1227058 - mixer seminar i manual

Table of Contents

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Table of Contents i

Important Safety Information ........................................1

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

Maintaining your Mixer Hydrostatic Pump and MotorSystem..........................................................................9

Gauge Installation Location ........................................15

Troubleshooting Your Mixer Hydrostatic System ....17

How to use the Fault Logic Charts ............................23

Troubleshooting Hydraulic Pumps and Motors ..........24

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

Eaton Hydraulic Division, Eaton Hydrostatic Pump - BallGuide ..........................................................................30

Control Valve - Old Style ............................................32

Control Valve - New Style S/N 0986 and higher ........33

Charge Pump Rotation Identification ........................34

Valve Plate Rotation ................................................35

Broken Pump Shaft ..................................................36

Hydrostatic Installation and Clean and FlushProcedures ................................................................37

Recommendations for Hydraulic FluidSpecifications ..........................................................38

Mixer Oil Specs ........................................................39

Water Tank Measurement ........................................41

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

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

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

Open Center Chute Valve AssemblyHOLD POSITION ......................................................45

Open Center Chute Valve AssemblyRAISE POSITION ....................................................46

Open Center Chute Valve AssemblyLOWER POSITION ..................................................47

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

Maintenance Periodic Inspection ............................49

Roller Adjustments ..................................................51

Universal Drive Shaft ..................................................52

Pump and Universal Alignment ................................53

ZF Drum Drives ........................................................54

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

Fluid Power Equivalents ............................................56

Common Abbreviations ..............................................57

Index ..........................................................................59

Important Safety Information

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Introduction and Safety Procedures 1

IMPORTANT SAFETY INFORMATION

READ AND UNDERSTAND THIS ENTIRE MANUALBEFORE OPERATING, REPAIRING, OR ADJUSTINGYOUR MCNEILUS MIXER. THOSE WHO USE ANDMAINTAIN THIS EQUIPMENT MUST BETHOROUGHLY TRAINED AND FAMILIAR WITH THEPRODUCT. IF INCORRECTLY USED ORMAINTAINED, THIS EQUIPMENT CAN CAUSESEVERE INJURY.

Always keep this manual in a location where it is readilyavailable for persons who operate or maintain theproduct. Additional copies of this manual are availablefrom McNeilus Truck and Manufacturing; (507) 374-6321 at no charge. Please contact McNeilus Truck andManufacturing if you require additional manuals or if youhave any questions concerning the information in thismanual or this product.

Some service operations may require special tools,equipment, or blocking devices (such as the body hoistor tailgate). If you require information on these items,please contact McNeilus Truck and Manufacturing at(507) 374-6321 before attempting these repairs andservice operations.

THESE SAFETY PROCEDURES ARE FOR YOUROWN PROTECTION.

DO NOT OPERATE OR REPAIR THIS EQUIPMENTUNTIL YOU HAVE READ THIS MANUAL ANDUNDERSTAND ITS CONTENTS THOROUGHLY.PLEASE CALL MCNEILUS TRUCK ANDMANUFACTURING AT (507) 374-6321 IF YOUREQUIRE ASSISTANCE!

SHOULD AN OPERATOR OF THIS EQUIPMENTHAVE A READING OR LEARNING DISABILITY,DYSLEXIA, OR OTHER SUCH CONDITION, THEN HEOR SHE MUST BE ASSIGNED A MENTOR/TRAINERTO READ AND EXPLAIN TO SUCH INDIVIDUAL THEENTIRE CONTENTS OF THIS MANUAL AS WELL ASTHE SAFETY GUIDELINES, DANGER, CAUTION ANDWARNING DECALS AND PLACARDS AFFIXED TOTHIS UNIT. SUCH INDIVIDUAL SHOULD NOT BEALLOWED TO OPERATE THIS EQUIPMENT UNTILHE OR SHE THOROUGHLY UNDERSTANDS ALL OFTHESE MATERIALS. FAILURE TO DO SO CANRESULT IN SERIOUS PERSONAL INJURY ORDEATH.

SAFETY AND SAFE WORKING PROCEDURES MUSTBE FOLLOWED AT ALL TIMES. OSHA LOCK OUTPROCEDURES MUST BE FOLLOWED WHENMAINTAINING THIS EQUIPMENT. IF YOU ARE

UNFAMILIAR WITH THE OSHA LOCK OUTPROCEDURES OR ANY SAFETY REQUIREMENTS,PLEASE CONTACT MCNEILUS TRUCK ANDMANUFACTURING AT (507) 374-6321 FORASSISTANCE.

Anytime you are working on this equipment or itsrelated systems, you must do the following:

1. Inform the truck driver that the equipment isgoing to be repaired and locked out and that hemust 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 truckwhich read: “CAUTION - MAN WORKING ON MIXER - DONOT START ENGINE”

4. Lock out supplies are available from McNeilusTruck and Manufacturing. Call (507) 374-6321for assistance.

READ, UNDERSTAND, AND FOLLOW THE SAFETYGUIDELINES, DANGERS, AND WARNINGS LISTEDBELOW AND CONTAINED IN THIS MANUAL TOPROMOTE RELIABLE OPERATION AND PREVENTSERIOUS PERSONAL INJURY.

Hydraulic hoses, fittings, and pipe must beinspected on a daily basis for leaks, cuts, abrasions,damage, aging, improper clearance, and along theframe for hidden damage. If you find hoses with anysuch adverse conditions or damage, they must bereplaced before the mixer is returned to service! Inany event, all hydraulic hoses must be replacedevery two years. Failure to properly inspect andmaintain your mixer may result in serious personalinjury.

Hydraulic systems are hot. DO NOT TOUCH!Serious personal injury may result from hot oil.When you have completed working on the hydraulicsystems, thoroughly clean any spilled oil from theequipment. Do not spill any hydraulic fluids on theground. Clean any hydraulic fluids from your skinas soon as you have completed your maintenanceand repairs. Dispose of used oil and filters asrequired by law.

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Hydraulic systems operate under high pressure -only experienced persons should attempt repairs ortroubleshooting on hydraulic systems.

Correct hoses, fittings, and adapters with thecorrect SAE rating must be used when replacinghoses to prevent possible serious injury. Alwaysreplace hoses, fittings, and adapters withreplacements that have a proper, suitable workingpressure rating. Replacement hoses must be of thecorrect length and must comply with the hosemanufacturer’s installation guidelines andrecommendations. Consult hose and fittingmanufacturers for correct specifications or contactMcNeilus Truck and Manufacturing at (507) 374-6321. Hydraulic hoses have the SAE ratings markedon the hose to assist you in selecting the correcthose. Any replacement hydraulic hoses and fittingassemblies must be supplied by the samemanufacturer. As an example: Brand “A” hose andbrand “B” fitting will not normally be compatible.No “twist” is allowed in the hydraulic hoses.“Twist” may result in premature hose failure. Pleasecontract McNeilus Truck and Manufacturing at (507)374-6321 for assistance when required.

Never remove hydraulic lines, fittings, and adaptersuntil all pressure has been relieved from thehydraulic system. Contact McNeilus Truck andManufacturing at (507) 374-6321 for assistance ifrequired.

Hydraulic components can be heavy. Use cautionwhile lifting these components. Serious personalinjury can be avoided with proper handling of thecomponents.

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

Do not heat hydraulic pipe. The carbon content ofthis steel tube is such that if heated for bending, andeither water or air quenched, the pipe may lose itsductility and thereby be subject to failure under highpressure or hydraulic shock conditions. Damagedor leaking pipes must be replaced before the mixeris returned to service. Please contact McNeilusTruck and Manufacturing at (507) 374-6321 if yourequire assistance or have questions.

All hydraulic pressures must be relieved from thehydraulic system prior to removing any componentsfrom the system to prevent oil from spraying orfunctions and systems from falling. Call McNeilusTruck and Manufacturing at (507) 374-6321 forinformation concerning relieving the hydraulicpressures.

Increasing hydraulic pressure beyond therecommendations may result in serious damage tothe mixer or serious personal injury. If you havequestions concerning hydraulic pressures or testingprocedures, please contact McNeilus Truck andManufacturing at (507) 374-6321 before attemptingthe test procedures or making adjustments.

When performing hydraulic test procedures, use theproper hydraulic gauges. Installing an incorrect testgauge could result in serious injury if the gaugefails. Use properly rated hydraulic hoses to allowthe test gauge to be read away from moving partsand functions. Contact McNeilus Truck andManufacturing at (507) 374-6321 for assistance.

Use the proper tools and equipment when servicingthe hydraulic system. Use only the McNeiluscharging kit when recharging the accumulator. CallMcNeilus Truck and Manufacturing at (507) 374-6321for assistance, if required.

Never operate the hydraulic system if a leak ispresent.

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2 Introduction and Safety Procedures © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved


Never enter under the chassis unless the mixer is inthe Lockout mode. Remember to follow the Lockoutprocedures when working under the truck

When working on the mixer, the wheels must beblocked, the parking brake on, Lock Out proceduresin effect, and the keys out of the truck’s ignition.

The mixer must not be modified in any way withoutauthorization from McNeilus Truck andManufacturing. Modifications may not comply withsafety standards, including ANSI safety standards,and may result in serious personal injury. Pleasecontact McNeilus Truck and Manufacturing at (507)374-6321 if you require assistance.

