speeds when going around curves or corners. You are carrying a higher center of gravity load.

! WARNING At the job site use the lowest transmission gear and proceed at low speed, 3 MPH maximum, to the discharge area.

! WARNING Always keep hands and feet clear of the mixer drum, revolving parts, and moving parts while checking load or washing down the mixer.

! WARNING Do not climb on ladders or ride on platforms while the truck is in motion or when ladders or platforms are wet or slippery. Serious personal injury may result due to a fall.

! WARNING All personnel must stand clear of the chutes during raising and lowering and when chutes are loaded with concrete. Position chutes while they are not loaded. A loaded chute falling on a person may cause serious injury. All chutes must be handled with great care to avoid injury. Do not stand on chutes.

! WARNING Main, foldover, and extension chutes must be inspected on a daily basis for damage, excessive wear, proper hardware fit, twist, and overall condition to determine that they are safe to use. Do not attempt to repair chutes. Unsafe chutes must be replaced with new chutes.

! WARNING Optional air chute lock is intended for use only on the job site. The manual chute lock should always be engaged during transport. Excessive wear or injury may result due to improper usage.


3

Important Safety Information ! WARNING Do not let persons, other than the driver, handle the chutes, unfold the foldover, and/or remove extension, or stow and secure the extensions for transit. Keep hands away from chute hardware where the chutes connect. Never stand in the path of the chute as it is being unfolded or while in use. Failure to follow the warnings concerning chute safety may result in serious injury.

! WARNING No passenger must be allowed in the cab unless a manufacturer’s approved passenger seat and seat belt are provided.

! DANGER Never back up without taking every precaution to be sure the rear is clear. Check behind truck before backing up. Watch the mirrors for activity. Never back up the mixer unless and until you are completely sure it is safe. Use a spotter/ observer and/or get out and check yourself to ensure it is safe to do so.

! WARNING Wear the proper protective clothing when operating or maintaining the mixer. Hard hats, safety glasses, gloves, and safety shoes should be worn. Reflective clothing is recommended for drivers and employees.

! WARNING The mixer and chassis should not be overloaded. Gross Vehicle Weights must not exceed the Manufacturer’s gross vehicle weight of this vehicle. Gross Vehicle Weights must meet Federal, State, and Local laws.

! DANGER Never drive the truck with the water tank pressurized.

! DANGER The water tank must be operated at no more than 55 psi.

! WARNING Safety decals must be replaced anytime they are damaged or missing or cannot be read clearly. If you require safety decals, please contact McNeilus Truck and Manufacturing at (507) 374-6321 for no charge replacement safety decals.

! WARNING Thoroughly understand the controls before operating the mixer. Be sure everyone is clear of the area around the truck before operating the mixer. Remain attentive at all times when operating the controls.

4

Maintaining your Mixer Hydrostatic Pump and Motor System

! WARNING The mixer should not be overloaded. Load pressures must match the load to be transported.

! WARNING Be sure to maintain correct accumulator charge pressure for correct and safe operation. Do not attempt to check or charge the accumulator until you have read and understand the instructions. Contact McNeilus Truck and Manufacturing at (507) 374-6321 for assistance.

! WARNING When working on the hydraulic or electrical system of a Bridgemaster or Tuck-A-Weigh unit the trailer should be in the down position or chained in the up position to prevent the trailer from lowering unexpectedly. Never stand behind the Bridgemaster or Tuck-A-Weigh when in the up position. If the Bridgemaster or Tuck-A-Weigh cylinder will not lower or raise, call McNeilus for assistance at (507) 374-6321 and ask for service.

! WARNING When working on the hydraulic system with the trailer raised, always chain the assembly to the upright or retracted position to prevent the assembly from coming down.


Important Safety Information ! WARNING Recheck the Hydraulic Down Pressure against the load to be transported. If their is too much pressure the truck driving tandem could be affected by loss of traction. Always set pressure to the lowest setting when mixer is unloaded. Do not run with trailer down when the mixer is not loaded.

! WARNING When recharging or checking the charge on the Bridgemaster or Tuck-A-Weigh accumulator, the following safety guidelines must be followed: The cylinder rod must be extended (trailer on the ground) before the accumulator is charged. Do not stand behind the cylinder when charging the accumulator. The hose on the McNeilus accumulator charge kit is long enough to allow the accumulator to be charged from the side of the mixer. Do not attempt to disassemble the cylinder. Use only McNeilus P/N 160.85455 Accumulator Charge Kit. Purge air from the Accumulator Charge Kit Hose by allowing a slight flow of nitrogen to escape while attaching the Accumulator Charge Kit to the Accumulator Charge Stem. The truck ignition key should be removed while charging the accumulator. Read these instructions thoroughly before attempting to charge the accumulator. Loosen only the top nut of the accumulator charge stem. If the bottom nut is loosened, damage to the o-ring seal could result. All gas pressure must be released from the accumulator before the accumulator charge stem can be removed for service. If you have any questions or experience difficulty with the cylinder or charging the accumulator, please call the McNeilus Service Department at (507) 374-6321. We’re glad to assist!


! DANGER The trailer should be lowered when servicing the accumulator. Do not stand behind the cylinder when charging the accumulator.

! WARNING The trailer pressures must match the load chart supplied with the mixer. If the pressure is too great for the load it is possible to raise the rear chassis wheels of the truck and the operator may lose control of the unit.

! WARNING Check trailer king pins, toe-in, tie rods, and components for proper adjustment. Replace any worn or loose components immediately. Contact McNeilus at (507) 374-6321 for any specifications or assistance you may require.

! WARNING With the trailer raised on the return trip, slower speeds are required when going around curves or corners as the unit could upset or roll over.

! WARNING Always be sure the area behind the mixer is clear of people or other obstacles when raising or lower the trailer.

! WARNING Always check indicator lights in the cab or at control panel at the front of the mixer for trailer and chute position. Replace lights or bulbs when required. NOTE: all models may not have indicator lights. Physically check position when indicator lights are absent.

! WARNING Check the tire condition and tire pressure of the trailer wheels daily to be sure the tires are inflated to proper pressure to withstand the applied loads. Do not exceed the recommended tire pressure marked on the tire sidewalls.


5

Important Safety Information ! WARNING Chutes must be completely lowered and centered before operating the Bridgemaster or Tuck-A-Weigh trailer. If chutes are not completely lowered and centered, the trailer may come in contact with the chutes and severely damage the mixer.

! WARNING If you are not familiar with the Bridgemaster or TuckA-Weigh, do not push or pull switches until you know what part of the system they will contact and understand the system’s operation.

! DANGER IF THE MIXER COMES INTO CONTACT OR CLOSE PROXIMITY WITH A POWER LINE OR THERE IS ANY ARCING, STAY IN THE TRUCK CAB AND KEEP AWAY FROM THE METAL PARTS OF THE UNIT. DO NOT LET ANYONE COME CLOSE TO THE TRUCK. DO NOT ATTEMPT TO JUMP CLEAR OF THE TRUCK. STAY IN THE CAB. THE POWER MUST BE DISCONNECTED BY THE POWER COMPANY BEFORE YOU CAN SAFELY LEAVE THE CAB. Minimum clearances from power lines: 50,000 Volts or Less...........................................4 Feet 50,000+ Volts ......................................................10 Feet 345,000 - 750,000 Volts ......................................16 Feet KNOW THE CLEARANCE OF OVERHEAD OBSTRUCTIONS. NEVER DRIVE THE MIXER UNDER ANY OVERHEAD OBSTRUCTION WITHOUT KNOWING THE CLEARANCE HEIGHT. IF UNIT HAS A FLIP-UP HOPPER, BE SURE HOPPER IS IN THE LOWERED POSITION. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE MIXER BODY OR TRUCK, AND MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

6



Internal Flo-Fuse™ With a continuing emphasis on safety, McNeilus recommends its internal Flo-Fuse. The internal Flo-Fuse is located on the inside of the McNeilus replacement chute lift cylinder. This protects the Flo-Fuse from damage and concrete build up. If the Flo-Fuse sees a sudden, abnormal increase in flow, it will close and stop the cylinder from retracting. This will stop your chutes. The internal Flo-Fuse is now standard on all McNeilus replacement chute lift cylinders for McNeilus Mixers. All owners of McNeilus Mixers should ensure they have a McNeilus replacement chute lift cylinder with the internal Flo-Fuse on each of their McNeilus Mixers. INTERNAL FLO-FUSE

• Update your fleet • Resets automatically

• P/N 200.107625 McNeilus 2-1/2” x 16” Cylinder

• Will not change chute speed • Premium quality • Recommended for all McNeilus Mixers

Please call McNeilus Truck and Manufacturing at (507) 374-6321 if you require assistance or have any questions.

WEATHER-PAK KIT P/N 9800.620080

10 MICRON FILTER ASSEMBLY P/N 140.00436


Internal Flo-Fuse

7

8


Maintaining your Mixer Hydrostatic Pump and Motor System MAINTAINING YOUR HYDROSTATIC PUMP AND MOTOR SYSTEM

V. Multiple Viscosity Hydraulic Fluid (MV) A. Shear Factor 1. Viscosity Index Improver (VIP)

THE HYDRAULIC FLUID I.

ISO68 - Ambient Less than 80°F

a.

Synthetic Polymer Chain

A. Specifications

b.

Typically Not Shear Stable in High Pressure Piston Pumps

1. SUS @ 210°F = 55-60

B. High Viscosity Index

2. Viscosity Index = 100 - 120

1. 130 - 150

3. Pour Point = -25°F Average II. ISO100 - Ambient More than 80°F

VI. Automatic Transmission Fluid (ATF) A. Should Not Be Used in Hydrostatics on Mixers

A. Specifications

B. Not Shear Stable in High Pressure Piston Pump

1. SUS @ 210°F = 60 - 70

1.

