Mixer Seminar II Manual

Transcription

SEMINAR BOOK II
Bridgemaster III
Troubleshooting and
Service Information
McNeilus Truck and Manufacturing, Co.
CORPORATE HEADQUARTERS
P.O. Box 70, Hwy. 14 East, Dodge Center, MN 55927
Telephone: (507) 374-6321
IMPORTANT SAFETY INFORMATION
FOR CUSTOMERS AND USERS OF THIS PRODUCT
DO NOT OPERATE THIS VEHICLE UNTIL YOU HAVE READ AND THOROUGHLY UNDERSTAND the operation and maintenance procedures described in this manual and in any other
manuals associated or supplied with this unit. In addition, it is your responsibility to become
familiar with the CAUTION, WARNING AND DANGER notices described throughout this manual
or on placards on the unit. These notices and placards advise against the use of practices and
techniques which could result in serious personal injury and/or cause damage to the vehicle.
PERSONS WHO DEVIATE FROM THE RECOMMENDED OPERATING INSTRUCTIONS,
MAINTENANCE METHODS, OR OPERATING PROCEDURES AS SPECIFIED IN THIS MANUAL AND/OR IGNORE THE CAUTION, WARNING AND DANGER NOTICES PROVIDED WITH
THIS VEHICLE DO SO AT THEIR OWN RISK. MCNEILUS TRUCK AND MANUFACTURING,
INC., SHALL NOT BE RESPONSIBLE FOR AND SPECIFICALLY DISCLAIMS ANY LIABILITY
FOR ANY INJURIES OR DAMAGES THAT MAY RESULT FROM ANY DEVIATIONS FROM
RECOMMENDED INSTRUCTIONS, METHODS OR PROCEDURES AND ANY FAILURES TO
ADHERE TO CAUTION, WARNING AND DANGER NOTICES.
The detailed maintenance and service instructions and their respective inspection methods
and time schedules (as recommended by McNeilus Truck and Manufacturing, Inc.) included in
this manual are very important. These instructions and inspection schedules were created for
the benefit of our customers and users of this product. This vehicle was produced with these
maintenance/service practices in mind. THE SAFE OPERATION, MAINTENANCE, AND SERVICE OF THIS VEHICLE DEPENDS UPON YOUR ADHERENCE TO THESE
MAINTENANCE/SERVICE PRACTICES.
If you have any questions, comments, or need assistance, please call McNeilus Truck and
Manufacturing, Inc., at (507) 374-6321.
Table of Contents
Important Safety Information.......................................................................................................................................ii
Recommended Updates for Your Older Mixers ...........................................................................................................viii
Internal Flo-Fuse™........................................................................................................................................................ix
Hydraulic System - How It Works ..................................................................................................................................1
High Pressure Filter - 15p Assembly .............................................................................................................................3
Parker Pressure Compensated Pump ........................................................................................................................4
Variable Volume Piston Pump........................................................................................................................................5
Parker Pump Dimensions ..............................................................................................................................................6
Production 1/96 Thru Present ......................................................................................................................................11
BMIII Combination Block- Double Acting Chute Lift Cylinder .....................................................................................11
Bridgemaster III Combination Block - Single Acting Chute Lift Cylinder 5/93 - 12/95..............................................12
Bridgemaster III Assembly - Control Block ..................................................................................................................13
Bridgemaster III Assembly - High Flow Block.............................................................................................................14
Bridgemaster or Tuck-A-Weigh Assembly - ................................................................................................................15
Motion Control Valve CB-4...........................................................................................................................................15
Bridgemaster III Hydraulic System...............................................................................................................................16
Bridgemaster III Control Block Schematic ...................................................................................................................17
Axle Down Schematic ..................................................................................................................................................18
Axle Up Schematic.......................................................................................................................................................19
Bridgemaster III System Troubleshooting Guide .......................................................................................................21
Pressure Compensating Pump Troubleshooting .......................................................................................................22
Bridgemaster Trailer System Electrical Troubleshooting .............................................................................................23
Bridgemaster or Tuck-A-Weigh ...................................................................................................................................27
Closed Center Chute Block Assembly .......................................................................................................................27
Closed Center Chute Lift Valve RAISE POSITION .....................................................................................................28
Closed Center Chute Lift Valve HOLD POSITION .....................................................................................................29
Closed Center Chute Lift Valve LOWER POSITION ...................................................................................................30
Closed Center Chute Lift Control Valve Troubleshooting - Bridgemaster .................................................................31
Cartridges ..................................................................................................................................................................32
Accumulators ...............................................................................................................................................................33
Piston-Type Accumulator .............................................................................................................................................34
Tuck-A-Weigh (Trailer Down).......................................................................................................................................35
Tuck-A-Weigh (Trailer Up) E Block Manifold Assembly .............................................................................................36
Troubleshooting Hydraulic Manifold Assembly - Type E..............................................................................................37
Troubleshooting Hydraulic Manifold Assembly - Type E..............................................................................................38
Troubleshooting Guide for the Tuck-A-Weigh - Main System......................................................................................39
Troubleshooting Guide for the Tuck-A-Weigh - Chute Lift Control Valve ....................................................................40
Westport Axle Information ............................................................................................................................................43
Westport Axle Information ............................................................................................................................................76
Mixer Maintenance and Periodic Inspection .............................................................................................................77
Additional Information ..................................................................................................................................................79
Safety Decal Page .......................................................................................................................................................80
Index ............................................................................................................................................................................84
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Table of Contents
i
Important Safety Information
IMPORTANT SAFETY INFORMATION
READ AND UNDERSTAND THIS ENTIRE MANUAL
BEFORE OPERATING, REPAIRING, OR ADJUSTING
YOUR MCNEILUS MIXER. THOSE 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.
!
WARNING
Anytime you are working on this equipment or its
related systems, you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that he
must not attempt to start the truck.
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) 374-6321 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.
2. Follow all OSHA and Mixer Lock Out procedures.
Remove the keys from the truck’s ignition.
3. Place magnetic signs on both doors of the truck
which read:
“CAUTION - MAN WORKING ON MIXER - DO
NOT START ENGINE”
4. Lock out supplies are available from McNeilus
Truck and Manufacturing. Call (507) 374-6321 for
assistance.
Some service operations may require special tools, equipment, or blocking devices (such as the body hoist or tailgate). If you require information on these items, please
contact McNeilus Truck and Manufacturing at (507) 3746321 before attempting these repairs and service operations.
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.
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. FAILURE 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. IF YOU ARE UNFAMILIAR WITH
THE OSHA LOCK OUT PROCEDURES OR ANY SAFETY REQUIREMENTS, PLEASE CONTACT MCNEILUS
TRUCK AND MANUFACTURING AT (507) 374-6321
FOR ASSISTANCE.
ii
!
WARNING
Hydraulic hoses, fittings, and pipe must be inspected on a daily basis for leaks, cuts, 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 the mixer is returned to service! In
any event, all hydraulic hoses must be replaced
every two years. Failure to properly 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
and repairs. Dispose of used oil and filters as
required by law.
!
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) 374-6321. 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.
!
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.
!
WARNING
Pressure should never exceed 55 psi. If pressure
exceeds 55 psi, depressurize water tank immediately
and replace with new McNeilus air regulator valve.
important Safety Information
iii
NEVER pressurize an empty water tank. NEVER
modify water tank in any way. Operating in excess of
55 psi, pressurizing an empty water tank, or modifying the tank may cause serious injury or death.
!
WARNING
Never drive the truck with the water tank pressurized. Serious personal injury or death may result.
!
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 high 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 condiiv
tion 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.
!
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.
!
WARNING
The water tank must be operated at no more than 55
psi.
!
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.
!
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 should not be overloaded. Load pressures must match the load to be transported.
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.
!
!
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
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.
v
!
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!
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.
!
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.
vi
!
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.
!
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.
vii
Recommended Updates for Your Older Mixers
REAR CONTROL BOX WITH SWITCH GUARD
P/N 280.82440B
MCNEILUS UPPER HANDRAIL ASSEMBLY
AND WASHOUT SCREEN ARE RECOMMENDED FOR ADDED SAFETY DURING WASHOUT.
