1976 2003 8

IMPORTANT SAFETY INFORMATION

FOR CUSTOMERS AND USERS OF THIS PRODUCT

DO NOT OPERATE THIS VEHICLE UNTIL YOU HAVE READ AND THOROUGHLY UNDER-
STAND the operation and maintenance procedures described in this manual and in any other
manuals associated or supplied with this unit. In addition, it is your responsibility to become
familiar with the CAUTION, WARNING AND DANGER notices described throughout this manual
or on placards on the unit. These notices and placards advise against the use of practices and
techniques which could result in serious personal injury and/or cause damage to the vehicle.
PERSONS WHO DEVIATE FROM THE RECOMMENDED OPERATING INSTRUCTIONS,
MAINTENANCE METHODS, OR OPERATING PROCEDURES AS SPECIFIED IN THIS MANU-
AL AND/OR IGNORE THE CAUTION, WARNING AND DANGER NOTICES PROVIDED WITH
THIS VEHICLE DO SO AT THEIR OWN RISK. MCNEILUS TRUCK AND MANUFACTURING,
INC., SHALL NOT BE RESPONSIBLE FOR AND SPECIFICALLY DISCLAIMS ANY LIABILITY
FOR ANY INJURIES OR DAMAGES THAT MAY RESULT FROM ANY DEVIATIONS FROM
RECOMMENDED INSTRUCTIONS, METHODS OR PROCEDURES AND ANY FAILURES TO
ADHERE TO CAUTION, WARNING AND DANGER NOTICES.

The detailed maintenance and service instructions and their respective inspection methods
and time schedules (as recommended by McNeilus Truck and Manufacturing, Inc.) included in
this manual are very important. These instructions and inspection schedules were created for
the benefit of our customers and users of this product. This vehicle was produced with these
maintenance/service practices in mind. THE SAFE OPERATION, MAINTENANCE, AND SER-
VICE OF THIS VEHICLE DEPENDS UPON YOUR ADHERENCE TO THESE
MAINTENANCE/SERVICE PRACTICES.