2. Viscosity Index = 100 - 120

High Viscosity Index a.

3. Pour Point = -5°F to +10°F

170 - 200

2. Tends to Shear to Base Stock Viscosity III. Recommended Additives

3. Looses Hydrodynamic Film

A. Anti-Rust

4. Not Always Compatible with Hydraulic Fluid

B. Anti-Foam

5. Normally Higher Priced than Hydraulic Fluid

C. Anti-Wear D. Anti-Corrosion

VII. Water Base Oil A. Do Not Use in Hydrostatic Systems

E. Anti-Oxidant

B. Shortens Lifetime of Hydrostatics

F. Emulsifier G. Detergent IV. Breakdown of Hydraulic Fluid

HOW HOT IS HOT? I.

Normal Maximum Operating Temperatures A. Outside Temperature (Ambient) + 100°F

A. Age 1. Changing Hydraulic Fluid a.

After the first 100 hours in Service

b.

Every six months or 1,000 Hours, thereafter whichever comes first

B. Heat 1. Breakdown Temperature Varies with Brands C. The Effects of Breakdown of Hydraulic Fluid 1. Oxidizes 2. Additives Breakdown 3. Varnish Forms 4. Contamination

B. Running Warmer Than Normal 1. Drum Stall 2. Hydraulic Fluid Should Be Changed More Often a.

Additive Package Breaks Down

b.

Hydraulic Fluid’s Ability to Tolerate Heat Lowers

C. Operating Cooler than Normal 1. Moisture Accumulation a.

Maximum Moisture = .001%

2. Hydraulic Fluid Should Be Changed More Often

5. Hydrodynamic Film Cannot be Maintained a.

The film of oil between moving parts



9

D. Filter Buggy (Three Filters Required)

4. Reservoir Breather Cap Installed by Customer

1. Coarse Filter (Approximately 40 Microns)

a.

2. Fine Filter (Approximately 5 Microns)

10 Micron Required if Sealed Cap is Replaced

3. Water Filter with Drain. THE HYDRAULIC HOSE E. Analyzing Oil 1. Use an Analysis Designed for Hydrostatics a.

Cleanliness Levels

b.

SUS @ 210°F

c.

Moisture Content

d.

Viscosity Index

I.

General Hose Information and Knowledge A. Ratings 1. Operating Pressure a.

2. Proof a.

F. Filtering Oil From Storage Containers 1. Use a 10 Micron Filter a.

b.

The pressure the hose is designed to \ operate at on a continuous basis

The Operating Pressure X 2 for Test Purposes

3. Burst

Low Pressure Applications

a.

The pressure at which the hose bursts

1. Mixer Hydro Filter Assembly

b.

Operating Pressure X 4

High Pressure Applications

4. SAE = Society of Automotive Engineers

1. Bridgemaster High Pressure Filter Assembly

5. DIN = Duetsch International Nominal 6. Mil Spec = Military (Lowest Rating) B. Hose Outer Covering Considerations

THE RESERVOIR I.

Unvented Reservoir on Standard Mixer A. Hydro has an even exchange of oil B. Chute Lift Cylinder Volume Minimal 1. Cylinder Capacity = .34 Gal C.

A sealed reservoir is cleaner

D. Thermal Expansion Aids Charge Pump E.

A Vent is Required if the System Has Large Cylinders 1. Bridgemaster Requires Vented Reservoir

II. Moisture Accumulation A. Source of Moisture 1. Condensation a.

Cool Down of Hydraulic Fluid

2. Induced Moisture a.

Bad Fitting Reservoir Cap

b.

Washing Hot Reservoir With Cold Water

1. Acid Wash Resistance 2. Synthetic Rubber Covering C. Twist Factor 1. 7°of Twist per Foot Shortens Hose Life by 95% D. Hose Shrinkage 1. Anticipate a 4% Shrinkage Factor a.

2” on a 50” Hose

E. Never Pressure Wash Hoses F. Inspect Hoses on a Daily Basis 1. Cuts 2. Leaks 3. Abrasions 4. Damage 5. Improper Clearance 6. Aging 7. Check Along Frames for Damage, Grommets

3. Hydraulic Fluid Not Reaching Operating Temperature 10



G. Hose Size = I.D. 1. Dash Sizes in 16th of an Inch a.

-4 = 4/16 or 1/4”

b.

-6 = 6/16 or 3/8”

c.

-8 = 8/16 or 1/2”

F. Replacement Tubing Must Meet SAE J1065 Rating 1. Coordinates Sidewall Thickness with Diameter 2. 4130 Cold Drawn Seamless Allow 3. .120 Sidewall Thickness 4. 92 Rockwell Hardness

II. Suction Hose Applications

G. Tubing Size = O.D.

A. SAE100R4 or Equivalent 1. 28” Vacuum

THE SUCTION FILTER

2. 200 PSI Maximum 3. Aeroquip FC310, 2661 or Equivalent

I.

10 Micron (µ ) Rating is Required A. 1 µ = 0.00003937 Inch

III. Chute Hose Applications

B. Human Hair = 70 Microns

A. SAE100R2 or DIN 20 022

C. Lower Limits of Human Visibility = 40 Microns

1. Minimum Operating Pressure of 3,000 PSI Required 2. Aeroquip GH781 or Equivalent

D. White Blood Cell = 25 Microns II. Beta Ratings Required by Eaton A. B10=2 Minimum

IV. Closed Loop System (Hydrostatic Pump & Motor)

B. B10=4 Better Rating

A. SAE100R12 1. Minimum Operating Pressure of 4,000 PSI

III. ISO Cleanliness Standard

2. GH493 or Equivalent

A. 18/13 Required 1. Particles per ML (1 cc)

THE HYDRAULIC TUBING I.

General Tubing Information

a.

5 = 2,500 Particles

b.

15 = 80 Particles

A. Ratings 1. Operating Pressure

IV. 10 Inches of Mercury (Hg) Maximum Warm A. Red Line on Vacuum Gauge

2. Design Factor 4:1 3. SAE = Society of Automotive Engineers

V. Bypass Opens at 20 Inches of Mercury A. Hydraulic Fluid is Unfiltered in Bypass

B. Should be zinc dichromate plated or primed

B. Filter Must Withstand 20 Inches of Mercury

1. Helps Prevent Rust and Deterioration C. High Pressure Tubing is -16 (1”)

VI. Many Filters Do Not Qualify

D. Return Tubing is -12 (3/4”)

A. Incorrect Beta Ratings

E. Inspect Tubing on a Daily Basis

1. B10=2 Minimum

1. Cuts 2. Leaks 3. Abrasions 4. Damage

THE HYDRAULIC FLUID COOLERS I.

Flow Capacity is Determined by Charge Pump Flow

5. Improper Clearance

A. 1.28 Charge Pump @ 2,000 RPM = 10.5 GPM @ 95% Efficiency

6. Aging

B. Bypass Valve to Limit Case Pressures

7. Check Along Frames for Damage


1. Two 35 PSI Bypass per Cooler


11

C. Front Mount Cooler 1. 15,670 BTU w/Ram Air (Unobstructed)

A. Standard Charge Pump

2. 2,000 - 4,000 BTU in Stationary Mode

B. Dual Element Charge Pump

D. 12 Volt Fan Cooler 1. 19,000 BTU w/Ram Air 2. 15,000 BTU w/Fan Air 3. Two 12 Volt Sensors for Redundancy a.

Lower Temp Sensor - 140°F

b.

Higher Temp Sensor - 180°F

4. ZF Mount is Standard II. Reverse Flushing the Cooler A. Cooler Must Be Flushed or System Will Be Immediately Contaminated on Start Up THE HYDROSTATIC PUMP I.

IV. Pump Configurations Available (CW or CCW)

Rotation A. Front Mount Pumps = LH (CCW) B. Rear Mount REPTO Pumps = RH (CW) 1. Rear Engine Power Take Off

1. Used with Optional Open Center Chute Lift Block C. SAE “A” Pad 1. Bridgemaster D. 1-3/8” or 1-1/2” Tapered Shaft V. Displacements A. 54 Series - Production Pump (5.4 cid) B. 46 Series and 64 Series (4.6 and 6.4 cid) 1. Available for Resale from McNeilus VI. Model and Serial Numbers A. The First Two Numbers of the Model Number Indicate Displacement 1. Example: “54” = 5.4 cid B. Next Two Numbers of the Model Number Indicated Ball Guide or Fixed Clearance Model 1. “2” = Pump 2. “0” = Ball Guide

II. Input Shaft Sizes A. Production - Approximately January 1997 1. 1-1/2” Tapered Shaft 2. 1350 Series Spicer Drive Line Components 3. Yoke Torque = 320 lb. ft. Minimum Lubricated

4. P/N 5421-5XX (5” Designates 1-1/2” Shaft) B. Production - Through 1997 1. 1-3/8” Tapered Shaft 2. 1310 Series Spicer Drive Line Components 3. Yoke Torque = 175 lb. Ft. Minimum Lubricated 4. P/N 5421-4XX (“4” or Lower Designates 13/8” Shaft III. Relief Valves (Called “Clipping Reliefs”) in Pump A. 6,000 PSI Clipping Relief Valves B. Poppet Style

3. “1” = Fixed Clearance 4. Example: a.