When using the emergency jumper procedure torotate the drum on a disabled mixer the followingmust be observed: Before removing the hydraulicmotor from the mixer drive on both the operatingand disabled mixer, be sure the drum has beenallowed to turn freely so that it is balanced with noforces transmitted to the hydraulic motor

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 upalarm, brake lights, clearance lights, head lamps, taillamps, safety equipment, and work lights. Thetruck’s air system must operate properly and haveno leaks. Water and moisture should be drainedfrom the truck’s air system daily. Call McNeilusTruck and Manufacturing at (507) 374-6321 forassistance.

Do not wear watches, rings, and jewelry whileoperating or working with this equipment or itselectrical and mechanical systems. These items canbe hazardous and can cause serious and painfulinjuries if they come into contact with electricalwires, moving parts, or hydraulic equipment.

Use slower speeds when going around curves orcorners. You are carrying a higher center of gravityload.

At the job site use the lowest transmission gear andproceed at low speed, 3 MPH maximum, to thedischarge area.

Always keep hands and feet clear of the mixer drum,revolving parts, and moving parts while checkingload or washing down the mixer.

Do not climb on ladders or ride on platforms whilethe truck is in motion or when ladders or platformsare wet or slippery. Serious personal injury mayresult due to a fall.

All personnel must stand clear of the chutes duringraising and lowering and when chutes are loadedwith concrete. Position chutes while they are notloaded. A loaded chute falling on a person maycause serious injury. All chutes must be handledwith great care to avoid injury. Do not stand onchutes.

Main, foldover, and extension chutes must beinspected on a daily basis for damage, excessivewear, proper hardware fit, twist, and overallcondition to determine that they are safe to use. Donot attempt to repair chutes. Unsafe chutes must bereplaced with new chutes.

Optional air chute lock is intended for use only onthe job site. The manual chute lock should alwaysbe engaged during transport. Excessive wear orinjury may result due to improper usage.

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4 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Do not let persons, other than the driver, handle thechutes, unfold the foldover, and/or removeextension, or stow and secure the extensions fortransit. Keep hands away from chute hardwarewhere the chutes connect. Never stand in the pathof the chute as it is being unfolded or while in use.Failure to follow the warnings concerning chutesafety may result in serious injury.

No passenger must be allowed in the cab unless amanufacturer’s approved passenger seat and seatbelt are provided.

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

Never drive the truck with the water tankpressurized.

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

Safety decals must be replaced anytime they aredamaged or missing or cannot be read clearly. Ifyou require safety decals, please contact McNeilusTruck and Manufacturing at (507) 374-6321 for nocharge replacement safety decals.

Thoroughly understand the controls beforeoperating the mixer. Be sure everyone is clear ofthe area around the truck before operating themixer. Remain attentive at all times when operatingthe controls.

Never back up without taking every precaution to besure the rear is clear. Check behind truck beforebacking up. Watch the mirrors for activity. Neverback up the mixer unless and until you arecompletely sure it is safe. Use a spotter/ observerand/or get out and check yourself to ensure it is safeto do so.

Wear the proper protective clothing when operatingor maintaining the mixer. Hard hats, safety glasses,gloves, and safety shoes should be worn. Reflectiveclothing is recommended for drivers andemployees.

The mixer should not be overloaded. Loadpressures must match the load to be transported.

Be sure to maintain correct accumulator chargepressure for correct and safe operation. Do notattempt to check or charge the accumulator untilyou have read and understand the instructions.Contact McNeilus Truck and Manufacturing at (507)374-6321 for assistance.

When working on the hydraulic or electrical systemof a Bridgemaster or Tuck-A-Weigh unit the trailershould be in the down position or chained in the upposition to prevent the trailer from loweringunexpectedly. Never stand behind the Bridgemasteror Tuck-A-Weigh when in the up position. If theBridgemaster or Tuck-A-Weigh cylinder will notlower or raise, call McNeilus for assistance at (507)374-6321 and ask for service.

When working on the hydraulic system with thetrailer raised, always chain the assembly to theupright or retracted position to prevent theassembly from coming down.

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Recheck the Hydraulic Down Pressure against theload to be transported. If their is too muchpressure the truck driving tandem could beaffected by loss of traction. Always set pressure tothe lowest setting when mixer is unloaded. Do notrun with trailer down when the mixer is not loaded.

When recharging or checking the charge on theBridgemaster or Tuck-A-Weigh accumulator, thefollowing safety guidelines must be followed:

The cylinder rod must be extended (traileron the ground) before the accumulator ischarged.

Do not stand behind the cylinder whencharging the accumulator. The hose on theMcNeilus accumulator charge kit is longenough to allow the accumulator to becharged from the side of the mixer.

Do not attempt to disassemble the cylinder.

Use only McNeilus P/N 160.85455Accumulator Charge Kit.

Purge air from the Accumulator Charge KitHose by allowing a slight flow of nitrogento escape while attaching the AccumulatorCharge Kit to the Accumulator ChargeStem.

The truck ignition key should be removedwhile charging the accumulator.

Read these instructions thoroughly beforeattempting to charge the accumulator.

Loosen only the top nut of the accumulatorcharge stem. If the bottom nut is loosened,damage to the o-ring seal could result. Allgas pressure must be released from theaccumulator before the accumulator chargestem can be removed for service.

If you have any questions or experiencedifficulty with the cylinder or charging theaccumulator, please call the McNeilusService Department at (507) 374-6321.We’re glad to assist!

The trailer should be lowered when servicing theaccumulator. Do not stand behind the cylinderwhen charging the accumulator.

The trailer pressures must match the load chartsupplied with the mixer. If the pressure is toogreat for the load it is possible to raise the rearchassis wheels of the truck and the operator maylose control of the unit.

Check trailer king pins, toe-in, tie rods, andcomponents for proper adjustment. Replace anyworn or loose components immediately. ContactMcNeilus at (507) 374-6321 for any specificationsor assistance you may require.

With the trailer raised on the return trip, slowerspeeds are required when going around curves orcorners as the unit could upset or roll over.

Always be sure the area behind the mixer is clearof people or other obstacles when raising or lowerthe trailer.

Always check indicator lights in the cab or atcontrol panel at the front of the mixer for trailer andchute position. Replace lights or bulbs whenrequired. NOTE: all models may not have indicatorlights. Physically check position when indicatorlights are absent.

Check the tire condition and tire pressure of thetrailer wheels daily to be sure the tires are inflatedto proper pressure to withstand the applied loads.Do not exceed the recommended tire pressuremarked on the tire sidewalls.

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Chutes must be completely lowered and centeredbefore operating the Bridgemaster or Tuck-A-Weightrailer. If chutes are not completely lowered andcentered, the trailer may come in contact with thechutes and severely damage the mixer.

If you are not familiar with the Bridgemaster or Tuck-A-Weigh, do not push or pull switches until youknow what part of the system they will contact andunderstand the system’s operation.

IF THE MIXER COMES INTO CONTACT OR CLOSEPROXIMITY WITH A POWER LINE OR THERE IS ANYARCING, STAY IN THE TRUCK CAB AND KEEPAWAY FROM THE METAL PARTS OF THE UNIT. DONOT LET ANYONE COME CLOSE TO THE TRUCK.DO NOT ATTEMPT TO JUMP CLEAR OF THE TRUCK.STAY IN THE CAB. THE POWER MUST BEDISCONNECTED BY THE POWER COMPANYBEFORE YOU CAN SAFELY LEAVE THE CAB.Minimum clearances from power lines:

50,000 Volts or Less...........................................4 Feet50,000+ Volts ......................................................10 Feet345,000 - 750,000 Volts ......................................16 Feet

KNOW THE CLEARANCE OF OVERHEADOBSTRUCTIONS. NEVER DRIVE THE MIXER UNDERANY OVERHEAD OBSTRUCTION WITHOUTKNOWING THE CLEARANCE HEIGHT. IF UNIT HASA FLIP-UP HOPPER, BE SURE HOPPER IS IN THELOWERED POSITION. FAILURE TO DO SO MAYRESULT IN DAMAGE TO THE MIXER BODY ORTRUCK, AND MAY RESULT IN SERIOUS PERSONALINJURY OR DEATH.

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Internal Flo-Fuse™

7© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Internal Flo-Fuse

10 MICRON FILTER ASSEMBLY

P/N 140.00436

WEATHER-PAK KIT

P/N 9800.620080

With a continuing emphasis on safety, McNeilus recommends its internal Flo-Fuse. The internalFlo-Fuse is located on the inside of the McNeilus replacement chute lift cylinder. This protects theFlo-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 McNeilusreplacement chute lift cylinders for McNeilus Mixers. Allowners of McNeilus Mixers should ensure they have aMcNeilus replacement chute lift cylinder with the internalFlo-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 Manufacturingat (507) 374-6321 if you require assistance orhave any questions.