HYDRO TEST KIT
P/N 260.00483
PARKER PUMP
P/N 160.02026
DUE TO CHANGING STATE
REQUIREMENTS, MCNEILUS
NOW OFFERS DATA PLACARDS
AND SIGHT GAUGE STRIPS
WITH BOTH STANDARD AND
METRIC CAPACITIES.
viii
HAYDEN FAN COOLER
ACCUMULATOR CHARGE KIT
P/N 160.108575
P/N 160.85455
Safety and New Changes
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
Will not change chute speed
Premium quality
Recommended for all McNeilus Mixers
• P/N 200.107625 McNeilus 2-1/2” x 16”
Cylinder
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
ix
x
Hydraulic System - How It Works
1. Pressure Compensated (PC) pump
a. The PC pump draws oil from the reservoir
as required
a. COMPENSATED PRESSURE flows into the
control block and moves into 3 areas within
the block:
1. One route directs compensated pressure to the closed center chute lift block
section
b. The PC pump develops pressure respective
to the compensator setting
1. This is called COMPENSATED PRESSURE
2. One route directs a flow of oil at compensated pressure to the Directional
Valve.
2. Compensated pressure has a +3,000
PSI range capability
3. One route directs a flow of oil at compensated pressure to the PRV 2 valve
3. The compensator is fully adjustable
c.
With the exception of internal leakage, the
pump only develops flow when the large
cylinder is in motion or the chute is being
raised
b. COMPENSATED PRESSURE to the directional valve
1. When the down position is activated,
the Directional Valve directs a flow of oil
at compensated pressure to the trailer
latch and PTS. The trailer latch opens
and the spool of the PTS shifts against
the PTS spring. This flow is via hose as
the PTS is located in the hi-flow block
on the barrel end of the large cylinder
1. You can check the bypass gauge on the
hi-pressure filter ONLY when the large
cylinder is being extended or retracted.
a. This would be a maximum flow situation
d. The PC pump develops approximately 1
GPM of leakage which is routed back to the
reservoir
e. Oil flows at compensated pressure from the
PC pump through the hi-pressure filter
2. Hi-Pressure Filter
a. The oil flow flows through the Bridgemaster
filter element trapping particles of contamination
b. If the element becomes full, the bypass will
open. This allows oil to flow directly through
the filter head without flowing through the
filter.
1. The bypass becomes functional any
time the OUTLET PRESSURE IS 50
PSI BELOW THE INLET PRESSURE.
At the same time, the indicator will read
“bypass”. You can only read the indicator when the large cylinder is being
extended or retracted.
c.
The oil flow continues to the Bridgemaster
III control block at compensated pressure
3. Control Block - COMPENSATED PRESSURE
TO REGULATED PRESSURE
c.
COMPENSATED PRESSURE to the PRV 2
1. The PRV 2 REDUCES COMPENSATED
PRESSURE from the Cessna pump to
the setting of the PRV 2
2. This new lower pressure from the PRV
2 is called “REGULATED” or
“REDUCED” pressure
d. This flow of reduced pressure travels to the
hi-flow block on the cylinder barrel end via
hose between the control block and hi-flow
block
4. Hi-Flow Block
a. The PTS valve receives an oil flow of
REDUCED PRESSURE from the PRV 2
flow and directs it to the barrel end of large
cylinder. This happens when the down trailer position is selected and an oil flow of
pilot pressure from the directional control
valve shifts the PTS’s spool against its
spring
1. With no pilot pressure, the spring holds
the PTS spool in its normal position
which blocks off regulated pressure and
exposes the large cylinder barrel end to
tank (trailer up)
1
b. At any time there is pressure in the large
cylinder barrel end, the pressure is also
exposed to the Hl-PRESSURE RELIEF
VALVE. Should the pressure exceed 3,300
PSI, the hi-pressure relief valve will open
and dump directly to the reservoir. This protects the systems from damage due to high
pressure.
c.
An oil flow of COMPENSATED PRESSURE
also flows from the hi-flow block to the
LATCH CYLINDER. This flow is tee’d from
the PTS pilot flow inside the hi-flow block
which arrives from the directional control
valve. The latch cylinder responds to
approximately 50-60 PSI whereas the PTS
spool responds to 175 PSI. Thus the latch
cylinder will open before the PTS shifts to
let the trailer down.
d. A drain line from the CB 4 cartridge also
joins the tank drain internally in the hi-flow
block
5. CB 4 Block
a. The CB 4 block mounts on the rod end of
the large cylinder
b. The CB 4 block contains a CB 4 cartridge
and a check valve
1. The CB 4 cartridge is sensitive to pressure differences between the cylinder
rod end and regulated pressure port on
the CB 4 block assembly. If the regulated pressure on the CB 4 block is lower
than the regulated pressure in the cylinder barrel end, the CB 4 cartridge will
close. This traps oil in the cylinder rod
end and terminates cylinder movement.
Previous CB 1 and CB 3 valves
requires pilot pressure for operation. All
CB cartridge installations or replacements should utilize the CB 4 block
assembly.
2.
2
The CHECK VALVE allows a flow of
reduced pressure toward the cylinder
rod end only. For the oil to flow from the
cylinder rod end, it must flow through
the CB 4 cartridge. The CB 4 also controls the down speed of the cylinder as
the opening through the CB 4 cartridge
is a specific size. This is not adjustable.
c.
A hydraulic hose is routed from the end of
the CB 4 cartridge to the hi-flow block. This
hose accumulates any normal leakage from
the CB 4 cartridge and routes it to tank
through the hi-flow block.
6. Trailer Down Operation
a. A flow of oil travels from the pump through
the filter (compensated pressure) to the
control block. The PRV 2 reduces the pressure to the amount required by the system.
The reduced pressure oil flows through the
PTS which was shifted by pilot pressure
from the directional valve. Oil which flows
through the PTS valve flows directly into the
barrel end of the cylinder. Because of a difference of area exposed to reduced pressure, the cylinder extends and the
Bridgemaster III trailer goes down
b. Reduced pressure flow in the rod end of the
cylinder leaves the cylinder through the CB
4 cartridge and returns to rejoin the oil flowing to the cylinder through the PTS in the
hi-flow block.
c.
The check valve remains closed during trailer down cycle
7. Trailer Up Operation
a. There is no flow through the directional
valve when the trailer up switch is activated
so the PTS in the hi-flow block drains the
barrel end of the large cylinder to tank. A
flow of oil travels from the pump through the
filter (compensated pressure) to the control
block. The PRV 2 reduces the pressure to
the amount required by the system.
b. A flow of oil at reduced pressure travels
through the hi-flow block from the control
block to the CB 4 block. The CB 4 is closed
as oil cannot flow through the CB 4 in that
direction.
c.
The reduced pressure oil flow opens the CK
valve in the CB 4 block and flows into the
rod end of the large cylinder. The cylinder
barrel end is drained to tank through the
PTS. With oil flowing into the rod end of the
cylinder at reduced pressure, the cylinder
retracts and the trailer goes up.
High Pressure Filter - 15p Assembly
item
1
2
3
4
5
Part No.
140.108551
140.108552
140.108553
100.108554
260.106555
Description
Head
Canister
Filter
O-Ring
Indicator
140.108550
Qty.
1
1
1
1
1
BRIDGEMASTER OR TUCK-A-WEIGH CUSTOMER INFORMATION BULLETIN HIGH PRESSURE FILTERS
A high pressure filter is installed on your Bridgemaster III or Tuck-A-Weigh. The hydraulic system on these units develop flow only when the Bridgemaster III or Tuck-A-Weigh cylinder extends. This is also the only time oil flows through
the high pressure filter and the only time the gauge on the high pressure filter will indicate normal (Green) or bypass
(Red) situation. If the gauge indicates a bypass (Red) situation the oil is not being filtered adequately and your system
may become contaminated and cause a malfunction.
A replacement filter element with a beta rating of B7 = 200 is required to adequately filter the hydraulic oil. Replacement
high pressure elements are available through your McNeilus branch. Order McNeilus P/N 140.108553. A filter element
with a lower beta rating will not filter adequately.
The O-Ring (100.108554) should also be replaced when the filter is replaced. Apply a light film of clean oil to the gasket before reinstalling.
Your older McNeilus Bridgemaster may have a larger filter element (140.106553) and O-ring (100.106554). This is a
model 30P filter. A tag on the filter will contain a model number.
!
WARNING
Be sure all pressure is relieved in the Bridgemaster or Tuck-A-Weigh system before the filter is serviced.