5421 = 54 Series Fixed Clearance Model

b. 5420 = 54 Series Ball Guide Model C. The First Four Digits of the S/N Indicate the Build Date 1. Example: 1097XXXX = October 1997. VII. Wet Spline “A” Pad A. S/N 0688 and Higher are Wet Spline 1. No Spline Lubrication is Required B. Lower S/N Must Be Lubricated Every Six Months or Converted to a Wet Spline 1. Conversion Kit P/N 180.02521 VIII.Control Valves A. S/N 0986 and Newer Have a New Style Control Valve Shaft and O-Ring Seal

1. Tend to be Self-Cleaning 2. Cooler Operation 12



B. Older Control Valves Can Be Updated With A New Shaft 1. Shaft P/N 340.12945 2. Seal Kit P/N 100.02468 C. Dust Cover Over Control Valve Shaft On All Current Control Valves 1. Keeps Cement Dust from O-Ring D. All Eaton Remanufactured Control Valves Have All Updates IX. Charge Pumps A. Standard Charge Pump = 1.28 cid B. Gerotor Style 1. Gerotor Style Tolerates Vacuum Well C. Models Available 1. Standard 2. Dual Element a.

Open Center Chute Lift Block

3. “A” Pad D. Rotation Easy To Reverse E. S/N 0385 and Newer Have Larger Charge Pump Shaft

IV. Changing Motor Sizes A. Installing a Larger Displacement Motor will Decrease Drum RPM and Increase Torque B. Installing a Smaller Displacement Motor will Increase Drum RPM and Decrease Torque V. Motor Spline Lubrication A. The ZF 21 Tooth Receptacle Seal is Nicked To Allow Gear Lube to Fill Cavity Between the ZF and Motor 1. This allows the motor spline to be continuously lubricated 2. When changing a ZF drive, the seal must be nicked at the 9:00 position VI. Model and Serial Numbers A. The First Two Numbers of the Model Number Indicate Displacement 1. Example: “54” = 5.4 cid B. Next Two Numbers of the Model Number Indicate Motor and Ball Guide or Fixed Clearance Model 1. “3” = Motor 2. “0” = Ball Guide 3. “1” = Fixed Clearance

THE HYDROSTATIC MOTOR I.

4. Example:

Spline

a. 5431 = 54 Series Fixed Clearance Model

A. All McNeilus Mixers have a 21 Spline Motor Shaft

b. 5430 = 54 Series Ball Guide Model

B. Rexworks = 20 and 23 Spline C. Smith, Jaeger, CMC = 14 Spline

C. The First Four Digits of the S/N Indicate the Build Date 1. Example: 1097XXXX = October 1997.

II. High Pressure Relief Valves A. The McNeilus has no High Pressure Relief on the Motor (Clipping Relief Valves on the Pump) B. 5,000 and 5,500 PSI Relief Valves were Common III. Displacement Sizes A. 54 Series Eaton (5.4 cid) B. 46 Series Eaton (4.6 cid) C. 39 Series Eaton (3.9 cid)



13

DRUM STALL AND INTERNAL LEAKAGE I.

1. Flush Reservoir and Wipe Clean 2. Reverse Flush the Cooler

Normal Internal Leakage of Hydraulic Fluid

3. Install New and Correct Filters

A. Leakage Cleans, Cools, and Lubricates

a.

B. Normal Leakage at Operating Temperature 1.

Pump = 1 GPM

2.

Motor = 1 GPM

C. Charge Pump Capacity @ 600 RPM = 3 GPM 1. Charge Pump Replaces Leakage (Make UP Fluid) 2. Fluid Not Used for Make Up (Leakage) Aids Cooling by Dumping Into Pump Case

B10=2 Beta Rating Minimum

4. Flush Hoses and Tubing and Blow Out with Air D. Torque the Pump Yoke as per Specifications E. Change Both the Pump and Motor F.

Install the Correct Hydraulic Fluid

G. Fill the Pump and Motor Case with Hydraulic Fluid H. Follow Clean and Flush Procedures

II. Excessive Internal Leakage A. Wear B. Wrong Hydraulic Fluid (too thin) C. Overheated 1. Possible Cooler Problems a.

Obstructed Air Flow

D. When Leakage Exceeds the Charge Pump’s Capacity for Make Up Fluid the Drum Will Stall III. Solutions A. Increase Charge Pump Capacity with Increased Engine RPM’s Whenever Possible 1. Don’t Let Engine Idle with a Load of Concrete While Sitting at Job Sight a. Use 1,000 or 1,200 rpm if possible while sitting B. Hydraulic Fluid with Correct SUS @ 210°F C. Correct Cooler Capacity D. Front Mount Coolers w/Clutch Fans 1. Install Fan Kit to Turn Fan On Manually E. Larger Hydrostatic Motor 1. Additional Torque F. Update to 12 Volt Fan Cooler System G. Truck Engine Idle at 600 - 700 RPM CHANGING HYDROSTATIC PUMPS AND MOTORS I.

Important Items to Complete A. Keep Everything Extremely Clean B. Check the Hoses C. Flush the System with Diesel or a Flushing Fluid

14



Gauge Installation Location

3. Case Pressure Test • Use 0-400 PSI gauge • Normal reading is 40-60 PSI • See step #3 - Checking Case Pressure

2. Charge Pump Pressure Test • Use 0-600 PSI gauge • Normal reading in neutral is 220 PSI ∆ (approximately 250 PSIG) • Normal reading in charge or discharge is 60 PSI less than neutral reading • See step #2 - Charge Pressure

1. Vacuum Test • Use 0-30” vacuum gauge • Test at operating temperature • Normal reading should not exceed 10” of vacuum • See step #1 - The Vacuum Check

4. High Pressure Test • Use 0-10,000 PSI gauge • Gauge will read pressure to turn the drum • Noram reading for an empty drum will be ±500 PSI. • Normal reading for a loaded drum will be 2,500 - 3,500 PSI depending on the slump of the concrete • See step #4 - Checking Hydrostatic High Pressure

Motor WITH high pressure relief valve manifold block. (used by McNeilus through 1987) Readings vary with load.

Motor WITHOUT high pressure relief valve manifold block. (used by McNeilus since 1988) Readings vary with load.


Gauge Installation Location

15

16


Troubleshooting Your Mixer Hydrostatic System Today’s new generation mixer pumps and motors are the result of extensive field testing, customer input, and the latest technology. They offer greater durability, increased power density, and greater efficiency. They also require proper lubrication, filtration, and good maintenance to deliver the years of service designed into them. Should a problem develop good troubleshooting procedures can help you identify and correct a problem before the problem becomes critical.

Most hydrostatic oil filters have a vacuum gauge which indicates the amount of vacuum required to draw the oil through the filter. As the filter becomes contaminated more vacuum will be required to draw the oil through the filter media. This filter vacuum gauge will not detect a problem between the filter and the charge pump. For this reason a reading is always taken at the charge pump inlet. A continuous high vacuum reading at the charge pump inlet will result in pump failure and will require immediate attention.

We’ll divide the hydrostatic troubleshooting into four steps which will cover the test procedures. The area discussed in this update will be analyzing the vacuum readings. Upcoming updates will discuss and analyze the remaining troubleshooting steps. Gauges, fittings, adapters, and hoses are required to troubleshoot the hydrostatics. McNeilus markets a hydro test kit (P/N 260.00483) which includes all of the required components organized in a portable carrying case. Contact your local McNeilus branch for details on the test kit. STEP #1—THE VACUUM CHECK

The charge pump develops the amount of vacuum required to move the oil from the reservoir to the charge pump. The normal oil route is from the reservoir, through the filter, and into the charge pump. Anything that restricts this oil route will increase the amount of vacuum required to move the oil to the charge pump. The amount of vacuum required to move the oil can be measured with a vacuum-pressure gauge.

McNeilus Hydro Test Kit 260.00483

The vacuum-pressure gauge is installed directly into the charge pump inlet. Remove the inlet hose and install a tee fitting into the charge pump inlet. Reattach the inlet hose to the tee. Plumb the vacuum-pressure gauge into the tee (see photo #1). The vacuum reading should be taken when the oil is warm. Cold oil will require more vacuum and result in a higher than normal reading. Vacuum is measured in inches of mercury (HG) rather than pounds per square inch (PSI) like pressure. A hydro system with a new filter and everything correct will normally read approximately two inches or less of vacuum. The maximum allowable vacuum on a continuous basis is 10 inches of mercury.

Photo 1


Troubleshooting Your Mixer Hydrostatic System

17

Cause

Remedy

Contaminated oil filter

Install new filter

Suction hose not used

Use SAE 100R4 Spec suction hose

Obstruction in hose or reservoir

Remove obstruction

Sharp hose bends restrict flow

Reroute hose

Oil too heavy

Install proper weight oil

Oil not warmed up

Let system warm up and recheck

Suction hose too small

Install correct size hose

Fitting ID too small

Install proper fittings

Filter element incorrect

Use 10-micron suction filter

The following areas are common causes of high vacuum readings:

STEP # 2 - CHARGE PRESSURE

The charge pump is the heart of your hydrostatic system. If the charge pressure is low or nonexistent, the hydrostatic pump will not provide the flow to turn the drum. The duties of the charge pump include: 1. Develop the vacuum to move the oil from the reservoir through the filter to the charge pump. 2. Provide flow under pressure to the control valve to allow the servo system to stroke the pump to charge or discharge modes. 3. Provide cool oil from the reservoir to the pump case to assist in cooling the hydrostatic system. 4. Provide make up oil to replace oil lost through normal leakage within the pump. 5. Provide flow under pressure to the rotating group (piston and slipper assembly) to maintain pressure and oil flow to the rotating group while the pump is in neutral. The charge pump pressure check is easy to perform. With the truck engine off remove the o-ring plug from the top of the pump (see photo #2). Normally the control cable is routed across the area of the o-ring plug and a 90-degree adapter and a short hose from the McNeilus

18


Photo 2 test kit is required to clear the cable. A 0 - 400 PSI gauge should be plumbed to the end of the hose. BE SURE EVERYONE IS CLEAR OF THE AREA . Start the truck and warm up the system. The gauge should read 220 ∆ PSI in neutral. The ∆ means 220 PSI (the setting of the relief valve on the charge pump) plus the pressure in the case of the pump. An example: If the pump case pressure is a normal 40 PSI your gauge would read 260 PSI in neutral (220 PSI charge pump pressure plus 40 PSI case pressure). Remember each system is unique and the gauge readings may vary slightly from pump to pump.