Maintaining your Mixer Hydrostatic Pump and Motor System

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintaining your Mixer Hydrostatic Pump and Motor System 9

MAINTAINING YOUR HYDROSTATIC PUMP ANDMOTOR SYSTEM

THE HYDRAULIC FLUID

I. ISO68 - Ambient Less than 80° F

A. Specifications

1. SUS @ 210° F = 55-60

2. Viscosity Index = 100 - 120

3. Pour Point = -25° F Average

II. ISO100 - Ambient More than 80° F

A. Specifications

1. SUS @ 210° F = 60 - 70

2. Viscosity Index = 100 - 120

3. Pour Point = -5° F to +10° F

III. Recommended Additives

A. Anti-Rust

B. Anti-Foam

C. Anti-Wear

D. Anti-Corrosion

E. Anti-Oxidant

F. Emulsifier

G. Detergent

IV. Breakdown of Hydraulic Fluid

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

5. Hydrodynamic Film Cannot be Maintained

a. The film of oil between moving parts

V. Multiple Viscosity Hydraulic Fluid (MV)

A. Shear Factor

1. Viscosity Index Improver (VIP)

a. Synthetic Polymer Chain

b. Typically Not Shear Stable in High Pressure Piston Pumps

B. High Viscosity Index

1. 130 - 150

VI. Automatic Transmission Fluid (ATF)

A. Should Not Be Used in Hydrostatics on Mixers

B. Not Shear Stable in High Pressure Piston Pump

1. High Viscosity Index

a. 170 - 200

2. Tends to Shear to Base Stock Viscosity

3. Looses Hydrodynamic Film

4. Not Always Compatible with Hydraulic Fluid

5. Normally Higher Priced than Hydraulic Fluid

VII. Water Base Oil

A. Do Not Use in Hydrostatic Systems

B. Shortens Lifetime of Hydrostatics

HOW HOT IS HOT?

I. Normal Maximum Operating Temperatures

A. Outside Temperature (Ambient) + 100° F

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

D. Filter Buggy (Three Filters Required)

1. Coarse Filter (Approximately 40 Microns)

2. Fine Filter (Approximately 5 Microns)

3. Water Filter with Drain.

E. Analyzing Oil

1. Use an Analysis Designed for Hydrostatics

a. Cleanliness Levels

b. SUS @ 210°F

c. Moisture Content

d. Viscosity Index

F. Filtering Oil From Storage Containers

1. Use a 10 Micron Filter

a. Low Pressure Applications

1. Mixer Hydro Filter Assembly

b. High Pressure Applications

1. Bridgemaster High Pressure Filter Assembly

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

3. Hydraulic Fluid Not Reaching OperatingTemperature

4. Reservoir Breather Cap Installed by Customer

a. 10 Micron Required if Sealed Cap is Replaced

THE HYDRAULIC HOSE

I. General Hose Information and Knowledge

A. Ratings

1. Operating Pressure

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

2. Proof

a. The Operating Pressure X 2 for Test Purposes

3. Burst

a. The pressure at which the hose bursts

b. Operating Pressure X 4

4. SAE = Society of Automotive Engineers

5. DIN = Duetsch International Nominal

6. Mil Spec = Military (Lowest Rating)

B. Hose Outer Covering Considerations

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



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”

II. Suction Hose Applications

A. SAE100R4 or Equivalent

1. 28” Vacuum

2. 200 PSI Maximum

3. Aeroquip FC310, 2661 or Equivalent

III. Chute Hose Applications

A. SAE100R2 or DIN 20 022

1. Minimum Operating Pressure of 3,000 PSI Required

2. Aeroquip GH781 or Equivalent

IV. Closed Loop System (Hydrostatic Pump & Motor)

A. SAE100R12

1. Minimum Operating Pressure of 4,000 PSI

2. GH493 or Equivalent

THE HYDRAULIC TUBING

I. General Tubing Information

A. Ratings

1. Operating Pressure

2. Design Factor 4:1

3. SAE = Society of Automotive Engineers

B. Should be zinc dichromate plated or primed

1. Helps Prevent Rust and Deterioration

C. High Pressure Tubing is -16 (1”)

D. Return Tubing is -12 (3/4”)

E. Inspect Tubing on a Daily Basis

1. Cuts

2. Leaks

3. Abrasions

4. Damage

5. Improper Clearance

6. Aging

7. Check Along Frames for Damage

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

G. Tubing Size = O.D.

THE SUCTION FILTER

I. 10 Micron (µ ) Rating is Required

A. 1 µ = 0.00003937 Inch

B. Human Hair = 70 Microns

C. Lower Limits of Human Visibility = 40 Microns

D. White Blood Cell = 25 Microns

II. Beta Ratings Required by Eaton

A. B10=2 Minimum

B. B10=4 Better Rating

III. ISO Cleanliness Standard

A. 18/13 Required

1. Particles per ML (1 cc)

a. 5 = 2,500 Particles

b. 15 = 80 Particles

IV. 10 Inches of Mercury (Hg) Maximum Warm

A. Red Line on Vacuum Gauge

V. Bypass Opens at 20 Inches of Mercury

A. Hydraulic Fluid is Unfiltered in Bypass

B. Filter Must Withstand 20 Inches of Mercury

VI. Many Filters Do Not Qualify

A. Incorrect Beta Ratings

1. B10=2 Minimum

THE HYDRAULIC FLUID COOLERS

I. Flow Capacity is Determined by Charge Pump Flow

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

B. Bypass Valve to Limit Case Pressures

1. Two 35 PSI Bypass per Cooler

C. Front Mount Cooler

1. 15,670 BTU w/Ram Air (Unobstructed)

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

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 BeImmediately Contaminated on Start Up

THE HYDROSTATIC PUMP

I. Rotation

A. Front Mount Pumps = LH (CCW)

B. Rear Mount REPTO Pumps = RH (CW)

1. Rear Engine Power Take Off

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 1-3/8” Shaft

III. Relief Valves (Called “Clipping Reliefs”) in Pump

A. 6,000 PSI Clipping Relief Valves

B. Poppet Style

1. Tend to be Self-Cleaning

2. Cooler Operation

IV. Pump Configurations Available (CW or CCW)

A. Standard Charge Pump

B. Dual Element Charge Pump

1. Used with Optional Open Center Chute LiftBlock

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

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


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

THE HYDROSTATIC MOTOR

I. Spline

A. All McNeilus Mixers have a 21 Spline Motor Shaft

B. Rexworks = 20 and 23 Spline

C. Smith, Jaeger, CMC = 14 Spline

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)

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

4. Example:

a. 5431 = 54 Series Fixed Clearance Model

b. 5430 = 54 Series Ball Guide Model

C. The First Four Digits of the S/N Indicate the BuildDate

1. Example: 1097XXXX = October 1997.



DRUM STALL AND INTERNAL LEAKAGE

I. Normal Internal Leakage of Hydraulic Fluid

A. Leakage Cleans, Cools, and Lubricates

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

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’sCapacity 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

1. Flush Reservoir and Wipe Clean

2. Reverse Flush the Cooler

3. Install New and Correct Filters

a. 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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Gauge Installation Location 15

Gauge Installation Location

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

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

Motor WITH high pressure relief valvemanifold block. (used by McNeilus through1987) Readings vary with load.

Motor WITHOUT high pressure relief valvemanifold block. (used by McNeilus since1988) Readings vary with load.

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 PSIdepending on the slump of theconcrete

• See step #4 - CheckingHydrostatic High Pressure

Today’s new generation mixer pumps and motors arethe result of extensive field testing, customer input, andthe latest technology. They offer greater durability,increased power density, and greater efficiency. Theyalso require proper lubrication, filtration, and goodmaintenance to deliver the years of service designedinto them. Should a problem develop goodtroubleshooting procedures can help you identify andcorrect a problem before the problem becomes critical.

We’ll divide the hydrostatic troubleshooting into foursteps which will cover the test procedures. The areadiscussed in this update will be analyzing the vacuumreadings. Upcoming updates will discuss and analyzethe remaining troubleshooting steps.

Gauges, fittings, adapters, and hoses are required totroubleshoot the hydrostatics. McNeilus markets a hydrotest kit (P/N 260.00483) which includes all of therequired components organized in a portable carryingcase. Contact your local McNeilus branch for details onthe test kit.

STEP #1—THE VACUUM CHECK

The charge pump develops the amount of vacuumrequired to move the oil from the reservoir to the chargepump. The normal oil route is from the reservoir, throughthe filter, and into the charge pump. Anything thatrestricts this oil route will increase the amount of vacuumrequired to move the oil to the charge pump. Theamount of vacuum required to move the oil can bemeasured with a vacuum-pressure gauge.

The vacuum-pressure gauge is installed directly into thecharge pump inlet. Remove the inlet hose and install atee fitting into the charge pump inlet. Reattach the inlethose to the tee. Plumb the vacuum-pressure gauge intothe tee (see photo #1).

The vacuum reading should be taken when the oil iswarm. Cold oil will require more vacuum and result in ahigher than normal reading. Vacuum is measured ininches of mercury (HG) rather than pounds per squareinch (PSI) like pressure. A hydro system with a new filterand everything correct will normally read approximatelytwo inches or less of vacuum. The maximum allowablevacuum on a continuous basis is 10 inches of mercury.

Most hydrostatic oil filters have a vacuum gauge whichindicates the amount of vacuum required to draw the oilthrough the filter. As the filter becomes contaminatedmore vacuum will be required to draw the oil through thefilter media. This filter vacuum gauge will not detect aproblem between the filter and the charge pump. Forthis reason a reading is always taken at the chargepump inlet. A continuous high vacuum reading at thecharge pump inlet will result in pump failure and willrequire immediate attention.