If you have any questions, comments, or need assistance, please call McNeilus Truck and
Manufacturing, Inc., at (507) 374-6321.
Important Safety Information
IMPORTANT SAFETY INFORMATION
READ AND UNDERSTAND THIS ENTIRE MANUAL
BEFORE OPERATING, REPAIRING, OR ADJUSTING
YOUR MCNEILUS MIXER. THOSE WHO USE AND
MAINTAIN THIS EQUIPMENT MUST BE
THOROUGHLY TRAINED AND FAMILIAR WITH THE
PRODUCT. IF INCORRECTLY USED OR
MAINTAINED, THIS EQUIPMENT CAN CAUSE
SEVERE INJURY.
Always keep this manual in a location where it is readily
available for persons who operate or maintain the
product. Additional copies of this manual are available
from McNeilus Truck and Manufacturing; (507) 374-
6321 at no charge. Please contact McNeilus Truck and
Manufacturing if you require additional manuals or if you
have any questions concerning the information in this
manual or this product.
Some service operations may require special tools,
equipment, or blocking devices (such as the body hoist
or tailgate). If you require information on these items,
please contact McNeilus Truck and Manufacturing at
(507) 374-6321 before attempting these repairs and
service operations.
THESE SAFETY PROCEDURES ARE FOR YOUR
OWN PROTECTION.
DO NOT OPERATE OR REPAIR THIS EQUIPMENT
UNTIL YOU HAVE READ THIS MANUAL AND
UNDERSTAND ITS CONTENTS THOROUGHLY.
PLEASE CALL MCNEILUS TRUCK AND
MANUFACTURING AT (507) 374-6321 IF YOU
REQUIRE ASSISTANCE!
SHOULD AN OPERATOR OF THIS EQUIPMENT
HAVE A READING OR LEARNING DISABILITY,
DYSLEXIA, OR OTHER SUCH CONDITION, THEN HE
OR SHE MUST BE ASSIGNED A MENTOR/TRAINER
TO READ AND EXPLAIN TO SUCH INDIVIDUAL THE
ENTIRE CONTENTS OF THIS MANUAL AS WELL AS
THE SAFETY GUIDELINES, DANGER, CAUTION AND
WARNING DECALS AND PLACARDS AFFIXED TO
THIS UNIT. SUCH INDIVIDUAL SHOULD NOT BE
ALLOWED TO OPERATE THIS EQUIPMENT UNTIL
HE OR SHE THOROUGHLY UNDERSTANDS ALL OF
THESE MATERIALS. FAILURE TO DO SO CAN
RESULT IN SERIOUS PERSONAL INJURY OR
DEATH.
SAFETY AND SAFE WORKING PROCEDURES MUST
BE FOLLOWED AT ALL TIMES. OSHA LOCK OUT
PROCEDURES MUST BE FOLLOWED WHEN
MAINTAINING THIS EQUIPMENT. IF YOU ARE
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
UNFAMILIAR WITH THE OSHA LOCK OUT
PROCEDURES OR ANY SAFETY REQUIREMENTS,
PLEASE CONTACT MCNEILUS TRUCK AND
MANUFACTURING AT (507) 374-6321 FOR
ASSISTANCE.
! WARNING
Anytime you are working on this equipment or its
related systems, you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that he
must not attempt to start the truck.
2. Follow all OSHA and Mixer Lock Out procedures.
Remove the keys from the truck’s ignition.
3. Place magnetic signs on both doors of the truck
which read:
“CAUTION - MAN WORKING ON MIXER - DO
NOT START ENGINE”
4. Lock out supplies are available from McNeilus
Truck and Manufacturing. Call (507) 374-6321
for assistance.
READ, UNDERSTAND, AND FOLLOW THE SAFETY
GUIDELINES, DANGERS, AND WARNINGS LISTED
BELOW AND CONTAINED IN THIS MANUAL TO
PROMOTE RELIABLE OPERATION AND PREVENT
SERIOUS PERSONAL INJURY.
! WARNING
Hydraulic hoses, fittings, and pipe must be
inspected on a daily basis for leaks, cuts, abrasions,
damage, aging, improper clearance, and along the
frame for hidden damage. If you find hoses with any
such adverse conditions or damage, they must be
replaced before the mixer is returned to service! In
any event, all hydraulic hoses must be replaced
every two years. Failure to properly inspect and
maintain your mixer may result in serious personal
injury.
! WARNING
Hydraulic systems are hot. DO NOT TOUCH!
Serious personal injury may result from hot oil.
When you have completed working on the hydraulic
systems, thoroughly clean any spilled oil from the
equipment. Do not spill any hydraulic fluids on the
ground. Clean any hydraulic fluids from your skin
as soon as you have completed your maintenance
and repairs. Dispose of used oil and filters as
required by law.
Introduction and Safety Procedures 1
Important Safety Information
! WARNING
Hydraulic systems operate under high pressure -
only experienced persons should attempt repairs or
troubleshooting on hydraulic systems.
! WARNING
Correct hoses, fittings, and adapters with the
correct SAE rating must be used when replacing
hoses to prevent possible serious injury. Always
replace hoses, fittings, and adapters with
replacements that have a proper, suitable working
pressure rating. Replacement hoses must be of the
correct length and must comply with the hose
manufacturer’s installation guidelines and
recommendations. Consult hose and fitting
manufacturers for correct specifications or contact
McNeilus Truck and Manufacturing at (507) 374-
6321. Hydraulic hoses have the SAE ratings marked
on the hose to assist you in selecting the correct
hose. Any replacement hydraulic hoses and fitting
assemblies must be supplied by the same
manufacturer. As an example: Brand “A” hose and
brand “B” fitting will not normally be compatible.
No “twist” is allowed in the hydraulic hoses.
“Twist” may result in premature hose failure. Please
contract McNeilus Truck and Manufacturing at (507)
374-6321 for assistance when required.
! WARNING
Never remove hydraulic lines, fittings, and adapters
until all pressure has been relieved from the
hydraulic system. Contact McNeilus Truck and
Manufacturing at (507) 374-6321 for assistance if
required.
! WARNING
Hydraulic components can be heavy. Use caution
while lifting these components. Serious personal
injury can be avoided with proper handling of the
components.
! WARNING
Any hydraulic pipe which is replaced must conform
to SAE J1065 specifications. If incorrect hydraulic
pipe is installed, the hydraulic system may fail.
Damage or leaking pipes must be replaced before
the mixer is returned to service. Please contact
McNeilus Truck and Manufacturing at (507) 374-6321
for assistance.
2 Introduction and Safety Procedures
! WARNING
Do not heat hydraulic pipe. The carbon content of
this steel tube is such that if heated for bending, and
either water or air quenched, the pipe may lose its
ductility and thereby be subject to failure under high
pressure or hydraulic shock conditions. Damaged
or leaking pipes must be replaced before the mixer
is returned to service. Please contact McNeilus
Truck and Manufacturing at (507) 374-6321 if you
require assistance or have questions.
! WARNING
All hydraulic pressures must be relieved from the
hydraulic system prior to removing any components
from the system to prevent oil from spraying or
functions and systems from falling. Call McNeilus
Truck and Manufacturing at (507) 374-6321 for
information concerning relieving the hydraulic
pressures.
! WARNING
Increasing hydraulic pressure beyond the
recommendations may result in serious damage to
the mixer or serious personal injury. If you have
questions concerning hydraulic pressures or testing
procedures, please contact McNeilus Truck and
Manufacturing at (507) 374-6321 before attempting
the test procedures or making adjustments.
! WARNING
When performing hydraulic test procedures, use the
proper hydraulic gauges. Installing an incorrect test
gauge could result in serious injury if the gauge
fails. Use properly rated hydraulic hoses to allow
the test gauge to be read away from moving parts
and functions. Contact McNeilus Truck and
Manufacturing at (507) 374-6321 for assistance.
! WARNING
Use the proper tools and equipment when servicing
the hydraulic system. Use only the McNeilus
charging kit when recharging the accumulator. Call
McNeilus Truck and Manufacturing at (507) 374-6321
for assistance, if required.
! WARNING
Never operate the hydraulic system if a leak is
present.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Important Safety Information
! WARNING
Never enter under the chassis unless the mixer is in
the Lockout mode. Remember to follow the Lockout
procedures when working under the truck
! WARNING
When working on the mixer, the wheels must be
blocked, the parking brake on, Lock Out procedures
in effect, and the keys out of the truck’s ignition.
! WARNING
The mixer must not be modified in any way without
authorization from McNeilus Truck and
Manufacturing. Modifications may not comply with
safety standards, including ANSI safety standards,
and may result in serious personal injury. Please
contact McNeilus Truck and Manufacturing at (507)
374-6321 if you require assistance.
! WARNING
When using the emergency jumper procedure to
rotate the drum on a disabled mixer the following
must be observed: Before removing the hydraulic
motor from the mixer drive on both the operating