When the pump is put into charge or discharge the charge pump pressure will decrease by approximately 60 PSI. As an example: A 260 PSI reading in neutral should drop to 200 PSI when the pump is put into charge or discharge. These gauge readings are normal and indicate good charge pump performance. If your charge pump pressure is low check the following areas: 1. Be sure your vacuum readings are normal. If vacuum readings are high, the pump may not be receiving the supply of oil required to achieve the pressure to operate the system. (See Step #1 for vacuum information).


2. Both the charge pump and motor bolted to the mixer drive have low pressure relief valves. If your charge pressure is OK in neutral but low in charge and discharge positions you probably have a problem with the motor’s low pressure relief valve. If your charge pressure is low in neutral but OK in charge or discharge your problem will most likely be the charge pump’s low pressure relief valve. The quickest way to verify this is to exchange the relief valve cartridge with a known good cartridge from another mixer. 3. If the pressure is low or non-existent in any control valve position the charge pump should be removed and inspected. It should rotate freely. Look for contamination, excess wear, or broken parts. If the charge pump is contaminated or has broken pieces the hydro system will require flushing to remove the contaminates from the system. If the pressure is low from a worn charge pump you may be able to change just the charge pump and continue. Remember - if the charge pump has enough hours to be worn out, the pump and motor may be in the same condition!! 4. If a pump is operating with oil which is too thin or operating at excessive temperatures, the charge pump may not be able to maintain the required pressures — especially at low RPM’s.

STEP #3 - CHECKING CASE PRESSURE

The hydrostatic pump and motor are designed to have internal oil leakage. This internal leakage occurs between the piston and piston sleeve which the piston travels in, between the slipper and piston where the slipper is wedged on the piston, and between the slipper and the swashplate. This normal internal oil leakage allows the oil to clean, lubricate, and cool as it passes through these close tolerances. Internal leakage collects in the motor case and flows out of the motor housing through a smaller low pressure hydraulic return line to the bottom of the hydrostatic pump case. The leakage flows into the pump and joins the internal pump leakage and other accumulated oil in the pump case. The total volume of leakage from the motor and pump then pass out of the top of the pump, flows through the oil cooler and returns to the oil reservoir.


It is important that the flow of oil from the motor and pump cases have a free unobstructed flow to the reservoir. If anything obstructs this flow of oil, the pressure required to move the oil increases. Increased pressure can cause problems with external leakage for your motor and pump around the shaft seals and control valve seals - especially if the case pressure approaches 100 PSI. Checking the case pressures on the hydros is easy! A 0400 PSI gauge is plumbed into the return line hose which is routed between the top of the hydrostatic pump and oil cooler. The return line which is plumbed into the top of the pump should be removed and a tee plumbed into the line. The gauge is plumbed into the third port of the tee. (See photo above) When the hydrostatic system is operating at normal temperatures, the gauge pressure should read 40 - 60 PSI. If the pressures are higher than this, the system should be


19

checked to determine why the pressures have increased. Two common causes of high case pressure on mixer applications are obstructed oil coolers and return lines which are pinched due to tight radius turns. Approximately 25 PSI is required to force the oil flow through the oil cooler. If you case pressure is high, you simply remove the two return lines from the oil cooler and join the hose ends with a union. If the case pressure dropped from a high reading to a low reading (example: 100 PSI with the cooler in the circuit dropping to 20 PSI with the cooler out of the circuit), the system is telling you that the cooler is obstructed internally. Most coolers can be reverse flushed with flushing fluid or diesel fuel to remove the contaminants. If the cooler can’t be properly flushed it should be replaced with a new cooler assembly (normally around $100.00). If a return line hose is pinched, it must be replaced and rerouted if necessary to eliminate tight bends and turns. A 3/4” ID return line may have only a 1/4” ID if pinched or in a bend which is too tight.

forced through the main relief valve generates heat at the rate of one degree per second for each one thousand pounds of pressure! More modern systems with the “power limiters” in the pump (used by McNeilus since 1988) allow the pump to destroke when pressures reach maximum. With the pump destroked, there is no oil flow to the motor and no heat is generated in the closed loop circuit. Checking the high pressure circuit requires a 0-10,000 PSI gauge be installed in the charge circuit port in the manifold of the motor (see the inset). When the hydrostatic system is turning the drum, the gauge will read the amount of hydrostatic pressures required to perform that function. A typical mixer system will require around 500 PSI to turn an empty drum and from 2,500 3,500 PSI to turn a drum with a load of mixed concrete. The lower the slump of the concrete, the harder the drum turns and the higher the pressures will be. (If you have a slump meter installed, you already have a high pressure gauge in the circuit).

STEP #4 - CHECKING HYDROSTATIC HIGH PRESSURE

Two high pressure relief valves on older style hydrostatic systems are typically found in the manifold on the rear of the hydrostatic motor. On later style systems, the relief valves have been replaced by “power limiter” valves which are located on the front of the pump rather than on the motor manifold. The job of these relief valves or “power limiter” valves is to protect the closed loop circuit and components (including the pump and motor) from excess hydrostatic pressures during the charge, mix, and discharge modes or if a problem develops which would cause the pressures to increase above the normal limits. In older systems with the relief valves located in the motor manifold, considerable heat can be generated if any significant amount of oil flows through the relief valves. As an example: a mixer with a drum drive locked up may prevent the motor from turning. If a driver placed the controls in charge or discharge, the pump will send a flow of oil to the motor in an attempt to turn the drum. Because the drive can’t turn the drum, the high pressure will immediately intensify to the relief valve setting and force the oil through the relief valve and back into the circuit. This situation causes tremendous amounts of heat to be generated in the hydrostatic system; enough to destroy the motor, hoses, and the pump if it is allowed to continue. Oil which is

20

Troubl eshooti ng Your Mi xer Hydrostatic System

New Style Motor Without Manifold Normal Reading - Varies with Load


If the drum won’t turn and the high pressure gauge reads low or zero while the pump is delivering oil flow to the motor, the high pressure relief valve or “power limiter” valves may be stuck in the open position and allowing oil flow with little or no resistance. Remove the valves and examine them for contamination, damaged o-rings, etc., and thoroughly clean the valves with WD-40 or an equivalent product. Normally the two valves can be interchanged to unload the drum. Pressure Gauge for Checking System Pressure 10,000 psi



21

22


How to use the Fault Logic Charts These fault-logic charts are designed to help you troubleshoot problems with hydrostatic pumps and motors at your location. Find the symptom and follow the steps shown in the box. The steps are laid out in the normal logical order, so start at the beginning and work your way through the steps in the order they are shown. Each step will have a number shown in the box. These numbers refer to the action steps listed on the page following the fault logic charts. As an example: If the symptom is neutral is difficult to find, the first step is “Inspect Control Linkage”. In the box is the number “1”. Turning to the page following the fault logic chart and looking at action stop number one gives you additional ideas for items to check. Anytime you have questions or require assistance, please feel free to call McNeilus Companies at one of the numbers shown in action step number 16.


How to use the Fault Logic Charts

23

Troubleshooting Hydraulic Pumps and Motors NEUTRAL, DIFFICULT OR IMPOSSIBLE TO FIND

Inspect Control Linkage

Inspect Control Valve

OK

1

Call McNeilus for Assistance

2

16

Defective

Defective

Repair or Replace

Repair or Replace

MIXER DRUM TURNS IN ONE DIRECTION ONLY


Inspect Relief Valves

OK

2

1

3

Defective

Defective

Defective

Repair or Replace

Repair or Replace

Repair or Replace


OK

16

24


OK

Neutral, Difficult or Impossible to Find

Inspect Charge Check Valves

5

OK

OK

Inspect Shuttle Valve

4 Defective

Defective

Repair or Replace

Repair or Replace


Troubleshooting Hydraulic Pumps and Motors SYSTEM RESPONSE SLUGGISH

Check Charge Pressure


OK 2

12

OK 16


Defective

Repair or Replace

Low in Neutral

Low in Charge or Discharge

Inspect Charge Relief Valve at Pump

Inspect Charge Relief Valve at Motor

13

14

OK

Low in Neutral, Charge or Discharge


13

OK

Inspect Inlet Filter

9, 10

OK

Inspect Charge Pump

15

Defective

Defective

Defective

Clogged

Defective

Repair or Replace

Repair or Replace

Repair or Replace

Replace

Repair or Replace


System Response Sluggish

25

Troubleshooting Hydraulic Pumps and Motors SYSTEM OPERATING HOT

Check Oil Level in Reservoir

6

Inspect Oil Cooler

OK

OK

7 Low

8 Defective

Fill to Correct Level

Inspect External Oil Cooler Bypass (If used)

OK 12

OK

Defective

Replace

Repair or Replace

Inspect Charge Pump


15


OK


OK

9, 10


13

High in Charge or Discharge


14

Defective

Clogged

Defective

Defective

Repair or Replace

Replace

Repair or Replace

Repair or Replace

OK

16


Check System High Pressure

OK

11 Low


3 Defective

Replace

NOTE: Normal reservoir oil temperature will be outside (ambient) temperature plus 100°F.