McNeilus Hydro Test Kit 260.00483

Photo 1

Troubleshooting Your Mixer Hydrostatic System

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Troubleshooting Your Mixer Hydrostatic System 17

The following areas are common causes of high vacuumreadings:

STEP # 2 - CHARGE PRESSURE

The charge pump is the heart of your hydrostaticsystem. If the charge pressure is low or nonexistent, thehydrostatic pump will not provide the flow to turn thedrum. The duties of the charge pump include:

1. Develop the vacuum to move the oil from thereservoir through the filter to the charge pump.

2. Provide flow under pressure to the control valve toallow the servo system to stroke the pump to chargeor discharge modes.

3. Provide cool oil from the reservoir to the pump caseto assist in cooling the hydrostatic system.

4. Provide make up oil to replace oil lost throughnormal leakage within the pump.

5. Provide flow under pressure to the rotating group(piston and slipper assembly) to maintain pressureand oil flow to the rotating group while the pump is inneutral.

The charge pump pressure check is easy to perform.With the truck engine off remove the o-ring plug from thetop of the pump (see photo #2). Normally the controlcable is routed across the area of the o-ring plug and a90-degree adapter and a short hose from the McNeilus

test kit is required to clear the cable. A 0 - 400 PSIgauge 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 gaugeshould read 220 ∆ PSI in neutral. The ∆ means 220 PSI(the setting of the relief valve on the charge pump) plusthe pressure in the case of the pump. An example: Ifthe pump case pressure is a normal 40 PSI your gaugewould read 260 PSI in neutral (220 PSI charge pumppressure plus 40 PSI case pressure). Remember eachsystem is unique and the gauge readings may varyslightly from pump to pump.

When the pump is put into charge or discharge thecharge pump pressure will decrease by approximately60 PSI. As an example: A 260 PSI reading in neutralshould drop to 200 PSI when the pump is put intocharge or discharge. These gauge readings are normaland indicate good charge pump performance.

If your charge pump pressure is low check the followingareas:

1. Be sure your vacuum readings are normal. Ifvacuum readings are high, the pump may not bereceiving the supply of oil required to achieve thepressure to operate the system. (See Step #1 forvacuum information).

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

18 Troubleshooting Your Mixer Hydrostatic System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Photo 2

2. Both the charge pump and motor bolted to the mixerdrive have low pressure relief valves. If your chargepressure is OK in neutral but low in charge anddischarge positions you probably have a problemwith the motor’s low pressure relief valve. If yourcharge pressure is low in neutral but OK in chargeor discharge your problem will most likely be thecharge pump’s low pressure relief valve. Thequickest way to verify this is to exchange the reliefvalve cartridge with a known good cartridge fromanother mixer.

3. If the pressure is low or non-existent in any controlvalve position the charge pump should be removedand inspected. It should rotate freely. Look forcontamination, excess wear, or broken parts. If thecharge pump is contaminated or has broken piecesthe hydro system will require flushing to remove thecontaminates from the system. If the pressure is lowfrom a worn charge pump you may be able tochange just the charge pump and continue.Remember - if the charge pump has enough hoursto be worn out, the pump and motor may be in thesame condition!!

4. If a pump is operating with oil which is too thin oroperating at excessive temperatures, the chargepump may not be able to maintain the requiredpressures — especially at low RPM’s.

STEP #3 - CHECKING CASE PRESSURE

The hydrostatic pump and motor are designed to haveinternal oil leakage. This internal leakage occursbetween the piston and piston sleeve which the pistontravels in, between the slipper and piston where theslipper is wedged on the piston, and between the slipperand the swashplate. This normal internal oil leakageallows the oil to clean, lubricate, and cool as it passesthrough these close tolerances. Internal leakage collectsin the motor case and flows out of the motor housingthrough a smaller low pressure hydraulic return line tothe bottom of the hydrostatic pump case. The leakageflows into the pump and joins the internal pump leakageand other accumulated oil in the pump case. The totalvolume of leakage from the motor and pump then passout of the top of the pump, flows through the oil coolerand returns to the oil reservoir.

It is important that the flow of oil from the motor andpump cases have a free unobstructed flow to thereservoir. If anything obstructs this flow of oil, thepressure required to move the oil increases. Increasedpressure can cause problems with external leakage foryour motor and pump around the shaft seals and controlvalve seals - especially if the case pressure approaches100 PSI.

Checking the case pressures on the hydros is easy! A 0-400 PSI gauge is plumbed into the return line hosewhich is routed between the top of the hydrostatic pumpand oil cooler. The return line which is plumbed into thetop of the pump should be removed and a tee plumbedinto the line. The gauge is plumbed into the third port ofthe tee. (See photo above)

When the hydrostatic system is operating at normaltemperatures, the gauge pressure should read 40 - 60 PSI.If the pressures are higher than this, the system should be


checked to determine why the pressures have increased.Two common causes of high case pressure on mixerapplications are obstructed oil coolers and return lineswhich are pinched due to t ight radius turns.Approximately 25 PSI is required to force the oil flowthrough the oil cooler. If you case pressure is high, yousimply remove the two return lines from the oil coolerand join the hose ends with a union. If the case pressuredropped from a high reading to a low reading (example:100 PSI with the cooler in the circuit dropping to 20 PSIwith the cooler out of the circuit), the system is tellingyou that the cooler is obstructed internally. Most coolerscan be reverse flushed with flushing fluid or diesel fuel toremove the contaminants. If the cooler can’t be properlyflushed it should be replaced with a new coolerassembly (normally around $100.00). If a return linehose is pinched, it must be replaced and rerouted ifnecessary to eliminate tight bends and turns. A 3/4” IDreturn line may have only a 1/4” ID if pinched or in abend which is too tight.

STEP #4 - CHECKING HYDROSTATIC HIGHPRESSURE

Two high pressure relief valves on older stylehydrostatic systems are typically found in the manifoldon the rear of the hydrostatic motor. On later stylesystems, the relief valves have been replaced by “powerlimiter” valves which are located on the front of the pumprather than on the motor manifold. The job of theserelief valves or “power limiter” valves is to protect theclosed loop circuit and components (including the pumpand motor) from excess hydrostatic pressures during thecharge, mix, and discharge modes or if a problemdevelops which would cause the pressures to increaseabove the normal limits.

In older systems with the relief valves located in themotor manifold, considerable heat can be generated ifany significant amount of oil flows through the reliefvalves. As an example: a mixer with a drum drivelocked up may prevent the motor from turning. If adriver placed the controls in charge or discharge, thepump will send a flow of oil to the motor in an attempt toturn the drum. Because the drive can’t turn the drum,the high pressure will immediately intensify to the reliefvalve setting and force the oil through the relief valveand back into the circuit. This situation causestremendous amounts of heat to be generated in thehydrostatic system; enough to destroy the motor, hoses,and the pump if it is allowed to continue. Oil which is

forced through the main relief valve generates heat atthe rate of one degree per second for each onethousand pounds of pressure!

More modern systems with the “power limiters” in thepump (used by McNeilus since 1988) allow the pump todestroke when pressures reach maximum. With thepump destroked, there is no oil flow to the motor and noheat is generated in the closed loop circuit.

Checking the high pressure circuit requires a 0-10,000PSI gauge be installed in the charge circuit port in themanifold of the motor (see the inset). When thehydrostatic system is turning the drum, the gauge willread the amount of hydrostatic pressures required toperform that function. A typical mixer system will requirearound 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 thedrum turns and the higher the pressures will be. (If youhave a slump meter installed, you already have a highpressure gauge in the circuit).

20 Troubleshooting Your Mixer Hydrostatic System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

New StyleMotor Without Manifold

Normal Reading - Varies with Load

If the drum won’t turn and the high pressure gaugereads low or zero while the pump is delivering oil flowto the motor, the high pressure relief valve or “powerlimiter” valves may be stuck in the open position andallowing oil flow with little or no resistance. Removethe valves and examine them for contamination,damaged o-rings, etc., and thoroughly clean thevalves with WD-40 or an equivalent product. Normallythe two valves can be interchanged to unload thedrum.


Pressure Gauge forChecking System Pressure10,000 psi

These fault-logic charts are designed to help youtroubleshoot problems with hydrostatic pumps andmotors at your location. Find the symptom and follow thesteps shown in the box. The steps are laid out in thenormal logical order, so start at the beginning and workyour way through the steps in the order they are shown.Each step will have a number shown in the box. Thesenumbers refer to the action steps listed on the pagefollowing the fault logic charts. As an example: If thesymptom 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 andlooking at action stop number one gives you additionalideas for items to check. Anytime you have questions orrequire assistance, please feel free to call McNeilusCompanies at one of the numbers shown in action stepnumber 16.