High Pressure Filter - 15p Assembly
3
Parker Pressure Compensated Pump
Model:
Inlet Size:
Outlet Size:
Case Drain:
Displacement:
Mounting Pad:
Spline:
Max. psi:
Max. rpm:
Flow:
Efficiency:
Noise Level:
Horsepower:
4
PVP16
-12 (3/4”) (Marked “IN” on end of pump)
-12 (3/4”)
-6 (3/8”)
.98 cid/rev
SAE “A”
SAE “A” (5/8” x 9 spline”
3,600 psi
3,000 rpm
5.2 gpm @ 1,200 rpm / 7.8 gpm @ 1,800 rpm
Approximately 95% @ 3,000 psi
80 dba @ 3,000 psi
15.2 @ max flow and pressure
1.75 @ 3,000 psi (Bridgemaster trailer not moving)
Parker Pressure Compensated Pump
Variable Volume Piston Pump
Variable Volume Piston Pumps
5
Parker Pump Dimensions
6
Parker Pump Dimensions
Parker Pump Information
7
8
PRESSURE COMPENSATED PISTON PUMP
BRIDGEMASTER
2-1/2 GPM Max Case Drain
Seal Kit P/N 100.02313
Eaton Model 70122
Model 70122 1.16 cu. in. displacement
Destroked to .75 cu. in. displacement
BMIII Service Manual
9
10
BMIII Combination Block-Double Acting Chute Lift Cylinder
Production 1/96 Thru Present
B
RP
C2
G
C1
WHITE (A)
Down Solenoid
and Cartridge
PC1
PC2
Cartridge P/N 260.85773A
Coil P/N 060.85774A
(Same for up or down)
BLACK (B)
GREEN (C)
DOWN
UP
.056
UP
DATE CODE STAMP
DOWN
Up Solenoid
and Cartridge
P
Pilot Operated Checks
P/N 260.85712
Directional
Valve
P/N 260.108105
Trailer Up/Down
Directional Valve
Cap can be removed and a second
Parker Directional Valve installed for a
"flow stop" function. A Weather-Pak
connector is provided in the harness.
The second Parker Directional Valve
can be plugged in.
RED LEAD
*Up Flow Control
P/N 260.85713
BLACK LEAD
NOTE: If red and black
leads are reversed, the
internal Biode will
PRV2
be damaged.
P/N 260.85745A
** Down Flow Control
P/N 260.106596
This current production BMIII control block incorporates the double acting chute
lift cylinder feature and was put into production on 1/96. A sealed PR2 (pilotoperated pressure reducing valve) is installed in the block. A directional valve is
used for the trailer up/down electrical function. A second directional valve can
be added for a “flow stop” function which will stop the trailer in any position.
The directional valve wiring terminates in a Weather-Pak connector which plugs
into the mixer harness. The double acting chute lift function is built into the rear
of the block. The same components are used for the chute lift function as previous control blocks. Both the chute up and down speed are adjustable. The coils
are sealed from the elements. O-ring seals around the coil hole prevent moisture from entering the cartridge stem. Both coils have suppressed circuits to
prevent transient voltage spikes from entering the electrical system. Chute
wiring terminates in a Weather-Pak connector which plugs into the mixer harness.
*
Normal Adjustment - Up Flow Control - Full Clockwise (in) and 1/4 turn
counter-clockwise (out)
** Normal Adjustment - Down Flow Control - Full counter-clockwise (out)
and 4-5 turns clockwise (in)
Chute Pressure
Switch
P/N 060.108015
Note:
1. Port Size
SAE -4: G
SAE -6: B. RP. C1. C2
SAE -8: P. T.
2. Torque Specification
Cartridge Valves:
35 Ft.-Lbs.
Coil Retaining Nuts:
15 In.-Lbs.
Mounting Bolts:
85 In.-Lbs.
3. Coils Orientated As Shown.
4. Optional Flow Stop Valve.
For Installation Remove Cover Plate/Install Orifice.
5. Coil Connectors
Weather Pack. 2 Terminal:12010973
Weather Pack. 3 Terminal:12010717
P
B
B
X T
X P
T
Flow
Stop
Trailer
Up/Down
Top of Combination Block
Orifice in ports marked "X"
BMIII Combination Block
11
Bridgemaster III Combination Block - Single Acting Chute Lift
Cylinder 5/93 - 12/95
Parker Directional Valve
P/N 260.108105
Cap can be removed and a second
Parker Directional Valve installed for a
“flow stop” function. A Weather-Pak
connector is provided in the harness.
The second Parker Directional Valve
can be plugged in.
“Chute Up”
Speed Control
P/N 260.85713
“Chute Up”
Solenoid and
Cartridge
“Chute Down”
Speed Control
P/N 260.106596
“Chute Down”
Solenoid and
Cartridge
NOTE: The Parker Directional Valve will directly replace the
older style directional valve. The red lead must be
wired to positive and the black lead must be negative.
Reversing the leads will damage the internal diode.
PRV 2
Valve
P/N 260.85745A
Chute Pressure Switch
P/N 060.108015
Chute Up/Down
Cartridge: P/N 260.85773A
Coil: P/N 060.85774A
RED LEAD
BLACK LEAD
Positive
Negative (ground)
NOTE: If red and black leads
are reversed, the internal
diode will be damaged.
Pilot Operated Check Valve
P/N 260.85712
The BMIII control block was in production from 5/93 12/98. A sealed PRV2 (pilot-operated pressure reducing
valve) is installed in the block. A directional valve is used
for the trailer up/down electrical function. A second directional valve can be added for a “flow stop” function which
will stop the trailer in any position. The directional valve
wiring terminates in a Weather-Pak connector which
plugs into the mixer harness. The single acting chute lift
function is built into the rear of the block. The same components are used for the chute lift function as previous
12
BMIII Combination Block
control blocks. Both the chute up and down speed are
adjustable. The coils are sealed from the elements. Oring seals around the center coil hole prevent moisture
from entering the cartridge stem. Both coils have suppressed circuits to prevent transient voltage spikes from
entering the electrical system. Chute wiring terminates in
a Weather-Pak connector which plugs into the mixer harness.
Production:
8/84 - 5/93
Bridgemaster III Assembly - Control Block
160.108010
PARKER DIRECTIONAL VALVE
P/N 260.108015
BT
A
"P" PRESSURE
IN FROM
FILTER/PUMP
PILOT
PRESSURE
ADJUSTABLE PRV2 VALVE
P/N 260.85745A
TANK (RESERVOIR)
CHUTE BLOCK
REDUCED
PRESSURE
GAUGE
NOTE: TRAILER FLOW-STOP
TANK DRAIN MAY BE
"TEE'D" IN HERE ALSO
Bridgemaster III Assembly - Control Block
13
Bridgemaster III Assembly - High Flow Block
Current
Production
160.108012
This High-Flow block is located on the barrel end of the
arge cylinder.
14
Bridgemaster III Assembly - High Flow Block
Current
Production
Bridgemaster or Tuck-A-Weigh Assembly Motion Control Valve CB-4
160.108115
This motion Control Valve (CB-4) is located on the rod
end of the large cylinder.
CYLINDER PORT
COUNTER BALANCE
VALVE CARTRIDGE
P/N 260.108116
TO DRAIN LINE
LARGE
"P" PORT
CHECK VALVE
P/N 260.106592
Bridgemaster or Tuck-A-Weigh Assembly
15
Bridgemaster III Hydraulic System
COMPONENT DESCRIPTIONS
1. Control Block
A. Bridgemaster Directional (Parker Valve)
Function: Directs pressure and flow to latch cylinder and pilot-to-shift directional valve to allow
Bridgemaster to raise or lower. Also used on Flow
Stop Block or can be added to current block for
flow stop function.
Failure symptom: Bridgemaster will not change
direction. Valve will not shift because of bad switch
connection, failed coil or sticking spool.
B. Adjustable Pressure Regulating Valve (PRV2)
Function: Adjusts and maintains correct down
pressure (regulated pressure).
Failure symptom: System will not develop desired
pressure. Pressure erratic or unstable caused from
sticking or binding spool. Can be cleaned with
WD40™ or equivalent and reused.
C. Chute Up or Down Solenoid and Cartridge
(Current Block) (3W2P Cartridge)
Function: (Up Cartridge): Allows oil flow to raise
chute when coil is energized. (Down Cartridge):
Allows oil flow to unseat Pilot-Operated Check so
oil can leave the chute-lift cylinder.
2. High Flow Block (Barrel end of BM Cylinder)
A. Pilot-to Shift Orifice
Function: Provides smooth shifting of pilot-to-shift
directional valve spool.
Failure symptom: Bridgemaster will not change
direction because of plugged orifice.
B. Pilot-To-Shift Valve (PTS)
Function: Normal position connects barrel end of
cylinder to tank, allowing Bridgemaster trailer to
raise. Shifted position connects regulated pressure
to barrel end of cylinder, forcing Bridgemaster trailer down.
Failure symptom: Bridgemaster trailer will not
change direction. Spool not shifting because of
plugged pilot orifice, binding or jammed spool from
system contamination.