26

System Operating Hot


Troubleshooting Hydraulic Pumps and Motors SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

Check Oil Level in Reservoir

6


OK

OK

1 Low

Fill to Correct Level


2

8

Defective

Defective

Repair or Replace

Inspect Charge Pump

OK



OK

OK

Defective

Repair or Replace

15

OK

OK

Inspect External Oil Cooler Bypass (if used)

Repair or Replace

OK

9, 10


13


High in Charge or Discharge


14

Defective

Clogged

Defective

Defective

Repair or Replace

Replace

Repair or Replace

Repair or Replace

16


Check System High Pressure

OK

11 Low


3 Defective

Replace


System will not operate in either direction

27

Diagram Action Steps 1. Inspect control linkage for: a. Cables out of adjustment, binding, broken, etc. b. Cables not coordinated with control valve neutral c. Arm on control valve slipping on control valve shaft spline d. Cable bracket loose or installed incorrectly 2. Inspect control valve for: a. Plugged control orifice b. Damaged mounting gasket c. Misadjusted, damaged or broken neutral return spring d. Broken control connector pin e. Broken or missing control linkage pins f. Galled, stuck, or contaminated control spool g. Exchange control valves with a units which works properly to verify the control valve is at fault 3.* Inspect relief valves for: a. Improper pressure relief setting b. Damaged or missing o-ring and backing ring c. Plugged orifices d. Center spool galled, stuck, or contaminated e. Poppet style relief valve may be stuck open or contaminated f. Older style motors have the high pressure relief valves installed in a manifold on the rear of the motor. These relief valves can normally be exchanged from port to port for test purposes (1987 and earlier on McNeilus mixers). g. Newer Eaton systems have poppet style high pressure relief valves (called power limiters) installed in the pump. These power limiters can be exchanged from port to port for test purposes (1988 and newer on McNeilus mixers). 4. Inspect shuttle valve (located on the end of the motor) for: a. Bent or broken return centering spring b. Galled, stuck, or contaminated spool c. Bent or broken shuttle spool d. Excess wear

6. Check Oil Level In Reservoir: a. Follow the manufacturer’s recommendations b. Normally oil should be to the sight glass with all cylinders retracted c. Do not overfill reservoir 7. Inspect Oil Cooler for: a. Obstructed air flow from dirt, grease, etc. on the outside of the cooler b. Improper plumbing c. Obstructed oil flow through the cooler; may require flushing the cooler or a new cooler 8. Inspect External Oil Cooler Bypass (if used): a. Broken, clogged, or defective bypass valve b. The McNeilus cooler has an internal bypass rather than an external bypass 9. Vacuum Hose Should Be Inspected for: a. SAE 100R4 rating - This hose must be correct or the internal liner may collapse under vacuum applications. Pressure hose will not work. 10. Inspect Inlet Filter for: a. Plugged or clogged filter element b. Obstructed inlet or outlet c. Incorrect rating filter (should be 10 micron filter designed for vacuum applications) d. High vacuum (10” maximum vacuum when oil is warm) 11. Check System High Pressure: a. See the test pages showing gauge installation and test procedures. b. A n em p t y d r um w i ll n or m a ll y re g i st e r approximately 500 PSI on the test gauge c. A loaded drum will normally register from 2,500 3,500 PSI on the gauge depending on the load and slump of the concrete in the drum d. WARNING: Do not attempt to “lock up” the system or prevent the drum from turning to test high pressure. The result may be serious damage to the system and serious personal injury.

5. Inspect Charge Check Valves (located behind charge pump) for: a. Damaged or missing o-ring b. Damaged check ball seat c. Stuck check ball

28

Diagram Action Steps


12.*Check charge pressure: a. Charge pressure is checked by installing a 0600 PSI gauge in the o-ring port on the top of the pump. See the test pages showing gauge installation and test procedures. b. Charge pressure on the Eaton hydrostatic systems normally reads 240 - 260 PSI on the gauge when the pump is in neutral. The reading should drop 60 PSI when the pump is put in charge or discharge. c. A minimum reading of approximately 150 PSI on the gauge is required to turn the drum 13.*Inspect Charge Relief Valve at Pump for: a. Improper charge relief pressure setting b. Plugged orifice c. Spool galled, contaminated, or stuck open or closed d. Damaged or missing o-ring e. Poppet valve held off seat f. Exchange a known good charge relief valve from another pump to verify the relief is the problem 14.*Inspect Charge Relief Valve at Motor for: a. Improper charge relief pressure setting b. Plugged orifice c. Spool galled, contaminated, or stuck open or closed d. Damaged or missing o-ring e. Poppet valve held off seat f. Exchange a known good charge relief valve from another pump to verify the relief is the problem

16. Call McNeilus for Assistance: a. Call your local McNeilus Branch: 1. 2. 3. 4. 5. 6. 7. 8.

Colton, CA Commerce City, CO Villa Rica, GA Gahanna, OH Morgantown, PA Hutchins, TX Tacoma, WA Dodge Center, MN

(909)370-2100 (303)287-7486 (770)459-5151 (614)868-0760 (610)286-0400 (972)225-2313 (253)536-0260 (507)374-6321

*Charge Relief Valve and High Pressure Relief Valve Identification: The relief valves are factory preset. The pressure code is stamped on the hex plug located on the end of the valve cartridge. To determine the pressure setting on the motor manifold high pressure relief valves, add a zero to the right of the stamped number (Eaton up to 1987). 1988 and newer high pressure relief valves (power limiter) located in the Eaton pump are marked internally. They must be removed to see the number. Charge Pressure Relief Valves

High Pressure Relief Valves

016 = 160 PSI 022 = 220 PSI

500 = 5,000 PSI 550 = 5,500 PSI

15. Inspect Charge Pump for: a. Broken tang b. Damaged or missing o-ring c. Broken drive key d. Excessive gerotor clearance e. Galled or broken gerotor set


Diagram Action Steps

29

Eaton Hydraulic Division, Eaton Hydrostatic Pump - Ball Guide

30

Eaton Hydrostatic Pump - Ball Guide

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved.

Eaton Hydraulic Division, Eaton Hydrostatic Pump - F.C.


Eaton Hydrostatic Pump - F.C.

31

Control Valve - Old Style

32

Control Valve - Old Style


Control Valve - New Style S/N 0986 and higher


Control Valve - New Style S/N 0986 and higher

33

Charge Pump Rotation Identification

Ridges are not aligned on body and pump section.

Counterclockwise (LH) Charge Pump Rotation Identification (Looking from “back” of Unit) (CCW)

Ridges are aligned on body and pump section.

Clockwise (RH) Charge Pump Rotation Identification (Looking from “back” of Unit) (CW)

34

Charge Pump Rotation Identification


Valve Plate Rotation PUMP VALVE PLATE FOR CCW INPUT SHAFT ROTATION (Lefthand) Fixed Clearance

54 PV LH Plate 1. Eaton P/N 105103 2. McNeilus P/N 080.025 Ball Guide Units

54 PV LH Plate 1. Eaton P/N 102795 2. McNeilus P/N 080.02447 46 PV LH Plate 1. Eaton P/N 102627 2. McNeilus P/N 080.02442

PUMP VALVE PLATE FOR CW INPUT SHAFT ROTATION (Righthand) Fixed Clearance

54 PV RH Plate 1. Eaton P/N 105102 2. McNeilus P/N 080.02525 Ball Guide Units

54 PV RH Plate 1. Eaton P/N 102744 2. McNeilus P/N 080.02446 46 PV RH Plate 1. Eaton P/N 02626 2. McNeilus P/N 080.02441


Valve Plate Rotation

35

Broken Pump Shaft The broken shaft coupling end noted on this shaft indicates a possible improper torquing of the mating coupling retaining nut. This condition usually is the result of the torque to turn the shaft being transmitted through the key and shaft keyway rather than proper shaft to coupling taper fit.

36

Broken Pump Shaft


Hydrostatic Installation and Clean and Flush Procedures Contamination (dirt, metal particles, etc.) in fluid of a hydrostatic transmission is the primary cause of failure. Before reinstalling a set of hydrostatic transmission units, the system must be completely free of contamination.Changing the filter element and fluid is not enough to thoroughly clean the system. For this reason, we have derived the following list of procedures that, when followed step by-step, will help assure system cleanliness; resulting in longer life for your hydrostatic transmission components. Remember, it is desirable that both the hydrostatic pump and motor be replaced at the same time. After Determining that the Hydrostatic Units Need to be Replaced:

1. Drain all fluid from the system at the lowest point. 2. Remove the old hydrostatic pump and motor and return it to McNeilus. 3. Remove the filter element and reservoir clean-out door. 4. Check the suction hose for kinks, collapsed or flaking liner, or any other obstructions. Check the function of the shut-off if installed. Inspect all other hose and fittings and replace as required. 5. Check the inside of the reservoir for contamination (particles of steel or brass, sludge, dirt, etc.) and be sure the pipe couplings from the reservoir to the suction hose are not obstructed. 6. Flush all hoses, pipes, tubing, filter housings, and reservoir with clean kerosene or solvent several times. 7. Fill all lines, hoses, pipes, etc. with clean kerosene or solvent and blow out with air pressure. 8. Reverse flush the oil cooler several times with clean kerosene or solvent and blow out with air pressure. 9. Hand wipe the inside of the reservoir and filler housing with clean, lint free towels. 10. Clean all hydrostatic pump and motor hose fittings and replace “O” rings as required. 11. Replace filter elements, filter gaskets and reservoir clean-out door gasket.

change. If the new filter doesn’t solve the problem, check for restrictions and proper SAE 100R4 suction line diameter. Many mixers had a primary filter internally in the reservoir and a filter assembly externally mounted in the system. It is our experience that the internal filter in the tank may be removed if a 10 micron filter assembly.with correct by-pass system and capacity is used externally in the suction line which goes from the reservoir to the charge pump. 13. Keep all loose hose ends capped after flushing to prevent contamination from entering the system. 14. Reinstall pump and motor units (on replacement motors. apply a thin coat of MOLYBDENUM DISULPHITE grease to the spline to prevent the motor shaft from seizing to the gear box receptacle). 15. Fill reservoir, hydrostatic pump and motor cases. hose, lines, etc. with new, clean pre-filtered fluid. Make certain fluids meet specifications of the equipment manufacturer or see a fluid recommendation chart. 16. Be sure to fill the hydrostatic pump and motor cases before start-up. Proceed with the start-up procedure. 17. Slotted pump yoke nut must be torqued to specs. CAUTION: Failure to properly torque the slotted pump yoke nut may result in a broken pump shaft. REMEMBER, KEEP IT CLEAN! This includes any oil drums, buckets, transfer pumps, etc., used to clean and flush the system!