and disabled mixer, be sure the drum has been
allowed to turn freely so that it is balanced with no
forces transmitted to the hydraulic motor
! WARNING
Daily inspection should be performed on the mixer.
This includes proper operation of the controls,
hydraulics lock out systems, electrical systems,
lighting system including turn signals, back up
alarm, brake lights, clearance lights, head lamps, tail
lamps, safety equipment, and work lights. The
truck’s air system must operate properly and have
no leaks. Water and moisture should be drained
from the truck’s air system daily. Call McNeilus
Truck and Manufacturing at (507) 374-6321 for
assistance.
! WARNING
Do not wear watches, rings, and jewelry while
operating or working with this equipment or its
electrical and mechanical systems. These items can
be hazardous and can cause serious and painful
injuries if they come into contact with electrical
wires, moving parts, or hydraulic equipment.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
! WARNING
Use slower speeds when going around curves or
corners. You are carrying a higher center of gravity
load.
! WARNING
At the job site use the lowest transmission gear and
proceed at low speed, 3 MPH maximum, to the
discharge area.
! WARNING
Always keep hands and feet clear of the mixer drum,
revolving parts, and moving parts while checking
load or washing down the mixer.
! WARNING
Do not climb on ladders or ride on platforms while
the truck is in motion or when ladders or platforms
are wet or slippery. Serious personal injury may
result due to a fall.
! WARNING
All personnel must stand clear of the chutes during
raising and lowering and when chutes are loaded
with concrete. Position chutes while they are not
loaded. A loaded chute falling on a person may
cause serious injury. All chutes must be handled
with great care to avoid injury. Do not stand on
chutes.
! WARNING
Main, foldover, and extension chutes must be
inspected on a daily basis for damage, excessive
wear, proper hardware fit, twist, and overall
condition to determine that they are safe to use. Do
not attempt to repair chutes. Unsafe chutes must be
replaced with new chutes.
! WARNING
Optional air chute lock is intended for use only on
the job site. The manual chute lock should always
be engaged during transport. Excessive wear or
injury may result due to improper usage.
Introduction and Safety Procedures 3
Important Safety Information
! WARNING
Do not let persons, other than the driver, handle the
chutes, unfold the foldover, and/or remove
extension, or stow and secure the extensions for
transit. Keep hands away from chute hardware
where the chutes connect. Never stand in the path
of the chute as it is being unfolded or while in use.
Failure to follow the warnings concerning chute
safety may result in serious injury.
! WARNING
No passenger must be allowed in the cab unless a
manufacturer’s approved passenger seat and seat
belt are provided.
! WARNING
The mixer and chassis should not be overloaded.
Gross Vehicle Weights must not exceed the
Manufacturer’s gross vehicle weight of this vehicle.
Gross Vehicle Weights must meet Federal, State,
and Local laws.
! DANGER
Never drive the truck with the water tank
pressurized.
! DANGER
The water tank must be operated at no more than 55
psi.
! WARNING
Safety decals must be replaced anytime they are
damaged or missing or cannot be read clearly. If
you require safety decals, please contact McNeilus
Truck and Manufacturing at (507) 374-6321 for no
charge replacement safety decals.
! WARNING
Thoroughly understand the controls before
operating the mixer. Be sure everyone is clear of
the area around the truck before operating the
mixer. Remain attentive at all times when operating
the controls.
4 Maintaining your Mixer Hydrostatic Pump and Motor System
! DANGER
Never back up without taking every precaution to be
sure the rear is clear. Check behind truck before
backing up. Watch the mirrors for activity. Never
back up the mixer unless and until you are
completely sure it is safe. Use a spotter/ observer
and/or get out and check yourself to ensure it is safe
to do so.
! WARNING
Wear the proper protective clothing when operating
or maintaining the mixer. Hard hats, safety glasses,
gloves, and safety shoes should be worn. Reflective
clothing is recommended for drivers and
employees.
! WARNING
The mixer should not be overloaded. Load
pressures must match the load to be transported.
! WARNING
Be sure to maintain correct accumulator charge
pressure for correct and safe operation. Do not
attempt to check or charge the accumulator until
you have read and understand the instructions.
Contact McNeilus Truck and Manufacturing at (507)
374-6321 for assistance.
! WARNING
When working on the hydraulic or electrical system
of a Bridgemaster or Tuck-A-Weigh unit the trailer
should be in the down position or chained in the up
position to prevent the trailer from lowering
unexpectedly. Never stand behind the Bridgemaster
or Tuck-A-Weigh when in the up position. If the
Bridgemaster or Tuck-A-Weigh cylinder will not
lower or raise, call McNeilus for assistance at (507)
374-6321 and ask for service.
! WARNING
When working on the hydraulic system with the
trailer raised, always chain the assembly to the
upright or retracted position to prevent the
assembly from coming down.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Important Safety Information
! WARNING
Recheck the Hydraulic Down Pressure against the
load to be transported. If their is too much
pressure the truck driving tandem could be
affected by loss of traction. Always set pressure to
the lowest setting when mixer is unloaded. Do not
run with trailer down when the mixer is not loaded.
! WARNING
When recharging or checking the charge on the
Bridgemaster or Tuck-A-Weigh accumulator, the
following safety guidelines must be followed:
The cylinder rod must be extended (trailer
on the ground) before the accumulator is
charged.
Do not stand behind the cylinder when
charging the accumulator. The hose on the
McNeilus accumulator charge kit is long
enough to allow the accumulator to be
charged from the side of the mixer.
Do not attempt to disassemble the cylinder.
Use only McNeilus P/N 160.85455
Accumulator Charge Kit.
Purge air from the Accumulator Charge Kit
Hose by allowing a slight flow of nitrogen
to escape while attaching the Accumulator
Charge Kit to the Accumulator Charge
Stem.
The truck ignition key should be removed
while charging the accumulator.
Read these instructions thoroughly before
attempting to charge the accumulator.
Loosen only the top nut of the accumulator
charge stem. If the bottom nut is loosened,
damage to the o-ring seal could result. All
gas pressure must be released from the
accumulator before the accumulator charge
stem can be removed for service.
If you have any questions or experience
difficulty with the cylinder or charging the
accumulator, please call the McNeilus
Service Department at (507) 374-6321.
We’re glad to assist!
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
! DANGER
The trailer should be lowered when servicing the
accumulator. Do not stand behind the cylinder
when charging the accumulator.
! WARNING
The trailer pressures must match the load chart
supplied with the mixer. If the pressure is too
great for the load it is possible to raise the rear
chassis wheels of the truck and the operator may
lose control of the unit.
! WARNING
Check trailer king pins, toe-in, tie rods, and
components for proper adjustment. Replace any
worn or loose components immediately. Contact
McNeilus at (507) 374-6321 for any specifications
or assistance you may require.
! WARNING
With the trailer raised on the return trip, slower
speeds are required when going around curves or
corners as the unit could upset or roll over.
! WARNING
Always be sure the area behind the mixer is clear
of people or other obstacles when raising or lower
the trailer.
! WARNING
Always check indicator lights in the cab or at
control panel at the front of the mixer for trailer and
chute position. Replace lights or bulbs when
required. NOTE: all models may not have indicator
lights. Physically check position when indicator
lights are absent.
! WARNING
Check the tire condition and tire pressure of the
trailer wheels daily to be sure the tires are inflated
to proper pressure to withstand the applied loads.
Do not exceed the recommended tire pressure
marked on the tire sidewalls.
Introduction and Safety Procedures 5
Important Safety Information