C. High Pressure Relief Valve
Function: Prevents pressure in barrel end of cylinder from exceeding 3300 PSI in abrupt grade
changes and rough roads or if accumulator charge
is low or flat.
Failure symptom: System will not develop desired
pressure if spool is stuck open.
3. Rod End Control Block (CB4)
Failure symptom: Chutes won’t move up or down
depending on cartridge affected. Can be cleaned
with WD40™ and reused. Also check coil for
magnetism when energized.
D. Pilot-Operated Check (PO CK)
Function: Holds chute in position.
Failure symptom: Chute drifts.
E. Chute Speed Control (See page 11)
Function: Control chute up and down speed.
• UP Speed Control - CW = slower
CCW = faster
• DN Speed Control - CW = faster
CCW = slower
Failure Symptom: Chute speed non adjustable
F. Chute Pressure Switch
Function: Senses chute not fully lowered.
A. Check Valve
Function: Allows free flow during Bridgemaster up
mode. Blocks flow in Bridgemaster down mode.
Failure symptom: Bridgemaster will not stop or
hold in mid-stroke position, or Bridgemaster moves
too fast in down mode. Failure is caused by system
contamination holding check valve open. If check
valve fails in the closed position, the axle will not
raise.
B. Counterbalance Valve
Function: Prevents Bridgemaster from being
lowered or dropping when truck is turned off, and
limits the speed the Bridgemaster can be lowered.
Failure symptom: Bridgemaster will not stop or
hold in mid-stroke position, caused by contamination holding the valve open. If check valve fails in
the closed position, the axle will not raise.
Failure symptom: BM trailer won’t move, red dash
light on. (Red dash light may also be caused by
faulty chute swing Prox or chute not centered.)
16
Bridgemaster III Hydraulic System
Bridgemaster III Control Block Schematic
Note: Tank Check Valve (CV) Added 10/97
Bridgemaster III Control Block Schematic
17
Axle Down Schematic
18
Axle Down Schematic
Axle Up Schematic
Axle Up Schematic
19
20
Bridgemaster III System Troubleshooting Guide
Symptom
System will not build pressure
Cause
Remedy
1. Defective Pump
Check pressure between pump and
valve assembly by dead heading pump
into a 0 to 5000 psi gauge. Reading
should be approximately 3100 psi
2. Adjustable Pressure Regulating
Valve (PRV-2) not operating
properly
Remove (PRV-2) valve from block, dip
in clean solvent and dry with compressed air to remove possible contamination, push on end of valve with finger-piston should move in and out.
replace with new valve
3. High Pressure Relief Valve stuck
open
Replace high pressure relieve valve
4. Pressure compensated pump
malfunctioned
Check compensator & inlet vacuum.
Dead head pump into 0 - 5000 psi
gauge. Reading should be approximately 3100 psi
1. Bridgemaster Directional control
valve (Parker) will Not Operate
Remove end caps and manually shift
valve with manual overrides. Check
and repair electrical connections or
replace valve
2. Pilot-to-Shift directional valve not
shifting properly
Check for plugged orifice (.025 dia.), or
install new valve
3. PSI set too low to open CB-4 valve
Adjust PRV-2 control valve to higher
setting
Excessive fluttering of pressure gauge
1. Accumulator charge low
Check and re-charge accumulator to
1150 psi. Check charging valve for
leakage
Bridgemaster drifts down when held
in mid position
1. Check valve leaking
Clean or replace check valve in rod
end of CB-4 control block
2. Counter balance valve CB-4 leaking
Replace counter balance cartridge in
CB-4 (rod end) control block
Bridgemaster will not change direction
during transport
Note: See Closed Center Chute Lift Block Control Valve Troubleshooting
Section for chute lift information.
Bridgemaster III System Troubleshooting Guide
21
Pressure Compensating Pump Troubleshooting
Symptom
Cause
Remedy
1. Noisy pump caused by cavitation
1. Oil too heavy
2. Suction strainer or filter plugged
3. Suction line plugged, too small, or
too long
4. Suction line closed internally
1. Change to proper viscosity
2. Clean or replace
3. Clean line and check for proper size
and length
4. Replace suction line (SAE 100R4)
2. Noisy pump caused by aeration
1. Oil supply low
2. Air leaking into suction line
3. Foaming oil
1. Fill reservoir
2. Tighten fittings
3. Drain reservoir and fill with nonfoaming type oil
3. Hydraulic system overheating
1. Oil supply low
2. Oil in system too light
1. Fill reservoir
2. Drain reservoir and refill with proper
viscosity oil
3. Disconnect case, remove drain line,
measure leakage volume while
pressurizing hydraulic system. Case
drain flow should not exceed 2.5
gpm. If excessive, remove pump,
disassemble and repair.
4. Tighten fittings
3. Excessive internal leakage
4. Aeration of oil
4. System not developing adequate
pressure
1. Excessive internal leakage
2. Compensator spool stuck open
3. Compensator spring weak or broken
5. System not developing adequate flow
22
1.
2.
3.
4.
Excessive internal leakage
Compensator spool stuck open
Compensator spring weak or broken
Pump cavitation
Pressure Compensating Pump Troubleshooting
1. Refer to 3c.
2. Disassemble compensator, inspect
for stuck spool, clean or replace
compensator assembly
3. Disassemble compensator, inspect
for weak or broken spring. Replace
spring if necessary.
1. Refer to 3c
2. Refer to 4b
3. Refer to 4c
4. Refer to causes and remedies for
1a, 1b, and 1c.
Bridgemaster Trailer System Electrical Troubleshooting
!
WARNING
Before lowering the Bridgemaster trailer, turn the
PRV-2 (Pressure Reducing Valve) fully counterclockwise to itís minimum gauge pressure of approximately 1,000 - 1,100 psi.
!
WARNING
Anytime you are working on this equipment or its
related systems, you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that he
must not attempt to start the truck.
2. Follow all OSHA and Mixer Lock Out procedures.
Remove the keys from the truck’s ignition.
3. Place magnetic signs on both doors of the truck
which read:
“CAUTION - MAN WORKING ON MIXER - DO
NOT START ENGINE”
4. Lock out supplies are available from McNeilus
Truck and Manufacturing. Call (507) 374-6321 for
assistance.
!
WARNING
Always be sure the area behind the mixer is clear of
people or other obstacles when raising or lower the
trailer.
console is on, this indicates that the chutes are not centered or are not fully lowered.
Provided that the chutes are centered, the electrical current next travels to the chute pressure switch located on
the rear of the main control block. This block is located
directly behind the cab on the driverís side Bridgemaster
frame rail.
If the chutes are raised, the resulting pressure in the
chute hoist hydraulic line will activate the chute pressure
switch, opening (eliminating) the circuit, and the
Bridgemaster trailer will not lower. If the red indicator
light on the in-cab console is on, the chutes are not fully
lowered or are not centered.
If the chutes are both centered and in the full down position, the electrical current next travels to the
Bridgemaster activate switch located on the in-cab console.
With the in-cab control console activate switch pressed,
move the up/down switch in the direction that you want
the trailer to move.
When all of the above circuits are active, the electrical
current is sent to the hydraulic solenoid directional valve
(the Parker valve) located on the top, driverís side of the
main control block (the Combo block). The trailer will
then raise or lower as directed by the up/down switch.
THE OPTIONAL MID-POSITION START/STOP SWITCH
NOTE: The chutes must be in the full down position or
the trailer will not raise or lower.
NOTE: The chutes must be centered or the trailer will
not raise or lower.
NOTE: Always use Dielectric grease on Weather-PakÆ
connections.
THE ELECTRICAL CIRCUIT
The electrical power for the Bridgemaster trailer
raise/lower function begins at the control console. Older
Bridgemaster units have a 5 amp resettable circuit
breaker on the front of the console. Current production
units have a 5 amp ATO fuse inside the passenger side
of the console.
12 volts travels directly from the console to the proximity
switch located at the main chute pivot. If the chutes are
not centered, the proximity switch opens eliminating the
electrical circuit and the Bridgemaster trailer will not
raise or lower. If the red indicator light on the in-cab
The optional mid-position start/stop switch allows you to
stop the trailer during the up or down cycle. This is
accomplished by interrupting the hydraulic flow prior to
the Bridgemaster up/down hydraulic solenoid directional
valve.
NOTE: When the mid-position start/stop switch is in the
stop position, the Bridgemaster trailer and the chutes will
be inoperative. The in-cab hydraulic pressure gauge will
read zero pressure and placing the transmission in
reverse will not raise the Bridgemaster trailer. As an
example: If the trailer was moving down before the
Bridgemaster mid-position switch was activated to stop
the trailer, the trailer will continue to move down when
the Bridgemaster mid-position switch is moved to the
ìonî position. If the trailer is moving down and the truck
transmission is placed in reverse, the trailer will change
direction and will go up.