Although these steps will take considerable time to complete, we at McNeilus feel that they are extremely important to prevent unnecessary replacements which result in expense and down time. Remember, we want you to get the most from your equipment and our hydrostatic transmission program. OPERATION RECOMMENDATION The engine must have at least 600 RPM at idle with a load in the mixer drum control to rotate the drum at 1-1/2 to 2 revolutions. In cold weather, allow for warm up of hydraulic oil before charging the mixer.

12. Check the filter vacuum gauge. The vacuum gauge is normally located on the filter assembly. Remember the importance of a good vacuum gauge in the system. If this vacuum reading exceeds 10 inches, the result may be cavitation in the system. Normally, this indicates a need for an oil filter


Hydrostatic Installation and Clean and Flush Procedures

37

Recommendations for Hydraulic Fluid Specifications HYDROSTATIC OIL The following oils are approved for the ISO 100 specification for Eaton Hydrostatics operating in ambient temperatures in excess of 80 degrees F.:

BRAND Citgo Conoco Drydene Fina Kendall Mobil Texaco Unocal

NAME AW Hyd Oil Super Hyd Oil 100 4044 AW Hyd Oil Four Seasons (7384) DTE10-18M Rando HD150 UNAX AW

SUS @ 210 63 64 65 64 63 71 72.7 65

VI 96 98 102 95 95 120 90 100

POUR POINT (F) +5 -25 +5 0 +10 -29 - 5 +10

The following oils are approved for the ISO 68 specification for Eaton Hydrostatics operating in ambient temperatures less than 80 degrees F.: Chevron Citgo Conoco Drydene Fina Kendall Mobil Texaco Unocal

38

Hyd Oil AW AW Hyd Oil Super Hyd Oil 68 4034 AW Hyd Oil Four Seasons (7382) DTE10-16M Rando HD68 UNAX AW

Recommendations for Hydraulic Fluid Specifications

54 55 56 54 55 56.0 62 53.5 55.4

99 94 100 105 96 100 120 98 102

-22 -20 -30 -15 -15 -5 -11 -25 -11


MIXER OIL SPECS ISO 100 OIL (Over 80 degrees ambient) SUS at 100 Degrees F. SUS at 210 Degrees F. Pour Point Viscosity Index

544 71 -20 F. <120

ISO 68 OIL (Less than 80 degrees ambient) SUS at 100 Degrees F. SUS at 210 Degrees F. Pour Point Viscosity Index

359 62 -30 F. <120

ADDITIVES RECOMMENDED Anti-Wear Anti-Foam Anti-Rust Anti-Corrosion Anti-Oxidant Emulsifier Detergent (minimum amount) The additives are a standard hydraulic oil package for any oil blender.


Recommendations for Hydraulic Fluid Specifications

39

40


Water Tank Measurement Contact ______________________________________

Date of Order _________________________________

Company Name _______________________________

Phone Number ________________________________

Mailing Address _______________________________

Shipping Address ______________________________

City _________________________________________

City _________________________________________

State ___________________ Zip__________________

State ___________________ Zip__________________

Special Notations ______________________________

Number of tanks wanted ______ Gallon capacity______

____________________________________________

Extra parts needed (example: site gauge kit)

____________________________________________

____________________________________________

____________________________________________

____________________________________________ ■ Steel

■ Aluminum

(SAMPLE of completed measurements)


Water Tank Measurement

41

Rear Pedestal Specification Sheet

42

Rear Pedestal Specification Sheet


Fender Measurement Contact_______________________________________

Date of Order _________________________________

Company Name ________________________________

Phone Number ________________________________

Mailing Address ________________________________

Shipping Address ______________________________

City__________________________________________

City _________________________________________

State ___________________ Zip __________________

State ___________________ Zip _________________

Special Notations_______________________________________________________________________________ _____________________________________________________________________________________________

PUSHER

A. __________________________________________

G. __________________________________________

B. __________________________________________

H. __________________________________________

C. __________________________________________

I. ___________________________________________

D. __________________________________________

■

Driver Side

E. __________________________________________

■

Pair

F. __________________________________________

■

Steel

■

Passenger Side

■

Aluminum

TAG For Tandem Fenders, Use A, B, C, D, H & G


Fender Measurement

43

Open Center Chute Block

NOTES: 1. TORQUE ALL CARTRIDGES TO 35 FT/LBS. 2. TORQUE COIL NUT TO 10 IN/LBS. 3. COILS ARE 12VDC 20 WATT

7

Item 1 2 3 4&8 4 5&8 5 6 7 8 9 10

Part No. 520.106591 260.106592 260.106593 260.106594A 260.106588A 260.106595A 260.106587A 260.106596 260.106597 060.85774A 040.106634 040.85743

Description Chute Block Body Only Check Valve Cartridge 5 P.S.I. Relief Valve 2200 P.S.I. Normally Open Solenoid Valve with Coil (Up) Normally Open Valve Poppet Only Normally Closed Solenoid Valve with Coil (Down) Normally Closed Valve Poppet Only (Screened) Flow Control Valve (Chute Down Speed) Check Valve 200 P.S.I. 12-Volt Coil Only Orifice Plate .062 (Chute Up Speed) Plug SAE 4

Qty 1 1 1 1 1 1 1 1 1 2 1 1

Items #4,5 and 8 refer to the new style coated rectangular solenoid valves. These will replace as an assembly only the old style poppet and round coils, the coils and poppets from new style to old are not interchangeable. All other parts remain unchanged.

44

Open Center Chute Block


Open Center Chute Valve Assembly

Hold position

Note: Use only McNeilus Chute Lift Cylinders with Internal Flo-Fuse.

Chute Lift Cylinder 2 1/2” x 16” 200.107620

C

N.C. Valve Assy. (CEC) w/12V. Coil 260.106595A

)(

N.C. Cartridge Only (CEC) 260.106587A 12 V. Coil Only (CEC) 060.85774A

Pressure Compensated Flow Control 260.106596

Normally Closed Solenoid Valve Energize to lower

200 P.S.I. Check 260.106597 5 P.S.I. Check 260.106592

)( N.O. Valve Assy (CEC) w/ 12 V. Coil 260.106594A N.O. Cartridge Only (CEC) 260.106588

.062 Orifice 040.106634

Normally Open Solenoid Valve Energize to raise

12 V. Coil Only (CEC) 060.85774A

Relief Valve 2200 P.S.I. 260.106593 T

A Revisions made in 1991 with CEC weather resistant coils (rectangular, rubber coated) and heavier valve assemblies. Previously used round metal sheated coils. The valve assemblies are interchangeable, the individual pieces are not.


P

Raise Pressure Return Pressure Open Center Chute Valve Assembly

45


RAISE POSITION



C

)( N.C. Valve Assy. w/12V. Coil 260.106595A N.C. Cartridge Only 260.106587A



12 V. Coil Only 060.85774A


)( N.O. Valve Assy w/ 12 V. Coil 260.106594A

.062 Orifice 040.106634


N.O. Cartridge Only 260.106588 12 V. Coil Only 060.85774A


P

Lowering Pressure Return Pressure

46




LOWER POSITION



C

)(


N.C. Valve Assy. w/12V. Coil 260.106595A


N.C. Cartridge Only 260.106587A 12 V. Coil Only 060.85774A


)( N.O. Valve Assy w/ 12 V. Coil 260.106594A N.O. Cartridge Only 260.106588

.062 Orifice 040.106634


12 V. Coil Only 060.85774A


P

Hold Pressure Return Pressure



47

Open Center Chute Valve Troubleshooting Symptom

Cause

Remedy

Chute drifts down

1. 200 PSI ch check leaks

Install new valve

2. Normally closed solenoid valve stuck open or leaks

1. Install new valve 2. Correct electrical

Chute drifts up during transport

5 PSI check leak

Replace valve

Chute will not raise

1. Normally open solenoid valve stuck closed

1. Replace valve 2. Ch C heck electrical

2. No Norm rmal ally ly cl clos osed ed va valv lve e stu stuck ck op open en

1. Repl Replac ace e val valve ve 2. Che Check ck ele electr ctrica icall

Chute will not raise with full load

Relief valve pressure set too low

Adjust with gauge to 2200 PSI

Chute will not lower

Normally closed valve stuck

1. Replace valve 2. Che Check ck ele electr ctrica icall

Chute lowers too fast or too slow

Flow adjustment not correct

Adjust down speed valve screw out to slow down or screw in to speed up

48

Open Center Chute Valve Troubleshooting


Maintenance Periodic Inspection

**

* Change oil after after first 100 hours. Thereafter Thereafter change every six months. months. Capacity: fill fill to check plug or or site glass. Change every 1000 hours or six months thereafter.

Service ZF twice annually with 85W-140 GL5 Spec. 85W-140 can be used year round. round. * NO NOTE TE:: Trans. hold down bolts previous S/N 14669 had 3/4” bolts that were torqued to 310 lbs. Now S/N 14669 has 7/8” bolts that are torqued to 420 lbs.