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

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

! DANGER
IF THE MIXER COMES INTO CONTACT OR CLOSE
PROXIMITY WITH A POWER LINE OR THERE IS ANY
ARCING, STAY IN THE TRUCK CAB AND KEEP
AWAY FROM THE METAL PARTS OF THE UNIT. DO
NOT LET ANYONE COME CLOSE TO THE TRUCK.
DO NOT ATTEMPT TO JUMP CLEAR OF THE TRUCK.
STAY IN THE CAB. THE POWER MUST BE
DISCONNECTED BY THE POWER COMPANY
BEFORE YOU CAN SAFELY LEAVE THE CAB.
Minimum clearances from power lines:

50,000 Volts or Less...........................................4 Feet

50,000+ Volts ......................................................10 Feet
345,000 - 750,000 Volts ......................................16 Feet

KNOW THE CLEARANCE OF OVERHEAD

OBSTRUCTIONS. NEVER DRIVE THE MIXER UNDER
ANY OVERHEAD OBSTRUCTION WITHOUT
KNOWING THE CLEARANCE HEIGHT. IF UNIT HAS
A FLIP-UP HOPPER, BE SURE HOPPER IS IN THE
LOWERED POSITION. FAILURE TO DO SO MAY
RESULT IN DAMAGE TO THE MIXER BODY OR
TRUCK, AND MAY RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.