23
!
WARNING
Anytime the mid-position start/stop switch is in the
“on” position and the truck transmission is placed in
reverse gear, the Bridgemaster trailer will raise
bypassing the proximity centering switch and the
chute pressure switches. This can cause severe
damage to the chutes and other components unless
the chutes are centered and fully lowered.
BRIDGEMASTER TRAILER WILL NOT RAISE OR
LOWER
1. If there is no voltage present, check the
fuse or check the wire.
2. If voltage is present, check the position
of the proximity switch (1/4” air gap) or
replace proximity switch.
IF THE RED LIGHT IS OFF:
A. Make sure the mid-position switch is in the “on” position.
Quick Checks if the Red Light is On:
1. There should be pressure showing on the cab
gauge.
A. Are the chutes in the full down position?
2. The chutes should move up and down.
B. Are the chutes centered (pointing directly to the
rear)?
B. Make sure the truck transmission is not in reverse.
C. If there is no hydraulic pressure on the cab gauge:
IF THE RED LIGHT STAYS ON:
1. Make sure the pump drive shaft is turning.
A. Unplug the Weather-PakÆ connector for the chute
pressure switch located on the passenger side of the
main control block.
2. Remove the PRV-2 valve (pressure reducing
valve) and push the end of the valve “in” and
ìoutî several times while spraying with WD-40.
Reinstall the PRV-2 and check for system pressure (older systems may have an orifice under
the PRV-2).
1. If the Red Light goes out after unplugging the
Weather-PakÆ connector, the problem is in the
hydraulic chute system or the chute pressure
switch.
a. Remove the pressure switch and check for
“open circuit” with ohm meter. If the switch
checks good, proceed to step B.
b. Change the “up” and “down” chute cartridges around, reconnect pressure switch,
and check for proper operation of the system.
c. Bleed all air from the chute hydraulic line by
loosening the line at the cylinder (has anyone changed the cylinder?)
2. If the Red Light stays on after unplugging the
Weather-PakÆ connector, the problem is in the
proximity switch on the rear chute pivot or associated wiring.
3. Remove the hose from the inlet side of the high
pressure filter located behind the cab of the
truck. Install a 0 - 5,000 psi gauge in the line
and ìdeadheadî the pump into the gauge. Start
the truck and check the pressure reading
(approximately 2,800 - 3,000 psi). If the pressure is low, call your nearest McNeilus branch
for assistance.
Anytime you have questions on troubleshooting or repair
of your McNeilus Bridgemaster, please contact your
McNeilus branch or call the McNeilus Corporate
Headquarters at (507) 374-6321 and ask for mixer service.
a. Disconnect the wiring for the proximity
switch.
b. Check for 12 volts DC at terminal “C” (red
wire).
24
Simplified Bridgemaster Trailer Schematic
Proximity Switch
Battery
5 Amp Fuse
D
C
A
B
- - - + + + +
Back-Up Lights
Axle Direction
y
;
;
y
;y ;y
Up
R
CAB
Down
Axle Activate
Chute Pressure Switch
Up
Down
Directional Valve
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved.
Simplified Bridgemaster Trailer Schematic
25
Bridgemaster Circuit
26
Bridgemaster Circuit
Bridgemaster or Tuck-A-Weigh
Closed Center Chute Block Assembly
FLOW CONTROL VALVE - UP
(ADJUSTABLE ONLY WHEN ENGINE IS OFF)
P/N 260.85713
INPUT PRESSURE
TANK
FLOW CONTROL
VALVE • DOWN
260.106596
Production 8/84 - 5/93
PILOT OPERATED CHECK
VALVE
P/N 260.85712
24" LEADS
CYL
UP
DOWN
3-WAY CARTRIDGES
P/N 260.85773A
COIL
CAN
12V COIL
P/N 060.85774A
NOTE: •
•
Replace old style assembly with
P/N 260.85773A cartridge and
P/N 060.85774A 12 Volt coil.
Old style no longer available.
The current style assembly has a single
piece molded epoxy coil rather than the
"coil can".
Bridgemaster or Tuck-A-Weigh Closed Center Chute Block
27
Closed Center Chute Lift Valve
RAISE POSITION
How It Works
1.
2.
3.
4.
Up Cartridge energized.
Flow from “P” Port passes through Up Cartridge.
Flow opens pilot operated check
Flow extends chute lift cylinder to raise chute
NOTE:
Chute Lift Cylinder
2" x 18" 200.107627
2" x 16" 200.107620
2-1/2" x 16" 200.107625
Use only McNeilus OEM Chute Lift
Cylinders with internal Flo-Fuse.
C
3
Pilot Operated Check
260.85712
Up Cartridge
3-Way Solenoid Valve
Down Cartridge
Coil P/N 060.85774A
2
Energize
to Lower
1
)(
P
28
Flow Control
Up Speed Adjust
260.85713
)(
Energize
to Raise
Pressure Compensated
Flow Control
Down Speed Adjust
260.106596
T
520.85770 HOLD POSITION
How It Works
1. Oil cannot leave chute-lift cylinder as pilotoperated check is closed.
2. Chute remains in Hold position.
NOTE:
Chute Lift Cylinder
2" x 18" 200.107627
2" x 16" 200.107620
2-1/2" x 16" 200.107625
C
260.85712
1
Down Cartridge
Up Cartridge
Coil P/N 060.85774A
Energize
to Lower
Energize
to Raise
)(
Flow Control
Up Speed Adjust
260.85713
P
)(
Flow Control
Down Speed Adjust
260.106596
T
Load Pressure
Return Pressure
Compensator Pressure
29
LOWER POSITION
How It Works
1.
2.
3.
4.
5.
Down Cartridge energized
Flow from “P” port passes through Down Cartridge
This flow becomes pilot pressure and lifts pilot operated check
Oil leaves chute-lift cylinder through the pilot operated check and
the up cartridge and returns to the reservoir.
Chute lowers
NOTE:
3
Chute Lift Cylinder
2" x 18" 200.107627
2" x 16" 200.107620
2-1/2" x 16" 200.107625
C
260.85712
Down Cartridge
Up Cartridge
Coil P/N 060.85774A
2
Energize
to Lower
4
Energize
to Raise
1
)(
P
Flow Control
Up Speed Adjust
260.85713
)(
Flow Control
Down Speed Adjust
260.106596
T
Lowering Pressure
Return Pressure
30
Closed Center Chute Lift Control Valve Troubleshooting - Bridgemaster
Symptom
Cause
Remedy
Chute drifts down while
in hold mode
1. Pilot operated check leaking
1. Install new pilot-operated valve
2. Down solenoid valve stuck in
energized position
1. Install new valve
2. Correct electrical if required
COIL SHOULD NOT BE ENERGIZED
1. Up solenoid valve does not operate
properly
2. Correct electrical
2. P.O. check not working (stuck shut)
1. Change P.O. check valve
1. Down solenoid valve does not
operate properly
2. P.O. check not working
1. Change P.O. check
Chute raises too fast
Flow adjustment not correct
Adjust up speed valve screw in to slow
down, screw out to speed up
Chute lowers too slow
or too fast
Adjust down speed valve screw out to slow
down, screw in to speed up
Chute will not raise
Chute will not lower
NOTE: Check electrical first
Solenoids should be energized when respective chute control button is depressed
Energized solenoid will be an electro magnet and should attract metal (such as a pocket knife blade)
Closed Center Chute Lift Control Valve Troubleshooting
31
Cartridges
I.
The Most Common Material Used for Hydraulic
Manifolds is 6061 Aluminum
A. The aluminum blocks are drilled and threaded
on a CNC machine
E. Using the following torque specifications for final
tightening:
1. #7 Series Cartridge (7/8” Hex) ......12 ft. lbs.
2. #10 Series Cartridge (1” Hex) .......35 ft. lbs.
B. The machined block is cleaned and hard
anodized
1. Hard anodizing coats the aluminum block on
both the inside and outside with a thin surface that is acid resistant and hard as steel
II. Replacing Seals on Cartridges
A. Clean the manifold block to remove dirt and
other debris from around the cartridge
3. #16 Series Cartridge (1 1/2” Hex)..65 ft. lbs
4. #20 Series Cartridge 1 7/8” Hex) ..70 ft. lbs.
G. For solenoid valves, the coil retaining nut
should be torqued to approximately 10 in.
lbs.