**Call McNeilus for additional oil or filter information at (507) 374-6321. © 3/98 McNeilus Truck and Manufacturing Manufacturing Co. All Rights Rights Reserved

Maintenance Periodic Periodic Inspection

49

Maintenance Periodic Inspection DAILY INSPECTIONS

1. H y dr dr a ul ul i c h os os e s, s, f i t ti ti n g s, s, a n d pi pi p e m us us t b e inspected on a daily basis for leaks, cuts, abrasions, damage, aging, improper clearance, and along the frame for hidden damage. If you find hoses hoses with any such adverse conditions or damage, they must be replaced before the mixer is returned to service! In any event, all hydraulic hoses must be replaced every two years. Failure to properly inspect inspect and maintain your mixer may result in serious personal injury. 2. Visual roller track and roller alignme alignment nt check check.. Check for “snapping” or “popping” noises while drum is turning. 3. Check oil level in hydraulic reservoir. Add oil if below sight gauge level with all cylinders retracted. Use correct oil.

4. Check filler cap and neck on oil reservoir reservoir for leaks. Check oil reservoir mounts. Make any necessary repairs immediately. 5. Check and record drum drum RPM while loading mixer with concrete and truck engine running at top governed RPM. If drum revolution revolution is 2 RPM less than that recorded at previous check, see manual for component check out. 6. Check inside of drum for concrete build up and clean as required. 7. Check mounting bolts for proper tightness. 8. Check ZF transm transmission ission drive plate bolts. Torqu Torque e to 170 lb ft. 9. Check ZF transmission hold down bolts. Torque to 420 lb. ft.

4. Start engine and warm up hydraulic system with truck engine at approximately 1,200 RPM and mixer drum turning at approximately 2 RPM. Warm up time minimum is 5 minutes.

10. Inspect debounce debouncerr for proper proper clearance. clearance.

5. Check vacuu vacuum m gauge on oil filter. Replac Replace e element if the reading exceeds 10 inches of vacuum after oil has reached operating temperature.

SIX MONTH INSPECTION

6. Check for and correct correct any external oil or air air leaks. NOTE: Do not tighten or loosen any connections while system is under pressure.

7. Lubricate pump drive shaft universal joints. 8. Lubricate roller bearings.

11. Inspect roller track for cracks, flat areas. Correct as necessary.

1. Change hydraulic oil and install new hydraulic oil filter(s). Remove filters and check for metal particles. Replace filter(s) with correct part number filter. Use the correct hydraulic oil as per McNeilus specs. Check with McNeilus before using any alternate hydraulic hydraulic oil or filters. Multiple Viscosity oils and Automatic Transmission Transmission Fluid (ATF) cannot cannot be used in the hydraulic system. 2. Lubricate control cables cables using the McNeilus Cable Lube Kit.

9. Lubricate and inspect rear cable control box. 10. Lubricate Lubricate chute pivot system system and inspect inspect chutes and chute hardware for wear or damage. WEEKLY INSPECTIONS

1. Check pump drive shaft cap screws for proper tightness. 2. Lubricate complete mixer per lube chart supplied with mixer. 3. Draw sample of oil from reservoir and check for presence of water. If water is present, the oil may be milky in appearance. Milky oil should be drained from the system and replaced and the source of the water entry found and corrected. 50

Maintenance Periodic Inspection

3. On Bridgemaster systems check the indicator gauge on the high pressure filter when the system is warm and the Bridgemaster Trailer is actually moving down (if the trailer is not moving, the indicator will not read). 4. Service the ZF transmission. The lubricant should be drained while the ZF drive is hot. 85w-140 with a GL5 spec is the proper lubricant. Do not overfill the drive. Proper oil level is to the bottom of the sight glass. 5. Inspect mixer main hold down bolts and springs. Replace or adjust as required.

© 3/ 3 /98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Roller Adjustments Drum Roller:

Roller Alignment:

Each drum roller is equipped with two tapered roller bearings. Seals are provided to exclude water and dirt. If it becomes necessary to replace the bearings, the assembly must be thoroughly cleaned before installing the new bearings. Pack the bearings with the recommended lubricant. (See lube chart).

Drum rollers must run parallel (in line) with roller track. Rollers are to be set by using a minimum 12” long straight edge, with one knife edge. Working from both sides of rear face of roller, straight edge is to match with chamfer on roller track (see below).

To take up bearings, tighten nut until roller cannot be turned by hand, then back off until roller turns with slight drag.

Face contact of track and roller is to be flat, no light showing through contact under rated load.

Unloaded Drum Roller Alignment:

Maintain a space of .012” to .015” by shimming under either side of roller bracket (see right).


Roller Adjustments

51

Universal Drive Shaft After the universal drive shaft has been assembled to the engine and pump, be sure that the following conditions exist: a. The drive shaft joint are in phase (See Below) b. The slip joint spline has ample engagement and that at least 3/8” of clearance exists between the end of the male spine and the bottom of the female spline. (See Below)

Misaligned

52

Universal Drive Shaft

CAUTION: If the yoke (00700) nut is not properly torqued to 175 ft. lbs., drive shaft failure may occur. In most universal drive shaft installations, a slight misalignment between driving and driven members is desirable but in no instance should the angle of the universal drive shaft between joints and the shaft centerline of the driving or driven member exceed 6°. (See Pump and Universal Alignment)

Aligned


Pump and Universal Alignment


Pump and Universal Alignment

53

ZF Drum Drives ZF was founded in 1915 by Count Zeppelin (the airship Zeppelin) and is the world’s leading manufacturer of transmission systems including axles and steering. McNeilus Companies has used ZF’s Drum Drive since the 1970’s. Since that time several models of the ZF have been developed and put into production. Over the years the torque rating of the ZF has continually increased to meet the demands of larger capacity mixer drums and lower slump concrete. The ZF drive is a double planetary reduction drive. The input rpm (where the motor is mounted) is reduced to the output rpm (the flange that bolts to the drum) by the ratio of the drive. As an example, if the ratio is 144:1, the flange rotates once for every 144 turns of the motor. This reduction is accomplished through planetary gears which rotate around a sun gear. There are two sets of planetary gears which accomplish the reduction. Planetary gears are very efficient and cool running. The drive is around 96% efficient meaning only 4% of the input energy is used by the drive. This compares to 80% efficiency for many of the straight gear reduction drives. Servicing the ZF drive is critical to the overall lifetime of the drive. The proper lubricant for the drive is 85W-140; the same lubricant commonly used in differentials. The spec of the lubricant is GL-5. This lubricant is available from nearly any oil distributor. It is important that the ZF be serviced after the first 100 hours in service. The drive should be drained while the lubricant is warm. This 100 hour period is considered the “clean up” lubricant change for the drive. Any contamination which washes from the new castings, bearings, gear wear-in, etc. can be drained at this time. After the initial service the drive should be serviced every six months or 1,000 hours; whichever comes first. Remember that the drive has a positive pressure within the case. The drive design allows a minimum amount of internal pressure to develop as the lubricant and drive warm up. This positive internal pressure helps prevent contamination from entering the internal drive components. This internal pressure also means that caution must be used when removing any fill plugs from the drive while the drive is warm. Safety glasses must be worn while servicing the ZF drive. Even though the internal pressure is minimal, the fill plug may want to blow from its port and spray lubricant from the port. Loosening the four hydrostatic motor mount bolts and then loosening the hydrostatic motor will normally relieve any pressure in the ZF drive. Any excess pressure developed in the drive is normally relieved by the output flange seal. The hydrostatic motor is bolted to the input of the drive. 54

ZF Drum Drive

The hydrostatic motor has a shaft seal which prevents the hydraulic fluid in the motor from leaking around the motor shaft under pressure. If this motor shaft seal leaks, hydraulic oil and pressure can transfer from the motor case to the ZF drive case. There is also an input seal in the ZF input cavity around the splined receptacle. This ZF seal is “nicked” at the factory in the 9:00 or 3:00 o’clock position. The nick allows the ZF lubricant to leak from the drive and lubricate the spline on the motor shaft and ZF splined receptacle. Without this lubrication, the motor spline and ZF receptacle will wear prematurely. Because this seal is “nicked”, there will normally be 85W140 lubricant in this cavity. The hydraulic fluid in the motor case is quite “thin” compared to the ZF lubricant. Also the ZF lubricant has its own strong odor. If there is hydraulic fluid in this cavity, the motor seal is leaking. Anytime the drive is overfilled - either from servicing the drive or from a leaky hydrostatic motor seal - the excess lubricant will exit the drive around the output flange seal and show up on the drum head. This seal is a heavy rubber lip seal which is quite strong. It is our experience that a leaky ZF output seal is generally an indication of a faulty motor seal or overfilled drive rather than a faulty ZF output seal. The seal cavity also holds a quantity of lubricant and may take two or three weeks for the lubricant around the seal cavity to dry up. Changing the seal is a difficult job which requires a 60 ton press. The seal is one of the last items to come out of the drive when it is completely disassembled. Never assume this heavy rubber lip seal is faulty. It normally only leaks only when the drive is overfilled. A ZF Repair Manual is available from McNeilus if you are planning on working on the drive. When changing the ZF drive it is important to retain the flange in its normal centered position that it is in when the drive is mounted on the mixer. Allowing the weight of the output flange to put its weight on the output seal may damage the seal; especially if it’s left in that position for any length of time. For this reason a bracket with a 90 ∫ bend should be fabricated. One end of the bracket should be bolted to the flat on top of the drive and the other to the flange. This bracket is especially important when storing a ZF drive for any length of time. There are flange bolts around the output flange which secure the drive flange to the mixer drum socket. The flange bolts should be torqued to 170 lb. ft and checked on a weekly basis. There are threaded holes in the ZF flange which are unused. When removing the ZF flange from the drum socket, bolts can be threaded into these extra threaded flange holes around the flange and pressure applied from the flange to the drum socket by tightening the bolts. This will help separate the ZF flange from the drum socket. The bolts work like a © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