How to use the Fault Logic Charts

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved How to use the Fault Logic Charts 23

Troubleshooting Hydraulic Pumps and Motors

24 Neutral, Difficult or Impossible to Find © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

MIXER DRUM TURNS IN ONE DIRECTION ONLY

NEUTRAL, DIFFICULT OR IMPOSSIBLE TO FIND

Inspect Control Linkage

Inspect Control Valve

InspectRelief Valves

Repair or Replace Repair or Replace Repair or Replace

1 2 3

16

Repair or Replace Repair or Replace

5 4

Call McNeilus forAssistance

Inspect ChargeCheck Valves

Inspect ShuttleValve

OK OK

OK OK

OK

Inspect Control Linkage

InspectControl Valve

Call McNeilus forAssistance


1 2 16

OK

Defective Defective

Defective Defective Defective

Defective Defective


© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved System Response Sluggish 25

SYSTEM RESPONSE SLUGGISH

Check ChargePressure

InspectControlValve

Inspect Charge ReliefValve at Pump

Inspect InletFilter

Inspect Charge Pump

CallMcNeilus

forAssistance

Inspect ChargeRelief Valve

at Pump

Repair or Replace

Low in Neutral,Charge orDischarge

Repair or Replace Replace Repair or Replace

12 2 16

Low in Neutral

13

Low in Charge or Discharge

Inspect ChargeRelief Valve at

Motor14 13 9, 10 15


OK OK

OK OK

OK

Defective Defective Defective Clogged Defective

Defective


26 System Operating Hot © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

SYSTEM OPERATING HOT

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

Check Oil Level in Reservoir

InspectExternal Oil

Cooler Bypass(If used)

CheckCharge

Pressure

CallMcNeilus

forAssistance

Repair or ReplaceLow in Neutral,

Charge or Discharge

High in Charge orDischarge

ReplaceFill to Correct Level

Inspect InletFilter

Replace Repair or Replace Repair or Replace

6

Inspect OilCooler

7 8 12

InspectCharge ReliefValve at Pump


at Motor15

InspectCharge Pump

9, 10 13

CheckSystem High

Pressure11

3

16

14

Inspect ReliefValves

Replace

Repair or Replace

OK

OK OK

OK

OK

OK

OK

Defective

Defective Clogged Defective Defective

Low

DefectiveDefectiveLow

OK


© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved System will not operate in either direction 27

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

Check Oil Level in Reservoir

InspectControl Valve

InspectExternal Oil

Cooler Bypass(if used)

CheckCharge

Pressure

CallMcNeilus

forAssistance

Repair or ReplaceHigh inCharge

orDischarge

Low inNeutral,Charge

orDischarge

Repair or ReplaceFill to Correct Level

Inspect InletFilter

Replace Repair or Replace Repair or Replace

6

InspectControlLinkage

1 2 8

InspectCharge ReliefValve at Pump


at Motor15

InspectCharge Pump

9, 10 13

CheckSystem High

Pressure11

3

16

14

Inspect ReliefValves

Replace

Repair or Replace

OK OK OK OK

OK

OK

OK

Defective

Defective Clogged Defective Defective

Low

Defective DefectiveDefectiveLow

OK OK

Repair or Replace

28 Diagram Action Steps © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Diagram Action Steps

1. Inspect control linkage for:a. Cables out of adjustment, binding, broken, etc.b. Cables not coordinated with control valve

neutralc. Arm on control valve slipping on control valve

shaft splined. Cable bracket loose or installed incorrectly

2. Inspect control valve for:a. Plugged control orificeb. Damaged mounting gasketc. Misadjusted, damaged or broken neutral return

springd. Broken control connector pine. Broken or missing control linkage pinsf. Galled, stuck, or contaminated control spoolg. Exchange control valves with a units which

works properly to verify the control valve is atfault

3.* Inspect relief valves for:a. Improper pressure relief settingb. Damaged or missing o-ring and backing ringc. Plugged orificesd. Center spool galled, stuck, or contaminatede. Poppet style relief valve may be stuck open or

contaminatedf. Older style motors have the high pressure relief

valves installed in a manifold on the rear of themotor. These relief valves can normally beexchanged from port to port for test purposes(1987 and earlier on McNeilus mixers).

g. Newer Eaton systems have poppet style highpressure relief valves (called power limiters)installed in the pump. These power limiters canbe exchanged from port to port for test purposes(1988 and newer on McNeilus mixers).

4. Inspect shuttle valve (located on the end of themotor) for:a. Bent or broken return centering springb. Galled, stuck, or contaminated spoolc. Bent or broken shuttle spoold. Excess wear

5. Inspect Charge Check Valves (located behindcharge pump) for:a. Damaged or missing o-ringb. Damaged check ball seatc. Stuck check ball

6. Check Oil Level In Reservoir:a. Follow the manufacturer’s recommendationsb. Normally oil should be to the sight glass with all

cylinders retractedc. Do not overfill reservoir

7. Inspect Oil Cooler for:a. Obstructed air flow from dirt, grease, etc. on the

outside of the coolerb. Improper plumbingc. 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 valveb. 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 vacuumapplications. Pressure hose will not work.

10. Inspect Inlet Filter for:a. Plugged or clogged filter elementb. Obstructed inlet or outletc. 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. An empty drum wil l normally register

approximately 500 PSI on the test gaugec. A loaded drum will normally register from 2,500 -

3,500 PSI on the gauge depending on the loadand slump of the concrete in the drum

d. WARNING: Do not attempt to “lock up” thesystem or prevent the drum from turning to testhigh pressure. The result may be seriousdamage to the system and serious personalinjury.

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Diagram Action Steps 29

12.*Check charge pressure:a. Charge pressure is checked by installing a 0-

600 PSI gauge in the o-ring port on the top ofthe pump. See the test pages showing gaugeinstallation and test procedures.

b. Charge pressure on the Eaton hydrostaticsystems normally reads 240 - 260 PSI on thegauge when the pump is in neutral. The readingshould drop 60 PSI when the pump is put incharge or discharge.

c. A minimum reading of approximately 150 PSI onthe 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 theproblem

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 theproblem

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

16. Call McNeilus for Assistance: a. Call your local McNeilus Branch:

1. Colton, CA (909)370-21002. Commerce City, CO (303)287-74863. Villa Rica, GA (770)459-51514. Gahanna, OH (614)868-07605. Morgantown, PA (610)286-04006. Hutchins, TX (972)225-23137. Tacoma, WA (253)536-02608. Dodge Center, MN (507)374-6321

*Charge Relief Valve and High Pressure Relief ValveIdentification:

The relief valves are factory preset. The pressure codeis stamped on the hex plug located on the end of thevalve cartridge. To determine the pressure setting on themotor manifold high pressure relief valves, add a zero tothe right of the stamped number (Eaton up to 1987).1988 and newer high pressure relief valves (powerlimiter) located in the Eaton pump are marked internally.They must be removed to see the number.

Charge Pressure High PressureRelief Valves Relief Valves

016 = 160 PSI 500 = 5,000 PSI022 = 220 PSI 550 = 5,500 PSI

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.

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Eaton Hydrostatic Pump - F.C. 31

Control Valve - Old Style

32 Control Valve - Old Style © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Control Valve - New Style S/N 0986 and higher

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Control Valve - New Style S/N 0986 and higher 33

Charge Pump Rotation Identification

34 Charge Pump Rotation Identification © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

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)

Valve Plate Rotation

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Valve Plate Rotation 35

PUMP VALVE PLATE FORCCW INPUT SHAFTROTATION (Lefthand)

Fixed Clearance

54 PV LH Plate1. Eaton P/N 1051032. McNeilus P/N 080.025

Ball Guide Units

54 PV LH Plate1. Eaton P/N 1027952. McNeilus P/N

080.02447

46 PV LH Plate1. Eaton P/N 1026272. McNeilus P/N

080.02442

PUMP VALVE PLATE FORCW INPUT SHAFT ROTATION(Righthand)

Fixed Clearance

54 PV RH Plate1. Eaton P/N 1051022. McNeilus P/N

080.02525

Ball Guide Units


080.02446


080.02441

Broken Pump Shaft

36 Broken Pump Shaft © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

The broken shaft coupling end noted on this shaftindicates a possible improper torquing of the matingcoupling retaining nut. This condition usually is theresult of the torque to turn the shaft being transmittedthrough the key and shaft keyway rather than propershaft to coupling taper fit.

Hydrostatic Installation and Clean and Flush Procedures

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Hydrostatic Installation and Clean and Flush Procedures 37

Contamination (dirt, metal particles, etc.) in fluid of ahydrostatic transmission is the primary cause of failure.Before reinstalling a set of hydrostatic transmissionunits, the system must be completely free ofcontamination.Changing the filter element and fluid isnot enough to thoroughly clean the system. For thisreason, we have derived the following list of proceduresthat, when followed step by-step, will help assuresystem cleanliness; resulting in longer life for yourhydrostatic transmission components. Remember, it isdesirable that both the hydrostatic pump and motor bereplaced at the same time.

After Determining that the Hydrostatic Units Need tobe Replaced:

1. Drain all fluid from the system at the lowest point.

2. Remove the old hydrostatic pump and motor andreturn it to McNeilus.

3. Remove the filter element and reservoir clean-outdoor.

4. Check the suction hose for kinks, collapsed orflaking liner, or any other obstructions. Check thefunction of the shut-off if installed. Inspect all otherhose and fittings and replace as required.

5. Check the inside of the reservoir for contamination (particles of steel or brass, sludge, dirt, etc.) and besure the pipe couplings from the reservoir to thesuction hose are not obstructed.

6. Flush all hoses, pipes, tubing, filter housings, andreservoir with clean kerosene or solvent severaltimes.

7. Fill all lines, hoses, pipes, etc. with clean keroseneor solvent and blow out with air pressure.

8. Reverse flush the oil cooler several times with cleankerosene or solvent and blow out with air pressure.

9. Hand wipe the inside of the reservoir and fillerhousing with clean, lint free towels.

10. Clean all hydrostatic pump and motor hose fittingsand replace “O” rings as required.

11. Replace filter elements, filter gaskets and reservoirclean-out door gasket.

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

change. If the new filter doesn’t solve the problem,check for restrictions and proper SAE 100R4 suctionline diameter. Many mixers had a primary filterinternally in the reservoir and a filter assemblyexternally mounted in the system. It is ourexperience that the internal filter in the tank may beremoved if a 10 micron filter assembly.with correctby-pass system and capacity is used externally inthe suction line which goes from the reservoir to thecharge pump.