NOTE: Overtightening cartridges will permanently
damage the cartridge.
B. Unscrew the cartridge from the manifold block
C. Inspect the cartridge and cartridge cavity to be
sure they are free of any o-ring fragments, chips,
or other contamination
D. Rinse the cartridge with WD-40® or an equivalent product
E. Dry the cartridge with compressed air
F. Remove and discard the work o-rings and split
back-up rings (if back-up rings are used)
G. Install new seals from the appropriate seal kit
1. Dipping each seal in clean oil before installation will aid the installation
III. Cartridge Valve Installation Procedure
A. Visually inspect the manifold block to make sure
the cavities are free of contamination including
machining burrs and chips
B. Check the cartridge valve to be sure it is free of
visible contamination
C. Be sure o-rings and/or split back-up rings (if
backup rings are used) are arranged properly on
the valve and are not damaged
D. Carefully screw the cartridge into the proper
cavity
32
Cartridges
Accumulators
A. Piston Type Accumulator
1. The piston accumulator is made of aluminum and has a two part sealing o-ring in
the center, a cast ring on each side of the
center seal, and a wiper ring on each end
of the piston
2. Any leakage from the piston type accumulator will be gradual and normally causes
no damage
3. The piston type accumulator is built into the
Tuck-A-Weigh/Bridgemaster cylinder rod
4. Because the accumulator piston is built into
the cylinder rod response time to pressure
changes are immediate and confined to the
cylinder
a. One kit will not fit all brands or styles of
accumulator systems
5. Purge air from the accumulator charge
hose
a. This prevents oxygen from entering the
accumulator
b. If oxygen enters the accumulator and
mixes with the oil during charging, an
internal accumulator ignition may result
1. The temperatures rises as the nitrogen gas is compressed and may go
high enough to ignite the oil/oxygen
mixture
B. Charging accumulators
When charging accumulators on transit mixer trailers the following safety guidelines must be followed
!
WARNING
Follow any OSHA procedures - the truck should be
“locked out” while the mechanic is working on the mixer
!
WARNING
The truck ignition key should be removed from the truck
to prevent someone from starting the truck while the
mechanic is working on the accumulator
1. The cylinder rod must be extended (trailer
on the ground) before the accumulator is
charged
2. Do not attempt to disassemble the accumulator or cylinders unless you have received
proper instruction
a. Contact McNeilus Truck and Mfg. for
instructions
“CHARGING AND GAUGING ASSEMBLY”
P/N 160.85455
If you have any questions on charging accumulators or require additional information on accumulators, contact McNeilus Truck and Manufacturing
Co., at 507-374-6321 and ask for the Mixer Service
Department.
3. Do not charge the nitrogen accumulator
until all hydraulic pressure is relieved from
the cylinder
4. Use the recommended McNeilus
Accumulator charge kit - P/N 160.85455
Accumulators
33
Piston-Type Accumulator
Cylinder
Port
Cylinder
Port
4-1/2” Rod
Important Information
•
Cylinder rod head is torqued to 1,500 ft. lbs.
•
Do not attempt to disassemble this cylinder unless you have
received proper instructions!
•
Accumulator must be entirely discharged before cylinder is
removed from the mixer.
Call McNeilus Truck and Manufacturing, Inc., at (507) 374-6321 for
assistance or information on the Accumulator cylinder before attempting
repair on the cylinder.
34
Piston - Type Accumulator
Tuck-A-Weigh (Trailer Down)
Manifold
Shuttle
Valve
260.106635
Secondary
Cylinders
200.107580
920 PSI
P
SC
Reg
T
Pressure
Regulating
Valve (Fixed)
260.85741
Orifice
260.85719
Pilot-To-Shift
Directional Valve
260.85717
P
T
.025
Orifice
260.106634
.062
Reg
To Chute
Valve
P
CB
C
)(
B
A
Main Cylinder
200.107530
3100
PSI
B
)(
Trailer Control
Valve
260.85720
A
Relief Valve
260.108006
Pressure
Regulating
Valve (Adjustable)
260.85745
T
)(
CR
.25
P
AUX
P
CD
Check Valve
260.85757
T
G
Counterbalance
Throttling Valve
160.85795
Filter
140.106550
Element
140.106553
Pump
Regulating
Pressure Gauge
260.85699
1.16 In3
Displ
Suction
Filter
Element
140.00429
Reservoir
Adjustable Regulated Pressure
NOTE: Suction filter (140.00429) is a 100 Mesh Filter
(not a 10 Micron Filter).
Return Pressure
Accumulator Charge
920 PSI Regulated
Tuck-A-Weigh (Trailer Down)
35
Tuck-A-Weigh (Trailer Up)
E Block Manifold Assembly 160.106630
Manifold
Shuttle
Valve
260.106635
SC
Reg
T
Secondary
Cylinders
200.107580
920 PSI
P
Pressure
Regulating
Valve (Fixed)
260.85741
Orifice
260.85719
Pilot-To-Shift
Directional Valve
260.85717
Trailer Control
Valve
260.85720
P
T
.025
Orifice
260.106634
.062
Reg
To Chute
Valve
P
CB
C
)(
B
A
Main Cylinder
200.107530
3100
PSI
B
)(
A
Relief Valve
260.108006
Pressure
Regulating
Valve (Adjustable)
260.85745
T
)(
CR
.25
P
AUX
P
CD
Check Valve
260.85757
T
G
Counterbalance
Throttling Valve
160.85795
Filter
140.106550
Element
140.106553
Pump
Regulating
Pressure Gauge
260.85699
1.16 In3
Displ
Suction
Filter
Element
140.00429
Reservoir
Adjustable Regulated Pressure
NOTE: Suction Filter (140.00429) is a 100 Mesh Filter
(Not a 10 Micron Filter).
36
Tuck-A-Weigh Trailer Up
Return Pressure
Accumulator Charge
Troubleshooting Hydraulic Manifold Assembly - Type E
TUCK-A-WEIGH CONTROL VALVE
FUNCTION:
TUCK-A-WEIGH UP:
Directs flow and pressure to
other system components for
raising and lowering the Tuck-AWeigh.
Connects pilot passages of pilotto-shift directional valve and
shuttle valve to tank. Connects
full system pressure (3000 PSI)
to fixed pressure regulating
valve tank port.
TUCK-A-WEIGH DOWN: Connects full system pressure
to pilot passages of pilot-to-shift
directional valve and
shuttle valve. Connects fixed
pressure regulating valve tank
port to tank.
FUNCTION:
Provides smooth shifting of pilotto-shift directional valve spool.
FAILURE SYMPTOM:
Tuck-A-Weigh will not change
direction because of plugged
orifice.
PRESSURE REGULATING VALVE (ADJUSTABLE)
FUNCTION:
Adjusts and maintains down
pressure of Tuck-A-Weigh.
FAILURE SYMPTOM:
System will not develop desired
pressure. Pressure erratic or
unstable caused from sticking or
binding spool.
CHECK VALVE
FAILURE:
Symptom: Tuck-A-Weigh will not
change direction. Valve will not
shift because of bad switch connection, failed coil, or sticking
spool. Manual override will shift
spool unless jammed with o-ring
or other system fragment.
FUNCTION:
Prevents a reverse flow of oil
from flowing through pump
when pump drive is disengaged.
FAILURE SYMPTOM:
Immediate loss of pressure
when pump is disengaged.
PILOT-TO-SHIFT DIRECTIONAL VALVE
SHUTTLE VALVE
FUNCTION:
FUNCTION:
Directs either full system pressure or adjustable regulated
pressure to fixed pressure regulating valve.
TUCK-A-WEIGH UP:
Shuttle ball shifts to direct regulated pressure to fixed pressure
regulating valve. Fixed pressure
regulating valve is piloted open
in this mode, which allows
adjustable regulated pressure to
reach secondary cylinders.
FAILURE SYMPTOM:
Normal position connects barrel
side of cylinders to tank, allowing Tuck-A-Weigh to raise.
Shifted position connects regulated pressure to barrel side of
cylinders, forcing Tuck-A-Weigh
down.
Tuck-A-Weigh will not change
direction. Spool not shifting
because of plugged orifice or
jammed spool from system fragments.
PILOT ORIFICE
TUCK-A-WEIGH DOWN: Shuttle ball shifts to direct full
system pressure (3000 PSI) to
fixed pressure regulating valve.
In this mode pressure is regulat-
37
TUCK-A-WEIGH DOWN: Shuttle ball shifts to direct full
system pressure (3000 PSI) to
fixed pressure regulating valve.
In this mode pressure is regulated at a constant 920 PSI to secondary cylinder.