6 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
2
3
LOCK OUT PROCEDURE FOR MIXER DRUM
4
5
6
7
Maintaining your Mixer Hydrostatic Pump and Motor System
MAINTAINING YOUR HYDROSTATIC PUMP AND V. Multiple Viscosity Hydraulic Fluid (MV)
MOTOR SYSTEM
A. Shear Factor

THE HYDRAULIC FLUID 1. Viscosity Index Improver (VIP)

I. ISO68 - Ambient Less than 80° F a. Synthetic Polymer Chain

A. Specifications b. Typically Not Shear Stable in High
Pressure Piston Pumps
1. SUS @ 210° F = 55-60
B. High Viscosity Index
2. Viscosity Index = 100 - 120
1. 130 - 150
3. Pour Point = -25° F Average

VI. Automatic Transmission Fluid (ATF)

II. ISO100 - Ambient More than 80° F
A. Should Not Be Used in Hydrostatics on Mixers
A. Specifications
B. Not Shear Stable in High Pressure Piston Pump
1. SUS @ 210° F = 60 - 70
1. High Viscosity Index
2. Viscosity Index = 100 - 120
a. 170 - 200
3. Pour Point = -5° F to +10° F
2. Tends to Shear to Base Stock Viscosity
III. Recommended Additives 3. Looses Hydrodynamic Film
A. Anti-Rust 4. Not Always Compatible with Hydraulic Fluid
B. Anti-Foam 5. Normally Higher Priced than Hydraulic Fluid
C. Anti-Wear
VII. Water Base Oil
D. Anti-Corrosion
A. Do Not Use in Hydrostatic Systems
E. Anti-Oxidant
B. Shortens Lifetime of Hydrostatics
F. Emulsifier
G. Detergent HOW HOT IS HOT?
I. Normal Maximum Operating Temperatures
IV. Breakdown of Hydraulic Fluid
A. Outside Temperature (Ambient) + 100° F
A. Age
B. Running Warmer Than Normal
1. Changing Hydraulic Fluid
1. Drum Stall
a. After the first 100 hours in Service
2. Hydraulic Fluid Should Be Changed More
b. Every six months or 1,000 Hours,
Often
thereafter whichever comes first
a. Additive Package Breaks Down
B. Heat
b. Hydraulic Fluid’s Ability to Tolerate Heat
1. Breakdown Temperature Varies with Brands
Lowers
C. The Effects of Breakdown of Hydraulic Fluid
C. Operating Cooler than Normal
1. Oxidizes
1. Moisture Accumulation
2. Additives Breakdown
a. Maximum Moisture = .001%
3. Varnish Forms
2. Hydraulic Fluid Should Be Changed More
4. Contamination Often
5. Hydrodynamic Film Cannot be Maintained
a. The film of oil between moving parts

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintaining your Mixer Hydrostatic Pump and Motor System 9
 D. Filter Buggy (Three Filters Required) 4. Reservoir Breather Cap Installed by
Customer
1. Coarse Filter (Approximately 40 Microns)
a. 10 Micron Required if Sealed Cap is
2. Fine Filter (Approximately 5 Microns)
Replaced
3. Water Filter with Drain.
THE HYDRAULIC HOSE

E. Analyzing Oil
I. General Hose Information and Knowledge
1. Use an Analysis Designed for Hydrostatics
A. Ratings
a. Cleanliness Levels
1. Operating Pressure
b. SUS @ 210°F
a. The pressure the hose is designed to \
c. Moisture Content operate at on a continuous basis
d. Viscosity Index 2. Proof
a. The Operating Pressure X 2 for Test
F. Filtering Oil From Storage Containers Purposes