13. Keep all loose hose ends capped after flushing toprevent contamination from entering the system.

14. Reinstall pump and motor units (on replacementmotors. apply a thin coat of MOLYBDENUMDISULPHITE grease to the spline to prevent themotor 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 theequipment manufacturer or see a f luidrecommendation chart.

16. Be sure to fill the hydrostatic pump and motor casesbefore start-up. Proceed with the start-up procedure.

17. Slotted pump yoke nut must be torqued to specs.CAUTION: Failure to properly torque the slottedpump 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 tocomplete, we at McNeilus feel that they are extremelyimportant to prevent unnecessary replacements whichresult in expense and down time. Remember, we wantyou to get the most from your equipment and ourhydrostatic transmission program.

OPERATION RECOMMENDATION The engine must have at least 600 RPM at idle with aload in the mixer drum control to rotate the drum at 1-1/2to 2 revolutions. In cold weather, allow for warm up ofhydraulic oil before charging the mixer.

Recommendations for Hydraulic Fluid Specifications

38 Recommendations for Hydraulic Fluid Specifications © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

HYDROSTATIC OIL

The following oils are approved for the ISO 100 specification for Eaton Hydrostaticsoperating in ambient temperatures in excess of 80 degrees F.:

SUS @ POURBRAND NAME 210 VI POINT (F)Citgo AW Hyd Oil 63 96 +5Conoco Super Hyd Oil 100 64 98 -25Drydene 4044 65 102 +5Fina AW Hyd Oil 64 95 0Kendall Four Seasons (7384) 63 95 +10 Mobil DTE10-18M 71 120 -29Texaco Rando HD150 72.7 90 - 5Unocal UNAX AW 65 100 +10

The following oils are approved for the ISO 68 specification for Eaton Hydrostaticsoperating in ambient temperatures less than 80 degrees F.:

Chevron Hyd Oil AW 54 99 -22Citgo AW Hyd Oil 55 94 -20Conoco Super Hyd Oil 68 56 100 -30Drydene 4034 54 105 -15Fina AW Hyd Oil 55 96 -15Kendall Four Seasons (7382) 56.0 100 -5Mobil DTE10-16M 62 120 -11Texaco Rando HD68 53.5 98 -25Unocal UNAX AW 55.4 102 -11

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Recommendations for Hydraulic Fluid Specifications 39

MIXER OIL SPECS

ISO 100 OIL (Over 80 degrees ambient)

SUS at 100 Degrees F. 544SUS at 210 Degrees F. 71Pour Point -20 F.Viscosity Index <120

ISO 68 OIL (Less than 80 degrees ambient)

SUS at 100 Degrees F. 359SUS at 210 Degrees F. 62Pour Point -30 F.Viscosity Index <120

ADDITIVES RECOMMENDED

Anti-WearAnti-FoamAnti-RustAnti-CorrosionAnti-OxidantEmulsifierDetergent (minimum amount)

The additives are a standard hydraulic oil package for any oil blender.

Water Tank Measurement

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Water Tank Measurement 41

Contact ______________________________________

Company Name _______________________________

Mailing Address _______________________________

City _________________________________________

State ___________________ Zip__________________

Special Notations ______________________________

____________________________________________

____________________________________________

____________________________________________

Date of Order _________________________________

Phone Number ________________________________

Shipping Address ______________________________

City _________________________________________

State ___________________ Zip__________________

Number of tanks wanted ______ Gallon capacity______

Extra parts needed (example: site gauge kit)

____________________________________________

____________________________________________

■■ Steel ■■ Aluminum

(SAMPLE of completed measurements)

Fender Measurement

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Fender Measurement 43

Contact_______________________________________ Date of Order _________________________________

Company Name ________________________________ Phone Number ________________________________

Mailing Address ________________________________ Shipping Address ______________________________

City__________________________________________ City _________________________________________

State ___________________ Zip __________________ State ___________________ Zip _________________

Special Notations_______________________________________________________________________________

_____________________________________________________________________________________________

A. __________________________________________

B. __________________________________________

C. __________________________________________

D. __________________________________________

E. __________________________________________

F. __________________________________________

G. __________________________________________

H. __________________________________________

I. ___________________________________________

■■ Driver Side ■■ Passenger Side

■■ Pair

■■ Steel ■■ Aluminum

PUSHER

TAGFor Tandem Fenders, Use A, B, C, D, H & G

Open Center Chute Block

44 Open Center Chute Block © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

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

Item Part No. Description Qty1 520.106591 Chute Block Body Only 12 260.106592 Check Valve Cartridge 5 P.S.I. 13 260.106593 Relief Valve 2200 P.S.I. 14 & 8 260.106594A Normally Open Solenoid Valve with Coil (Up) 14 260.106588A Normally Open Valve Poppet Only 15 & 8 260.106595A Normally Closed Solenoid Valve with Coil (Down) 15 260.106587A Normally Closed Valve Poppet Only (Screened) 16 260.106596 Flow Control Valve (Chute Down Speed) 17 260.106597 Check Valve 200 P.S.I. 18 060.85774A 12-Volt Coil Only 29 040.106634 Orifice Plate .062 (Chute Up Speed) 110 040.85743 Plug SAE 4 1

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

7

Open Center Chute Valve Assembly Hold position

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Open Center Chute Valve Assembly 45

Raise Pressure

Return Pressure

Chute Lift Cylinder2 1/2” x 16”200.107620

) (

) (N.C. Valve Assy. (CEC)w/12V. Coil260.106595A

N.C. Cartridge Only (CEC)260.106587A

12 V. Coil Only (CEC)060.85774A

Pressure CompensatedFlow Control260.106596

Normally Closed Solenoid ValveEnergize to lower

5 P.S.I. Check260.106592

Normally Open Solenoid ValveEnergize to raise

Relief Valve2200 P.S.I.260.106593

N.O. Valve Assy (CEC)w/ 12 V. Coil260.106594A

N.O. Cartridge Only (CEC)260.106588

12 V. Coil Only (CEC)060.85774A

.062 Orifice040.106634

200 P.S.I. Check260.106597

T P

C

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.

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

Open Center Chute Valve Assembly RAISE POSITION

46 Open Center Chute Valve Assembly © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Lowering Pressure

Return Pressure


) (

) (N.C. Valve Assy.w/12V. Coil260.106595A

N.C. Cartridge Only 260.106587A

12 V. Coil Only 060.85774A



5 P.S.I. Check260.106592



N.O. Valve Assy w/ 12 V. Coil260.106594A

N.O. Cartridge Only 260.106588

12 V. Coil Only 060.85774A

.062 Orifice040.106634

200 P.S.I. Check260.106597

T P

C


Open Center Chute Valve Assembly LOWER POSITION

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Open Center Chute Valve Assembly 47

Hold Pressure

Return Pressure


) (

) (N.C. Valve Assy.w/12V. Coil260.106595A

N.C. Cartridge Only 260.106587A

12 V. Coil Only 060.85774A



5 P.S.I. Check260.106592



N.O. Valve Assy w/ 12 V. Coil260.106594A

N.O. Cartridge Only 260.106588

12 V. Coil Only 060.85774A

.062 Orifice040.106634

200 P.S.I. Check260.106597

T P

C


Open Center Chute Valve Troubleshooting

48 Open Center Chute Valve Troubleshooting © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Symptom Cause Remedy

Chute drifts down 1. 200 PSI check leaks Install new valve

2. Normally closed solenoid valve 1. Install new valvestuck open or leaks 2. Correct electrical

Chute drifts up during 5 PSI check leak Replace valvetransport

Chute will not raise 1. Normally open solenoid valve 1. Replace valvestuck closed 2. Check electrical

2. Normally closed valve stuck open 1. Replace valve2. Check electrical

Chute will not raise with Relief valve pressure set too low Adjust with gauge to 2200 PSIfull load

Chute will not lower Normally closed valve stuck 1. Replace valve2. Check electrical

Chute lowers too fast Flow adjustment not correct Adjust down speed valve screw out toor too slow slow down or screw in to speed up

Maintenance Periodic Inspection

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintenance Periodic Inspection 49

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.

**

* 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.

Maintenance Periodic Inspection

50 Maintenance Periodic Inspection © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

DAILY INSPECTIONS

1. Hydraulic hoses, f i t t ings, and pipe must beinspected on a daily basis for leaks, cuts, abrasions,damage, aging, improper clearance, and along theframe for hidden damage. If you find hoses with anysuch adverse conditions or damage, they must bereplaced before the mixer is returned to service! Inany event, all hydraulic hoses must be replacedevery two years. Failure to properly inspect andmaintain your mixer may result in serious personalinjury.

2. Visual roller track and roller alignment check. Checkfor “snapping” or “popping” noises while drum isturning.

3. Check oil level in hydraulic reservoir. Add oil ifbelow sight gauge level with all cylinders retracted.Use correct oil.