FAILURE SYMPTOM:
Secondary cylinders will not
sequence properly. (Note:
Failure of shuttle valve very
unlikely. See fixed pressure regulating valve).
FIXED PRESSURE REGULATING VALVE- 920 PSI
FUNCTION:
Controls pressure to secondary
cylinders.
TUCK-A-WEIGH UP:
Valve is piloted open, allowing
adjustable regulated pressure to
reach secondary cylinders.
TUCK-A-WEIGH DOWN: Pressure is regulated at a constant 920 PSI to secondary
cylinders.
FAILURE SYMPTOM:
Secondary cylinders will not
sequence properly during TuckA-Weigh-up operation. (May not
tuck away).
Tuck-A-Weigh will kick out in
down mode.
NOTE:
Suction Filter (140.00429) is a
100 Mesh Filter (not a 10 Micron
Filter).
NOTE:
Hi Pressure Filter should have a
BETA Rating of B7 = 200.
38
Troubleshooting Guide for the Tuck-A-Weigh - Main System
Symptom
Cause
Remedy
System will not build pressure
1. Defective pump
Check pressure between pump and valve
assembly. If pressure is low, repair or
replace.
2. Adjustable pressure regulating
operating properly
1. Remove valve
2. Inspect orifice at bottom of cavity for
plugged condition
1. Tuck-A-Weigh control valve will
not shift
1. Operates with manual overrides
2. Repair electrical if required
2. Pilot to shift directional valve will
not shift
1. Check for plugged orifice
2. Install not valve
Excessive fluttering of
pressure gauge during
transport
Accumulator charge low
Charge accumulator
Secondary cylinders will
not kick out in Tuck-A-Weigh
down mode
1. Fixed pressure regulating
valve not operating properly
Install new valve
2. Idle RPM too low
Minimum engine RPM should be 500
3. Shuttle valve jammed
Install new valve
1. Fixed pressure regulating valve
not operating properly
Install new valve
2. Pilot-to-Shift directional valve
not fully shifted
1. Check for plugged orifice
3. Shuttle valve jammed
Install new valve
Tuck-A-Weigh will not
change direction
Secondary cylinders will
not retract in Tuck-A-Weigh
up mode
Tuck-A-Weigh Main System
39
Troubleshooting Guide for the Tuck-A-Weigh -
Chute Lift Control Valve
Symptom
Cause
Remedy
Chute drifts down while in
hold mode
1. Pilot operated check leaking
Install new valve
2. Down solenoid valve stuck in
energized position
2. Correct electrical if required
COIL SHOULD NOT BE ENERGIZED
Chute will not raise
Up solenoid valve does not
operate properly
Chute will not lower
Down solenoid valve does not
operate properly
Chute raises too fast
Adjust up speed valve screw in to slow
down, screw out to speed up
Chute lowers too slow
or too fast
Adjust up speed valve screw out to slow
down, screw in to speed up
NOTE: Check electrical first
Solenoids should be energized when respective chute control button is depressed
Energized solenoid will be magnetized
40
Tuck-A-Weigh Chute Lift Control Valve
CB4 Conversion
A pre-1988 Bridgemaster ll or Tuck-A-Weigh can be
retrofitted to a new style motion control valve (CB4).
Should a problem arise with the motion control valve on
a Bridgemaster ll (CB1) or a Tuck-A-Weigh (CB3), this
CB4 conversion would not only save the customer
money, but provide to be more efficient. All Bridgemaster
lll units built after 1/2/88 incorporate a CB4 as a standard
equipment.
To convert a CB3 on a Tuck-A-Weigh to the CB4 unit the
following steps should be followed:
1. Unplumb and remove existing CB3.
2. Eliminate the pilot line which runs between the
high pressure relief valve assembly. (HPRV) and
the CB3.
3. Install a plug in the pilot port on the HPRV as this
will no longer be required.
4. Install new CB4 to rod end of cylinder with the
ports pointing toward the HPRV.
5. Plumb the drain line from the HPRV to the end of
the CB4 cartridge (the end cap of the cartridge is
threaded to accept a fitting). A -4 to -6 adapter
will be required .
6. Plumb the large “CR” hose which was removed
from the CB3 to the CB4.
7. Check trailer performance on a scale. The new
CB4 is more efficient and may require recalibration.
To convert a CB1 on a Bridgemaster ll to the CB4 unit the
following steps should be followed:
1. Unplumb and remove the existing CB1.
2. Eliminate the pilot line which runs to the CB1
from either the HPRV or the “P aux” port of the
“C” block (control block).
3. Install a plug in the port which the pilot pressure
line came from. A pilot line is no longer required.
4. Install new CB4 to the rod end of the cylinder
with the ports pointing toward the HPRV.
5. Install a drain line from the CB4 cartridge end
(threaded to accept a fitting) to the reservoir (or
HPRV drain if equipped).
6. Plumb the large “CR” hose which was removed
from the CB1 to the CB4.
7. Check trailer performance on a scale. The new
CB4 is more efficient and will require recalibration.
The CB4 is quite simple to install. It has only three ports:
the port which attaches directly to the cylinder via a fitting
which is included with the CB4, a port for high flow which
allows oil to enter or leave the cylinder, and a cartridge
drain line which is designed to thread directly into the cartridge.
CB4 Conversion
41
42
Westport Axle Information
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Mixer Maintenance and Periodic Inspection
DAILY INSPECTIONS
1. Hydraulic hoses, fittings, and pipe must be inspected
on a daily basis for leaks, cuts, 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 the mixer is returned to service! In any event,
all hydraulic hoses must be replaced every two years.
Failure to properly inspect and maintain your mixer
may result in serious personal injury.
2. Visual roller track and roller alignment 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. 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.
5. Check vacuum gauge on oil filter. Replace element if
the reading exceeds 10 inches of vacuum after oil has
reached operating temperature.
6. Check for and correct any external oil or air leaks.
NOTE: Do not tighten or loosen any connections
while system is under pressure.
7. Lubricate pump drive shaft universal joints.
4. Check filler cap and neck on oil reservoir for leaks.
Check oil reservoir mounts. Make any necessary
repairs immediately.
5. Check and record drum RPM while loading mixer with
concrete and truck engine running at top governed
RPM. If drum 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 transmission drive plate bolts. Torque to
170 lb ft.
9. Check ZF transmission hold down bolts. Torque to
420 lb. ft.
10. Inspect debouncer for proper clearance.
11. Inspect roller track for cracks, flat areas. Correct as
necessary.
SIX MONTH INSPECTION
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 oil or filters. Multiple Viscosity oils and
Automatic Transmission Fluid (ATF) cannot be used
in the hydraulic system.
8. Lubricate roller bearings.
2.
9. Lubricate and inspect rear cable control box.
10. Lubricate chute pivot system and 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. 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.
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.
Lubricate control cables using the McNeilus Cable
Lube Kit.
Inspect mixer main hold down bolts and springs.
Replace or adjust as required.
77
REF.
UNIT ASSEMBLY
LUBE TYPE
APPLICATION
FREQUENCY
1.
Universal Joint
General Purpose EP Grease #2
Zerk Fitting
Semi-Weekly
2.
Drum Drive - Z.F.
Recommended lubricant: GL5 Spec.
85w - 140
Pour or Pump
3.
Chute Pivot System
General Purpose EP Lithium
Zerk Fitting
4.
Drum Rollers
Base Grease #2
Zerk Fitting
5.
Roller Track
7.
Hyd. Control Box
General Purpose EP Grease #2
Zerk Fitting
Semi-Weekly
8.
Hyd. Reservoir
ISO 68 for Temp ≤ 80°F
ISO 100 for Temp > 80°F
Fill to Sight
Gauge Level
*See Below
9.
Main Hold Down Bolts
Torque to 185 lbs.
Check
Weekly
10.
Sec. Hold Down Bolts
Bolts just snug
Check
1000 hours
11.
Trans. Hold Down
Bolts
Check
Weekly
12.
Debouncer
Adjustment range
3/8" to 1/2" maximum clearance
13.
Main Frame Bolts
Torque to 310 lb.s
Check
Weekly
14.
Drive Flange Bolts
Torque to 170 lb.s - 5/8" bolt
Check
Weekly
*See Below
Daily
Brush On
**Torque to 420 lb.s - 7/8" bolt
Inspect Daily
* Change oil after first 100 hours. Thereafter change every six months. Capacity: fill to check plug 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.
* NOTE: 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.