1. Use a 10 Micron Filter 3. Burst

a. Low Pressure Applications a. The pressure at which the hose bursts

1. Mixer Hydro Filter Assembly b. Operating Pressure X 4

b. High Pressure Applications 4. SAE = Society of Automotive Engineers

1. Bridgemaster High Pressure Filter 5. DIN = Duetsch International Nominal

Assembly 6. Mil Spec = Military (Lowest Rating)
B. Hose Outer Covering Considerations
THE RESERVOIR 1. Acid Wash Resistance
2. Synthetic Rubber Covering
I. Unvented Reservoir on Standard Mixer
C. Twist Factor
A. Hydro has an even exchange of oil
1. 7° of Twist per Foot Shortens Hose Life by
B. Chute Lift Cylinder Volume Minimal 95%
1. Cylinder Capacity = .34 Gal D. Hose Shrinkage
C. A sealed reservoir is cleaner 1. Anticipate a 4% Shrinkage Factor
D. Thermal Expansion Aids Charge Pump a. 2” on a 50” Hose
E. A Vent is Required if the System Has Large E. Never Pressure Wash Hoses
Cylinders
F. Inspect Hoses on a Daily Basis
1. Bridgemaster Requires Vented Reservoir
1. Cuts
II. Moisture Accumulation 2. Leaks
A. Source of Moisture 3. Abrasions
1. Condensation 4. Damage
a. Cool Down of Hydraulic Fluid 5. Improper Clearance
2. Induced Moisture 6. Aging
a. Bad Fitting Reservoir Cap 7. Check Along Frames for Damage, Grommets
b. Washing Hot Reservoir With Cold
Water
3. Hydraulic Fluid Not Reaching Operating
Temperature

10 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
 G. Hose Size = I.D. F. Replacement Tubing Must Meet SAE J1065
Rating
1. Dash Sizes in 16th of an Inch
1. Coordinates Sidewall Thickness with
a. -4 = 4/16 or 1/4”
Diameter
b. -6 = 6/16 or 3/8”
2. 4130 Cold Drawn Seamless Allow
c. -8 = 8/16 or 1/2”
3. .120 Sidewall Thickness

II. Suction Hose Applications 4. 92 Rockwell Hardness

A. SAE100R4 or Equivalent G. Tubing Size = O.D.

1. 28” Vacuum
THE SUCTION FILTER
2. 200 PSI Maximum
3. Aeroquip FC310, 2661 or Equivalent I. 10 Micron (µ ) Rating is Required
A. 1 µ = 0.00003937 Inch
III. Chute Hose Applications
B. Human Hair = 70 Microns
A. SAE100R2 or DIN 20 022
C. Lower Limits of Human Visibility = 40 Microns
1. Minimum Operating Pressure of 3,000 PSI
D. White Blood Cell = 25 Microns
Required
2. Aeroquip GH781 or Equivalent II. Beta Ratings Required by Eaton
A. B10=2 Minimum
IV. Closed Loop System (Hydrostatic Pump & Motor)
B. B10=4 Better Rating
A. SAE100R12
1. Minimum Operating Pressure of 4,000 PSI III. ISO Cleanliness Standard
2. GH493 or Equivalent A. 18/13 Required
1. Particles per ML (1 cc)
THE HYDRAULIC TUBING
a. 5 = 2,500 Particles
I. General Tubing Information b. 15 = 80 Particles
A. Ratings
IV. 10 Inches of Mercury (Hg) Maximum Warm
1. Operating Pressure
A. Red Line on Vacuum Gauge
2. Design Factor 4:1
V. Bypass Opens at 20 Inches of Mercury
3. SAE = Society of Automotive Engineers
A. Hydraulic Fluid is Unfiltered in Bypass
B. Should be zinc dichromate plated or primed
B. Filter Must Withstand 20 Inches of Mercury
1. Helps Prevent Rust and Deterioration
C. High Pressure Tubing is -16 (1”) VI. Many Filters Do Not Qualify
D. Return Tubing is -12 (3/4”) A. Incorrect Beta Ratings
E. Inspect Tubing on a Daily Basis 1. B10=2 Minimum
1. Cuts
2. Leaks THE HYDRAULIC FLUID COOLERS
3. Abrasions
I. Flow Capacity is Determined by Charge Pump Flow
4. Damage
A. 1.28 Charge Pump @ 2,000 RPM = 10.5 GPM
5. Improper Clearance @ 95% Efficiency
6. Aging B. Bypass Valve to Limit Case Pressures
7. Check Along Frames for Damage
1. Two 35 PSI Bypass per Cooler

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintaining your Mixer Hydrostatic Pump and Motor System 11
 C. Front Mount Cooler IV. Pump Configurations Available (CW or CCW)
1. 15,670 BTU w/Ram Air (Unobstructed) A. Standard Charge Pump
2. 2,000 - 4,000 BTU in Stationary Mode B. Dual Element Charge Pump
D. 12 Volt Fan Cooler 1. Used with Optional Open Center Chute Lift
Block
1. 19,000 BTU w/Ram Air
C. SAE “A” Pad
2. 15,000 BTU w/Fan Air
1. Bridgemaster
3. Two 12 Volt Sensors for Redundancy
D. 1-3/8” or 1-1/2” Tapered Shaft
a. Lower Temp Sensor - 140° F
b. Higher Temp Sensor - 180° F V. Displacements
4. ZF Mount is Standard A. 54 Series - Production Pump (5.4 cid)
B. 46 Series and 64 Series (4.6 and 6.4 cid)
II. Reverse Flushing the Cooler
1. Available for Resale from McNeilus
A. Cooler Must Be Flushed or System Will Be
Immediately Contaminated on Start Up
VI. Model and Serial Numbers
THE HYDROSTATIC PUMP A. The First Two Numbers of the Model Number
Indicate Displacement
I. Rotation 1. Example: “54” = 5.4 cid
A. Front Mount Pumps = LH (CCW) B. Next Two Numbers of the Model Number
B. Rear Mount REPTO Pumps = RH (CW) Indicated Ball Guide or Fixed Clearance Model