4. Start engine and warm up hydraulic system withtruck engine at approximately 1,200 RPM and mixerdrum turning at approximately 2 RPM. Warm uptime minimum is 5 minutes.

5. Check vacuum gauge on oil filter. Replace elementif the reading exceeds 10 inches of vacuum after oilhas 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.

8. Lubricate roller bearings.

9. Lubricate and inspect rear cable control box.

10. Lubricate chute pivot system and inspect chutes andchute hardware for wear or damage.

WEEKLY INSPECTIONS

1. Check pump drive shaft cap screws for propertightness.

2. Lubricate complete mixer per lube chart supplied withmixer.

3. Draw sample of oil from reservoir and check forpresence of water. If water is present, the oil maybe milky in appearance. Milky oil should be drainedfrom the system and replaced and the source of thewater entry found and corrected.

4. Check filler cap and neck on oil reservoir for leaks.Check oil reservoir mounts. Make any necessaryrepairs immediately.

5. Check and record drum RPM while loading mixerwith concrete and truck engine running at topgoverned RPM. If drum revolution is 2 RPM lessthan that recorded at previous check, see manualfor component check out.

6. Check inside of drum for concrete build up andclean as required.

7. Check mounting bolts for proper tightness.

8. Check ZF transmission drive plate bolts. Torque to170 lb ft.

9. Check ZF transmission hold down bolts. Torque to420 lb. ft.

10. Inspect debouncer for proper clearance.

11. Inspect roller track for cracks, flat areas. Correct asnecessary.

SIX MONTH INSPECTION

1. Change hydraulic oil and install new hydraulic oilf i l ter(s). Remove fi lters and check for metalparticles. Replace filter(s) with correct part numberfilter. Use the correct hydraulic oil as per McNeilusspecs. Check with McNeilus before using anyalternate hydraulic oil or filters. Multiple Viscosityoils and Automatic Transmission Fluid (ATF) cannotbe used in the hydraulic system.

2. Lubricate control cables using the McNeilus CableLube Kit.

3. On Bridgemaster systems check the indicator gaugeon the high pressure filter when the system is warmand the Bridgemaster Trailer is actually movingdown (if the trailer is not moving, the indicator willnot read).

4. Service the ZF transmission. The lubricant shouldbe drained while the ZF drive is hot. 85w-140 with aGL5 spec is the proper lubricant. Do not overfill thedrive. Proper oil level is to the bottom of the sightglass.

5. Inspect mixer main hold down bolts and springs.Replace or adjust as required.

Roller Adjustments

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Roller Adjustments 51

Drum Roller:

Each drum roller is equipped with two tapered rollerbearings. Seals are provided to exclude water and dirt. Ifit becomes necessary to replace the bearings, theassembly must be thoroughly cleaned before installingthe new bearings. Pack the bearings with therecommended lubricant. (See lube chart).

To take up bearings, tighten nut until roller cannot beturned by hand, then back off until roller turns with slightdrag.

Roller Alignment:

Drum rollers must run parallel (in line) with roller track.

Rollers are to be set by using a minimum 12” longstraight edge, with one knife edge. Working from bothsides of rear face of roller, straight edge is to match withchamfer on roller track (see below).

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

Unloaded Drum Roller Alignment:

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

Universal Drive Shaft

52 Universal Drive Shaft © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

After the universal drive shaft has been assembled tothe engine and pump, be sure that the followingconditions exist:

a. The drive shaft joint are in phase (See Below)

b. The slip joint spline has ample engagement and thatat least 3/8” of clearance exists between the end ofthe male spine and the bottom of the female spline.(See Below)

CAUTION: If the yoke (00700) nut is not properlytorqued to 175 ft. lbs., drive shaft failure may occur. Inmost universal drive shaft installations, a sl ightmisalignment between driving and driven members isdesirable but in no instance should the angle of theuniversal drive shaft between joints and the shaftcenterline of the driving or driven member exceed 6°.(See Pump and Universal Alignment)

Misaligned Aligned

54 ZF Drum Drive © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

ZF Drum DrivesZF was founded in 1915 by Count Zeppelin (the airshipZeppelin) and is the world’s leading manufacturer oftransmission systems including axles and steering.McNeilus Companies has used ZF’s Drum Drive sincethe 1970’s. Since that time several models of the ZFhave been developed and put into production. Over theyears the torque rating of the ZF has continuallyincreased to meet the demands of larger capacity mixerdrums and lower slump concrete.

The ZF drive is a double planetary reduction drive. Theinput rpm (where the motor is mounted) is reduced to theoutput rpm (the flange that bolts to the drum) by the ratioof the drive. As an example, if the ratio is 144:1, theflange rotates once for every 144 turns of the motor.This reduction is accomplished through planetary gearswhich rotate around a sun gear. There are two sets ofplanetary gears which accomplish the reduction.Planetary gears are very efficient and cool running. Thedrive is around 96% efficient meaning only 4% of theinput 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 ofthe drive. The proper lubricant for the drive is 85W-140;the same lubricant commonly used in differentials. Thespec of the lubricant is GL-5. This lubricant is availablefrom nearly any oil distributor.

It is important that the ZF be serviced after the first 100hours in service. The drive should be drained while thelubricant is warm. This 100 hour period is considered the“clean up” lubricant change for the drive. Anycontamination 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 everysix months or 1,000 hours; whichever comes first.

Remember that the drive has a positive pressure withinthe case. The drive design allows a minimum amount ofinternal pressure to develop as the lubricant and drivewarm up. This positive internal pressure helps preventcontamination from entering the internal drivecomponents. This internal pressure also means thatcaution must be used when removing any fill plugs fromthe drive while the drive is warm. Safety glasses must beworn while servicing the ZF drive. Even though theinternal pressure is minimal, the fill plug may want toblow from its port and spray lubricant from the port.Loosening the four hydrostatic motor mount bolts andthen loosening the hydrostatic motor will normally relieveany pressure in the ZF drive. Any excess pressuredeveloped in the drive is normally relieved by the outputflange seal.

The hydrostatic motor is bolted to the input of the drive.

The hydrostatic motor has a shaft seal which preventsthe hydraulic fluid in the motor from leaking around themotor shaft under pressure. If this motor shaft sealleaks, hydraulic oil and pressure can transfer from themotor case to the ZF drive case. There is also an inputseal in the ZF input cavity around the splined receptacle.This ZF seal is “nicked” at the factory in the 9:00 or 3:00o’clock position. The nick allows the ZF lubricant to leakfrom the drive and lubricate the spline on the motor shaftand ZF splined receptacle. Without this lubrication, themotor spline and ZF receptacle will wear prematurely.Because this seal is “nicked”, there will normally be 85W-140 lubricant in this cavity. The hydraulic fluid in themotor case is quite “thin” compared to the ZF lubricant.Also the ZF lubricant has its own strong odor. If there ishydraulic fluid in this cavity, the motor seal is leaking.

Anytime the drive is overfilled - either from servicing thedrive or from a leaky hydrostatic motor seal - the excesslubricant will exit the drive around the output flange sealand show up on the drum head. This seal is a heavyrubber lip seal which is quite strong. It is our experiencethat a leaky ZF output seal is generally an indication of afaulty motor seal or overfilled drive rather than a faulty ZFoutput seal. The seal cavity also holds a quantity oflubricant and may take two or three weeks for thelubricant around the seal cavity to dry up. Changing theseal is a difficult job which requires a 60 ton press. Theseal is one of the last items to come out of the drivewhen it is completely disassembled. Never assume thisheavy rubber lip seal is faulty. It normally only leaks onlywhen the drive is overfilled. A ZF Repair Manual isavailable from McNeilus if you are planning on workingon the drive.

When changing the ZF drive it is important to retain theflange in its normal centered position that it is in when thedrive is mounted on the mixer. Allowing the weight of theoutput flange to put its weight on the output seal maydamage the seal; especially if it’s left in that position forany length of time. For this reason a bracket with a 90∫bend should be fabricated. One end of the bracketshould be bolted to the flat on top of the drive and theother to the flange. This bracket is especially importantwhen storing a ZF drive for any length of time.

There are flange bolts around the output flange whichsecure the drive flange to the mixer drum socket. Theflange bolts should be torqued to 170 lb. ft and checkedon a weekly basis. There are threaded holes in the ZFflange which are unused. When removing the ZF flangefrom the drum socket, bolts can be threaded into theseextra threaded flange holes around the flange andpressure applied from the flange to the drum socket bytightening the bolts. This will help separate the ZFflange from the drum socket. The bolts work like a

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved ZF Drum Drive 55

ZF Drum Drivespuller to help separate the flange from the drum socket.Heat may have to be applied to the flange and drumsocket area to separate the flange from the drum socket.

Normal maintenance of the ZF drive includes checkingthe torque of the mounting bolts. It’s important to checkthese mounting bolts that hold the ZF drive to the frontpedestal on a weekly basis. Acid wash and moisture canget into the area where the six bolts pass through the ZFmount and pedestal. Over a period of time the bolts candeteriorate in these areas of the ZF drive mount and frontpedestal which can’t be readily seen or inspected. If abolt has deteriorated, it will break when torqued. If onebolt breaks, all six should be replaced as all mountingbolts should be considered to be in the same condition.If only one bolt comes loose, the ZF drive mount maycrack. Should this happen, the entire drive will have tobe replaced. The correct bolt for the application andwhich is installed at the factory is a Bowman productcalled “Bowmalloy”. This Bowmalloy bolt is a SpecialUltra Hi-Strength Alloy Steel Quenched and TemperedBolt. The proof load of this bolt is 165,000 psi and thetensile strength is 185,000 psi. No lesser bolt can beinstalled in this ZF mount application! This Bowmalloybolt is readily available locally or from the McNeilusbranches (McNeilus P/N 020.100990).