78
Additional Information
1. REPAIRING CHUTES
A. McNeilus does not recommend that chutes be
repaired. Use caution if you decide to repair
main chutes, foldovers, and extensions for
emergency use
1. Many repaired chutes are not safe and can
result in injury or death, or present a liability
problem should an accident occur
B. Hardware and bolt holes may be elongated
C. Use only high strength bolts when replacing
main and foldover chute bolts
D. Use safety chains on main chutes and
foldovers
2. WATER TANKS
A. Inspect water tanks for damage, dents, leaks,
rust, and corrosion on a weekly basis.
1. Also inspect the area around the water tank
mounting brackets
B. Mixers should not be transported with water
tanks pressurized
1. This is a law in some states
C. Do not exceed the manufacturer’s recommended pressures
D. When replacing components on the water tank
air pressure system, the same pressure value
components must be installed
1. Specifications of the McNeilus air pressure
system components
a. Hold back valve . . . . . . . . . . . . . . 75 psi
b. Regulator . . . . . . . . . . . . . . . . . . . 55 psi
c. Relief Valve . . . . . . . . . . . . . . . . . 60 psi
d. Pressure Gauge . . . . . . . . . . 0 - 100 psi
E. Use only DOT-approved air lines when replacing air lines
F. Replace pressure gauges which are defective
G. Replace any damaged or missing water tank
decals
3. ROLLER AND DEBOUNCER ALIGNMENT
A. Roller and debouncer alignment should be
inspected visually on a daily basis
B. Rollers should be parallel with the roller track
1. A machined surface for a straight edge is
provided on the rear of the roller on the
McNeilus mixer to check if the rollers are
parallel with each other
C. When the mixer is loaded the roller should have
maximum contact with the track
D. The debouncer should be adjusted to allow
minimum up-down drum movement
4. DECALS, WARNINGS, PLACARDS
A. Replace the decals, warnings, and placards if
the decals are damaged, worn, or painted over
B. Replace the chute warning decals when the
chutes are replaced.
C. Information may be required for rating plates,
capacity placards, etc
D. Safety decals must conform to the current standards for color, language, symbols, etc., to be
legal
5. FOLLOW OSHA PROCEDURES AND RULES
WHEN WORKING ON EQUIPMENT
A. When working on the mixer inform the truck driver that the mixer is going to be repaired and
“locked out” and that he must not attempt to
start the truck
B. Remove the keys from the ignition
C. Place magnetic caution sign on both doors
which read: “CAUTION - MAN WORKING ON
MIXER - DO NOT START ENGINE”
D. Read, understand, and follow the safety guidelines contained in the owner’s manual and on
the decals located on your mixer
E. McNeilus has no charge information on lockout
procedures available upon request
F. No passengers are allowed in the cab unless a
Manufacturer’s approved passenger seat and
seat belt are provided.
Additional Information
79
Safety Decal Sheet
80
Safety Decal Sheet
Safety Decal Sheet
Safety Decal Sheet
81
Safety Decal Sheet
82
Safety Decal Sheet
Safety Decal Sheet
Safety Decal Sheet
83
Index
10 Micron Filter Assembly, ......ii-vii,
J-K-L
V-W-X-Y-Z
A-B-C
kit, ........................ii-vii, 9, 32-33, 77
Latch Cylinder, ........................2, 16
vacuum gauge, ..........................77
WARNINGS, ......................ii-vii, 79
washout screen, ......................ii-vii,
Water Tanks, ..............................79
WD-40®, ..............................24, 32
ZF transmission, ........................77
Accumulator, ................ii-vii, 16, 21,
..........................................33-34, 39
Accumulator Charge Kit, ..ii-vii, 33,
....................................................84
Adjust down speed, ....................31
Adjust up speed, ..................31, 40
air chute lock, ..........................ii-vii,
air leaks, ....................................77
Automatic Transmission Fluid, ....77
blocking devices, ......................ii-vii
BMIII control block, ................11-12
Bridgemaster III System
Troubleshooting Guide, ..........ii-vii,
....................................................21
bypass, ....................................1, 3
Cartridges, ....................ii-vii, 24, 32
CB 4, ............................................2
Chute Pressure Switch, ............12,
..........................................16, 23-24
Closed Center Chute Block
Assembly, ..........................ii-vii, 27
Closed Center Chute Lift Control
Valve Troubleshooting, ......ii-vii, 31
Compensated Pressure, ............1-2
cylinder, ..................ii -3, 11-12, 16,
..................24, 28-30, 33-34, 38, 41
M-N-O
McNeilus Cable Lube Kit, ..........77
Mixer Maintenance and Periodic
Inspection, ....................ii-vii, 77-78
O-Ring, ....ii-vii, 3, 11-12, 32-33, 37
OSHA, ....................ii-vii, 23, 33, 79
P-Q-R
data placards, ..........................ii-vii,
debouncer, ............................77, 79
DECALS, ............................ii-vii, 79
Double Acting Chute Lift Cylinder, ..
....................................................11
drum, ............................ii-vii, 77, 79
Parker Directional Valve, ............12
Parker Pressure Compensated
Pump, ..................................ii-vii, 4
Parker Pump, ....................ii-vii, 6-7
Pilot-Operated Check, ..........16, 29
Pilot-to Shift Orifice, ....................16
Placards, ........................ii-vii, 2, 79
Pressure Compensated Piston
Pump, ............................................9
Pressure Compensating Pump
Troubleshooting, ................ii-vii, 22
PRV 2, ................................1-2, 12
PTS, ....................................1-2, 16
pump, ..........ii-vii, -2, 4-7, 9, 21-22,
..................................24, 37, 39, 77
rating plates, ..............................79
rear control box, ......................ii-vii,
Regulated Pressure, ..........1-2, 16,
................................................37-38
Repairing Chutes, ......................79
roller alignment, ..........................77
Roller and Debouncer Alignment, ..
....................................................79
roller track, ............................77, 79
G-H-I
S - T- U
Gross Vehicle Weight, ............ii-vii,
handrail assembly, ....................ii-vii
Hayden Fan Cooler, ..................ii-vii
Hi-Flow Block, ............................1-2
High Flow Block, ..........ii-vii, 14, 16
Hi-Pressure Relief Valve, ..............2
hoses, ................................ii-vii, 77
Hydraulic Down Pressure, ......ii-vii,
hydraulic hoses, ..................ii-vii, 77
Hydro test kit, ..........................ii-vii,
SAE J1065, ..............................ii-vii,
Safety, ................ii-vii, 2, 33, 79-84
sight gauge strips, ..................ii-vii,
Single Acting Chute Lift Cylinder,
............................................ii-vii, 12
torque specifications, ..................32
trailer pressures, ......................ii-vii,
Tuck-A-Weigh, ..............ii-vii, 3, 15,
....................................27, 33, 35-41
turn signals, ............................ii-vii,
D-E-F
84
Index
McNeilus Truck and Manufacturing Co.
CORPORATE HEADQUARTERS
P.O. Box 70, Hwy. 14 East, Dodge Center, MN., 55927
Phone: (507) 374-6321
BRANCH FACILITIES
CALIFORNIA
P.O. Box 1588, 401 North Pepper, Colton, CA 92324
Phone: 909-370-2100 • FAX: 909-370-0739
COLORADO
P.O. Box 1128, 7080 Eudora Drive, Commerce City, CO 80022
Phone: 303-287-7486 • FAX: 303-287-2780
GEORGIA
P.O. Box 367, 148 Punkintown Road, Villa Rica, GA 30180
Phone: 770-459-5151 • FAX: 770-459-0068
OHIO
P.O. Box 30777, 1130 Morrison Road, Gahanna, OH 43230
Phone: 614-868-0760 • FAX: 614-868-0498
PENNSYLVANIA
P.O. Box 219, 955 Hemlock Road, Morgantown, PA 19543
Phone: 610-286-0400 • FAX: 610-286-2094
TEXAS
P.O. Box 458, 1101 Interstate Hwy. 45 South, Hutchins, TX 75141
Phone: 972-225-2313 • FAX: 972-225-4407
WASHINGTON
5315 - 140th Street East, Tacoma, WA 98446
Phone: 253-536-0260 • FAX: 253-536-0483
©3/98 McNeilus Truck and Manufacturing. All Rights Reserved.

Mixer Seminar II Manual

Transcription

Similar documents

Structure Of August Srew Air Compressor

TWO-PIECE VALVE COVERS

deuter Streamer 2.0 Liter

COUNTRY FARM AUCTION

Crane Trucks

The Murzan PI 50 Sanitary Pump Gently Handles the Widest Range

CYLINDER KIT WITH POWER VALVE SYSTEM

By A-1 Auto Upholstery Inc.

Small Engine Parts Four-Cycle