1. Rear Engine Power Take Off 1. “2” = Pump

2. “0” = Ball Guide
II. Input Shaft Sizes
3. “1” = Fixed Clearance
A. Production - Approximately January 1997
4. Example:
1. 1-1/2” Tapered Shaft
a. 5421 = 54 Series Fixed Clearance
2. 1350 Series Spicer Drive Line Components Model
3. Yoke Torque = 320 lb. ft. Minimum b. 5420 = 54 Series Ball Guide Model
Lubricated
C. The First Four Digits of the S/N Indicate the
Build Date
4. P/N 5421-5XX (5” Designates 1-1/2” Shaft) 1. Example: 1097XXXX = October 1997.
B. Production - Through 1997
VII. Wet Spline “A” Pad
1. 1-3/8” Tapered Shaft
A. S/N 0688 and Higher are Wet Spline
2. 1310 Series Spicer Drive Line Components
1. No Spline Lubrication is Required
3. Yoke Torque = 175 lb. Ft. Minimum
Lubricated B. Lower S/N Must Be Lubricated Every Six
Months or Converted to a Wet Spline
4. P/N 5421-4XX (“4” or Lower Designates 1-
3/8” Shaft 1. Conversion Kit P/N 180.02521

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

A. 6,000 PSI Clipping Relief Valves A. S/N 0986 and Newer Have a New Style
Control Valve Shaft and O-Ring Seal
B. Poppet Style
1. Tend to be Self-Cleaning
2. Cooler Operation

12 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
B. Older Control Valves Can Be Updated With A IV. Changing Motor Sizes
New Shaft
A. Installing a Larger Displacement Motor will
1. Shaft P/N 340.12945 Decrease Drum RPM and Increase Torque
2. Seal Kit P/N 100.02468 B. Installing a Smaller Displacement Motor will
Increase Drum RPM and Decrease Torque
C. Dust Cover Over Control Valve Shaft On All
Current Control Valves
V. Motor Spline Lubrication
1. Keeps Cement Dust from O-Ring
A. The ZF 21 Tooth Receptacle Seal is Nicked To
D. All Eaton Remanufactured Control Valves Allow Gear Lube to Fill Cavity Between the ZF
Have All Updates and Motor
1. This allows the motor spline to be
IX. Charge Pumps
continuously lubricated
A. Standard Charge Pump = 1.28 cid
2. When changing a ZF drive, the seal must be
B. Gerotor Style nicked at the 9:00 position
1. Gerotor Style Tolerates Vacuum Well
VI. Model and Serial Numbers
C. Models Available
A. The First Two Numbers of the Model Number
1. Standard Indicate Displacement
2. Dual Element 1. Example: “54” = 5.4 cid
a. Open Center Chute Lift Block B. Next Two Numbers of the Model Number
3. “A” Pad Indicate Motor and Ball Guide or Fixed
Clearance Model
D. Rotation Easy To Reverse
1. “3” = Motor
E. S/N 0385 and Newer Have Larger Charge
Pump Shaft 2. “0” = Ball Guide
3. “1” = Fixed Clearance
THE HYDROSTATIC MOTOR
4. Example:

I. Spline a. 5431 = 54 Series Fixed Clearance Model

A. All McNeilus Mixers have a 21 Spline Motor b. 5430 = 54 Series Ball Guide Model
Shaft C. The First Four Digits of the S/N Indicate the Build
B. Rexworks = 20 and 23 Spline Date

C. Smith, Jaeger, CMC = 14 Spline 1. Example: 1097XXXX = October 1997.

II. High Pressure Relief Valves

A. The McNeilus has no High Pressure Relief on
the Motor (Clipping Relief Valves on the Pump)
B. 5,000 and 5,500 PSI Relief Valves were
Common