If your mixer is S/N 14,669 or previous, the ZF mountbolts 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 ZFmount bolts will be a 7/8” bolt and should be torqued to420 lb. ft.

Please call your McNeilus branch or McNeilus Truck andManufacturing’s Corporate Headquarters at 507-374-6321 if you require assistance with the ZF drive or havequestions. We’re glad to help.

56 Fluid Power Equivalents © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved

Fluid Power EquivalentsEXACT EQUIVALENTS:

1 US Gallon = 231 Cubic Inches

1 Bar at Sea Level = 14.504 psi

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

1 PSI = 2.0416” Hg= 27.72” Water= .0689 Bar

1” HG = 0.490 PSI= 1.131 Ft. Water

1 Atmosphere = 1.013 Bars= 29.921” HG= 14.696 psi

1 Foot Water Column = 0.432 psi

1 Foot Oil Column = 0.354 psi

1 Barrel of Oil = 42 Gallons

1 Micro-Meter = 1 Millionth of a meter

APPROXIMATE EQUIVALENTS

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

1 Cubic Inch = 330 drops of oil1 Cubic Centimeter (cc) = 6 drops

1 Gallon = 3,785 Cubic Centimeter (cc)

1 Oz. = 28.4 Cubic Centimeter (cc)

Area of a Cylinder = Diameter Squared X .7854

Force = Area X Pressure

Cylinder Volume = Area x Stroke ˜ 231Pump Flow = Displacement x RPM ˜ 231

Horsepower = Flow X Pressure ˜ 1714

BTU's per Hour = Horsepower x 2545

Torque (In./Lb) = Horsepower x 63025 ˜ RPM

Torque in Ft./Lb = In./Lb ˜ 12

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Common Abbreviations 57

Common Abbreviations15P: Parker Bridgemaster Filter30P: 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 PumpsA-SPLINE: SAE Spline - 5/8”x 9 Tooth AISI: American Iron and Steel InstituteANSI: American National Standards InstituteASL: Automated Side LoaderASME: American Society of Mechanical EngineersASTM: American Society for Testing MaterialsB-SPLINE: SAE Spline - 7/8”x 13 ToothBTU: British Thermal UnitCB: Counter BalanceCCI: Cylinder City, Inc.CEC: Component Engineering CompanyCFM: Cubic Feet per MinuteCIC: Commercial Intertech CompanyC PAD: SAE”C” Pad MountC-SPLINE: SAE Spline - 1-1/4” X 14 Tooth CC: Cubic CentimetersCD10: Muncie PTOCID: Cubic Inch Displacement CCW: Counterclockwise (also LH)CW: Clockwise (also RH)CYL: CylinderDA: Double Acting CylinderDE: Dual ElementEOS: Electronic OverspeedE-STOP: Emergency StopFE: Full EjectFEL: Front End LoaderFF: Flow FuseGPM: Gallons Per MinuteGVW: Gross Vehicle WeightGW: Gross WeightHOC: Hydraulic Overspeed ControlHP: HorsepowerHPRV: High Pressure Relief ValveIFI: Industrial Fasteners InstituteISO: International Standards OrganizationJ20A: John Deere Oil SpecJDM: John Deere Motorworks (oil specs)LCD: Liquid Crystal DisplayLED: Light Emitting DiodeLH: Left Hand (counterclockwise)LORV: Lock Out Relief ValveLPM: Liters per MinuteLPRV: Low Pressure Relief ValveMF: Motor with Fixed Swash PlateMIL: Military SpecificationMM: MillimeterMRV: Main Relief ValveMS: Military StandardMSL: Manual Side LoaderNEMA: Weatherproof RatingNC: Normally Closed

N-M: Newton MeterNO: Normally OpenNPT: National Pipe TaperNPTF: National Pipe Taper FuelOEM: Original Equipment ManufacturerORS: O-Ring SealPFD: Priority Flow DividerPTO: Power Take OffP/N: Part NumberPV: Pump with Variable Swash plateREGEN: RegenerationREL: Rear LoaderRH: Right Hand (clockwise)RPM: Revolutions per MinuteRV: Relief ValveSA: Single Acting CylinderSAE: Society of Automotive EngineersSE10: Mixer Hydro FilterSUS: Saybolt Universal SecondsTELE: Multi-Stage Telescopic CylinderTG: TailgateTVS: Transient Voltage SpikeUNC: Unified National Coarse Threads (bolts)UNF: Unified National Fine Threads (bolts)VA20: Commercial Intertech Spool Valve - 40 GPMVA35: Commercial Intertech Spool Valve - 70 GPMVI: Viscosity IndexVIN: Vehicle Identification NumberVIP: Viscosity Index ImproverWPRV: Work Port Relief Valve

Index

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Index 59

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

A - B - C

Accumulator Charge Kit, ....................5adapters, ......................................2, 17air chute lock, ......................................3air leaks, ............................................50ANSI, ............................................3, 57Automatic Transmission Fluid, ......9, 50blocking devices, ................................1Bridgemaster, ..........4-6, 10, 12, 50, 57Broken Pump Shaft, ....................36-37Charge Pump, ................10-15, 17-19, ..........................................25-29, 34, 37Charge Pump Rotation, ....................34Charge Relief Valve, ..............25-27, 29Check Valve, ..............................24, 44contamination, ............9, 19, 21, 37, 54

D - E - F

debouncer, ........................................50Diagram Action Steps, ................28-29electrical, ....................................3-4, 48extension chutes, ................................3External Oil Cooler Bypass, ........26-28fault-logic charts, ..............................23Fender, ..............................................43

G - H - I

high pressure, ..............2, 9-11, 13, 15, ..............................20-21, 26-29, 50, 57

Hydraulic Down Pressure, ..................5hydraulic fluid, ..........1, 9-11, 14, 38-39, ..........................................................54

Hydraulic Fluid Specifications, ....38-39, ..........................................................59

Hydraulic hoses, ........................1-2, 50hydraulic pipe, ....................................2Hydrostatic Installation, ....................37Hydrostatic Pump, ................4, 6, 9-14, ....................................18-19, 30-31, 37

J - K - L

kit, ............2, 5, 7, 12-14, 17-18, 41, 50Lock out, ..................................1, 3, 57Lower Position, ................................47

M - N - O

Main, ................................3, 20, 50, 57McNeilus Cable Lube Kit, ..................50mixer drum, ................3, 24, 37, 50, 54Molybdenum Disulphite, ....................37o-ring, ..............5, 12-13, 18, 28-29, 57oil, ....................1-2, 9-10, 17-21, 26-28, ........................37-39, 49-50, 54, 56-57

Oil Level, ................................26-28, 50Open Center Chute Block, ................44

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

P - Q - R

Periodic Inspection, ....................49-50power limiters, ............................20, 28proper protective clothing, ..................4Pump and Universal Alignment, ..52-53Raise Position, ..................................46Rear Pedestal, ..................................42Roller Adjustments, ..........................51Roller Alignment, ........................50-51roller track, ..................................50-51

S - T - U

SAE J1065, ..................................2, 11Safety, ........................................1-7, 54tapered roller bearings, ....................51trailer, ........................................4-6, 50transmission, ................3, 9, 37, 50, 54Troubleshooting, ..........2, 17-21, 24-27, ..........................................................48

Tuck-A-Weigh, ................................4-6universal drive shaft, ........................52

V - W - X - Y - Z

vacuum gauge, ........11, 15, 17, 37, 50Vacuum Hose, ..................................28Valve Plate Rotation, ........................35Water Tank Measurement, ..............41ZF Drum Drives, ..........................54-55ZF transmission, ..............................50

McNeilus Truck and Manufacturing Co.CORPORATE HEADQUARTERS

P.O. Box 70, County Road 34E, Dodge Center, MN 55927Phone: 507-374-6321 • FAX: 507-374-6306

BRANCH FACILITIESCALIFORNIA

P.O. Box 1588, 401 North Pepper, Colton, CA 92324 Phone: 909-370-2100 • FAX: 909-370-0739

COLORADOP.O. Box 1128, 7080 Eudora Drive, Commerce City, CO 80022

Phone: 303-287-7486 • FAX: 303-287-2780GEORGIA

P.O. Box 367, 148 Punkintown Road, Villa Rica, GA 30180Phone: 706-459-5151 • FAX: 706-459-0068

OHIOP.O. Box 30777, 1130 Morrison Road, Gahanna, OH 43230

Phone: 614-868-0760 • FAX: 614-868-0498PENNSYLVANIA

P.O. Box 219, Hemlock Road, Morgantown, PA 19543Phone: 215-286-0400 • FAX: 215-286-2094

TEXASP.O. Box 458, 1101 Interstate Hwy. 45 South, Hutchins, TX 75141

Phone: 214-225-2313 • FAX: 214-225-4407WASHINGTON

1911 Southwest Campus Drive, Suite 448, Federal Way, WA 98023Phone: 206-874-2150 • FAX: 206-874-0873

1227058 - mixer seminar i manual

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