ZF Drum Drives puller to help separate the flange from the drum socket. Heat may have to be applied to the flange and drum socket area to separate the flange from the drum socket. Normal maintenance of the ZF drive includes checking the torque of the mounting bolts. It’s important to check these mounting bolts that hold the ZF drive to the front pedestal on a weekly basis. Acid wash and moisture can get into the area where the six bolts pass through the ZF mount and pedestal. Over a period of time the bolts can deteriorate in these areas of the ZF drive mount and front pedestal which can’t be readily seen or inspected. If a bolt has deteriorated, it will break when torqued. If one bolt breaks, all six should be replaced as all mounting bolts should be considered to be in the same condition. If only one bolt comes loose, the ZF drive mount may crack. Should this happen, the entire drive will have to be replaced. The correct bolt for the application and which is installed at the factory is a Bowman product called “Bowmalloy”. This Bowmalloy bolt is a Special Ultra Hi-Strength Alloy Steel Quenched and Tempered Bolt. The proof load of this bolt is 165,000 psi and the tensile strength is 185,000 psi. No lesser bolt can be installed in this ZF mount application! This Bowmalloy bolt is readily available locally or from the McNeilus branches (McNeilus P/N 020.100990). If your mixer is S/N 14,669 or previous, the ZF mount bolts will be a 3/4” bolt and should be torqued to 310 lb. ft. If your mixer serial number is 14,670 or higher, the ZF mount bolts will be a 7/8” bolt and should be torqued to 420 lb. ft. Please call your McNeilus branch or McNeilus Truck and Manufacturing’s Corporate Headquarters at 507-3746321 if you require assistance with the ZF drive or have questions. We’re glad to help.


ZF Drum Drive

55

Fluid Power Equivalents EXACT EQUIVALENTS:

APPROXIMATE EQUIVALENTS

1 US Gallon = 231 Cubic Inches

1 Fluid Oz. (volume) = 600 drops of oil

1 Bar at Sea Level = 14.504 psi

1 Cubic Inch = 330 drops of oil 1 Cubic Centimeter (cc) = 6 drops

1 Horsepower = 33,000 Ft. Lbs. per Minute = 2545 BTU per hour = 746 Watts or 0.746 kw

1 Gallon = 3,785 Cubic Centimeter (cc) 1 Oz. = 28.4 Cubic Centimeter (cc)

1 PSI

= = =

2.0416” Hg 27.72” Water .0689 Bar

Area of a Cylinder = Diameter Squared X .7854 Force = Area X Pressure

1” HG = 0.490 PSI = 1.131 Ft. Water 1 Atmosphere

= 1.013 Bars = 29.921” HG = 14.696 psi

Cylinder Volume = Area x Stroke ˜ 231 Pump Flow = Displacement x RPM ˜ 231 Horsepower = Flow X Pressure ˜ 1714 BTU's per Hour = Horsepower x 2545

1 Foot Water Column = 0.432 psi Torque (In./Lb) = Horsepower x 63025 ˜ RPM 1 Foot Oil Column = 0.354 psi Torque in Ft./Lb = In./Lb ˜ 12 1 Barrel of Oil = 42 Gallons 1 Micro-Meter = 1 Millionth of a meter

56

Fluid Power Equivalents


Common Abbreviations 15P: Parker Bridgemaster Filter 30P: Parker Bridgemaster Filter (older style) 2W2P: Two Way - Two Position (common cartridge) 3W2P: Three Way - Two Position (common cartridge( 3W3P: Three Way - Three Position (common spool valve) 4W3P: Four Way - Three Position (common spool valve) 40CN: Parker Packer Return Line Filter ▲ : Delta A-PAD: SAE Standard Pad for Mounting Pumps A-SPLINE: SAE Spline - 5/8”x 9 Tooth AISI: American Iron and Steel Institute ANSI: American National Standards Institute ASL: Automated Side Loader ASME: American Society of Mechanical Engineers ASTM: American Society for Testing Materials B-SPLINE: SAE Spline - 7/8”x 13 Tooth BTU: British Thermal Unit CB: Counter Balance CCI: Cylinder City, Inc. CEC: Component Engineering Company CFM: Cubic Feet per Minute CIC: Commercial Intertech Company C PAD: SAE”C” Pad Mount C-SPLINE: SAE Spline - 1-1/4” X 14 Tooth CC: Cubic Centimeters CD10: Muncie PTO CID: Cubic Inch Displacement CCW: Counterclockwise (also LH) CW: Clockwise (also RH) CYL: Cylinder DA: Double Acting Cylinder DE: Dual Element EOS: Electronic Overspeed E-STOP: Emergency Stop FE: Full Eject FEL: Front End Loader FF: Flow Fuse GPM: Gallons Per Minute GVW: Gross Vehicle Weight GW: Gross Weight HOC: Hydraulic Overspeed Control HP: Horsepower HPRV: High Pressure Relief Valve IFI: Industrial Fasteners Institute ISO: International Standards Organization J20A: John Deere Oil Spec JDM: John Deere Motorworks (oil specs) LCD: Liquid Crystal Display LED: Light Emitting Diode LH: Left Hand (counterclockwise) LORV: Lock Out Relief Valve LPM: Liters per Minute LPRV: Low Pressure Relief Valve MF: Motor with Fixed Swash Plate MIL: Military Specification MM: Millimeter MRV: Main Relief Valve MS: Military Standard MSL: Manual Side Loader NEMA: Weatherproof Rating NC: Normally Closed © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

N-M: Newton Meter NO: Normally Open NPT: National Pipe Taper NPTF: National Pipe Taper Fuel OEM: Original Equipment Manufacturer ORS: O-Ring Seal PFD: Priority Flow Divider PTO: Power Take Off P/N: Part Number PV: Pump with Variable Swash plate REGEN: Regeneration REL: Rear Loader RH: Right Hand (clockwise) RPM: Revolutions per Minute RV: Relief Valve SA: Single Acting Cylinder SAE: Society of Automotive Engineers SE10: Mixer Hydro Filter SUS: Saybolt Universal Seconds TELE: Multi-Stage Telescopic Cylinder TG: Tailgate TVS: Transient Voltage Spike UNC: Unified National Coarse Threads (bolts) UNF: Unified National Fine Threads (bolts) VA20: Commercial Intertech Spool Valve - 40 GPM VA35: Commercial Intertech Spool Valve - 70 GPM VI: Viscosity Index VIN: Vehicle Identification Number VIP: Viscosity Index Improver WPRV: Work Port Relief Valve

Common Abbreviations

57

Index 10 Micron Filter Assembly, ............7, 37

Open Center Chute Valve Assembly, ......................................................45-47

A - B -C P-Q-R Accumulator Charge Kit, ....................5 adapters, ......................................2, 17 air chute lock, ......................................3 air leaks, ............................................50 ANSI, ............................................3, 57 Automatic Transmission Fluid, ......9, 50 blocking devices, ................................1 Bridgemaster, ..........4-6, 10, 12, 50, 57 Broken Pump Shaft, ....................36-37 Charge Pump, ................10-15, 17-19, ..........................................25-29, 34, 37 Charge Pump Rotation, ....................34 Charge Relief Valve, ..............25-27, 29 Check Valve, ..............................24, 44 contamination, ............9, 19, 21, 37, 54 D-E-F debouncer, ........................................50 Diagram Action Steps, ................28-29 electrical, ....................................3-4, 48 extension chutes, ................................3 External Oil Cooler Bypass, ........26-28 fault-logic charts, ..............................23 Fender, ..............................................43 G-H-I high pressure, ..............2, 9-11, 13, 15, ..............................20-21, 26-29, 50, 57 Hydraulic Down Pressure, ..................5 hydraulic fluid, ..........1, 9-11, 14, 38-39, ..........................................................54 Hydraulic Fluid Specifications, ....38-39, ..........................................................59 Hydraulic hoses, ........................1-2, 50 hydraulic pipe, ....................................2 Hydrostatic Installation, ....................37 Hydrostatic Pump, ................4, 6, 9-14, ....................................18-19, 30-31, 37

Periodic Inspection, ....................49-50 power limiters, ............................20, 28 proper protective clothing, ..................4 Pump and Universal Alignment, ..52-53 Raise Position, ..................................46 Rear Pedestal, ..................................42 Roller Adjustments, ..........................51 Roller Alignment, ........................50-51 roller track, ..................................50-51 S-T-U SAE J1065, ..................................2, 11 Safety, ........................................1-7, 54 tapered roller bearings, ....................51 trailer, ........................................4-6, 50 transmission, ................3, 9, 37, 50, 54 Troubleshooting, ..........2, 17-21, 24-27, ..........................................................48 Tuck-A-Weigh, ................................4-6 universal drive shaft, ........................52 V-W-X-Y-Z vacuum gauge, ........11, 15, 17, 37, 50 Vacuum Hose, ..................................28 Valve Plate Rotation, ........................35 Water Tank Measurement, ..............41 ZF Drum Drives, ..........................54-55 ZF transmission, ..............................50

J-K-L kit, ............2, 5, 7, 12-14, 17-18, 41, 50 Lock out, ..................................1, 3, 57 Lower Position, ................................47 M-N-O Main, ................................3, 20, 50, 57 McNeilus Cable Lube Kit, ..................50 mixer drum, ................3, 24, 37, 50, 54 Molybdenum Disulphite, ....................37 o-ring, ..............5, 12-13, 18, 28-29, 57 oil, ....................1-2, 9-10, 17-21, 26-28, ........................37-39, 49-50, 54, 56-57 Oil Level, ................................26-28, 50 Open Center Chute Block, ................44 © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Index

59

Notes

Notes

Notes

Notes

1227058 - Mixer Seminar I Manual

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