III. Displacement Sizes

A. 54 Series Eaton (5.4 cid)
B. 46 Series Eaton (4.6 cid)
C. 39 Series Eaton (3.9 cid)

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintaining your Mixer Hydrostatic Pump and Motor System 13
DRUM STALL AND INTERNAL LEAKAGE 1. Flush Reservoir and Wipe Clean
2. Reverse Flush the Cooler
I. Normal Internal Leakage of Hydraulic Fluid
3. Install New and Correct Filters
A. Leakage Cleans, Cools, and Lubricates
a. B10=2 Beta Rating Minimum
B. Normal Leakage at Operating Temperature
4. Flush Hoses and Tubing and Blow Out with
1. Pump = 1 GPM Air
2. Motor = 1 GPM D. Torque the Pump Yoke as per Specifications
C. Charge Pump Capacity @ 600 RPM = 3 GPM E. Change Both the Pump and Motor
1. Charge Pump Replaces Leakage (Make UP F. Install the Correct Hydraulic Fluid
Fluid)
G. Fill the Pump and Motor Case with Hydraulic
2. Fluid Not Used for Make Up (Leakage) Aids Fluid
Cooling by Dumping Into Pump Case
H. Follow Clean and Flush Procedures
II. Excessive Internal Leakage
A. Wear
B. Wrong Hydraulic Fluid (too thin)
C. Overheated
1. Possible Cooler Problems
a. Obstructed Air Flow
D. When Leakage Exceeds the Charge Pump’s
Capacity for Make Up Fluid the Drum Will Stall

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

CHANGING HYDROSTATIC PUMPS AND MOTORS

I. Important Items to Complete

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

14 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
 HYDROSTATIC CLEAN, FLUSH, AND INSTALLATION PROCEDURES
Contamination (dirt, metal particles, etc.) in fluid
of a hydrostatic transmission is the primary cause
of failure. Before reinstalling a set of hydrostatic
transmission units, the system must be
completely free of contamination. Changing the
filter element and fluid is not enough to
thoroughly clean the system. For this reason, we
have derived the following list of procedures that,
when followed step-by-step, will help assure
system cleanliness; resulting in longer life for
your hydrostatic transmission components.
Remember that it is desirable that both the
hydrostatic pump and motor be replaced at the
same time.
AFTER DETERMINING THAT THE HYDROSTATIC
UNITS NEED TO BE REPLACED:
1. Drain all fluid from the system at the lowest
point.
2. Remove the old hydrostatic pump and motor
and return it to McNeilus.
3. Remove the filter element and thoroughly
flush the reservoir.
4. Check the suction hose for kinks, collapsed
or flaking liner, or any other obstructions.
Use only SAE100R4 suction hose for
replacement hose if required. Check the
function of the shut-off valve to be sure it
opens fully. Inspect all other hose and
fittings and replace as required.
5. Check the inside of the reservoir for
contamination (particles of steel or brass,
sludge, dirt, etc.) and be sure the pipe
couplings from the reservoir to the suction
hose are not obstructed.
6. Flush all hoses, pipes, tubing, filter housings,
and reservoir several times with clean
kerosene, diesel, or solvent.
7. Fill all lines, hoses, pipes, etc. with clean
kerosene, diesel, or solvent and blow out with
air pressure.
8. Reverse flush the oil cooler several times with
clean kerosene, diesel, or solvent and blow
out with air pressure.
9. If the reservoir has a clean-out door, hand-
wipe the inside of the reservoir and filler
housing with a clean, lint-free cloth.
10. Clean all hydrostatic pump and motor hose
fittings and replace o-rings.
11. Replace filter elements, filter gaskets, and
reservoir clean out door gasket if equipped.
12. Check the filter vacuum gauge (MTM P/N
00422). The vacuum gauge is normally
located on the filter assembly. Remember the
importance of a good vacuum gauge in the
system. If this vacuum reading exceeds 10”
of vacuum when the oil is warm, the result
may be cavitation in the system. Normally
this indicates a need for an oil filter change
(MTM Spin-On P/N 00436). If the new filter
doesn’t solve the problem, check for
restrictions and proper SAE100R4 suction
line diameter. Many mixers had a primary
filter internally in the reservoir and a filter
externally mounted in the system. It is our
experience that the internal filter in the tank
may be removed if a proper 10-micron filter
assembly with the correct by-pass system
and capacity (MTM P/N 00435) is installed
externally in the suction line which goes from
the reservoir to the charge pump.
13. Keep all loose hose ends capped after
flushing to prevent contamination from
entering the system.
14. Reinstall pump and motor units (on
replacement motors, apply a thin coat of
Molybdenum Disulfide grease to the motor
spline to prevent the motor shaft from seizing
to the gear box receptacle.
15. Fill reservoir, hydrostatic pump and motor
cases, hose, lines, etc. with new, clean pre-
filtered fluid. Make certain fluids meet Eaton
specifications.
16. Be sure to fill the hydrostatic pump and motor
cases before start-up. Proceed with the start-
up procedure.
17. Slotted pump yoke nut must be torqued to
specs. CAUTION: Failure to properly torque
the slotted pump yoke nut may result in a
broken pump shaft.
REMEMBER – KEEP IT CLEAN!
This includes any oil drums, buckets, transfer
pumps, etc., used to clean and flush the system!
Although these steps will take considerable time
to complete, we at McNeilus feel that they are
extremely important to prevent unnecessary
replacements that result in expense and down
time. Remember that we want you to get the most
from your equipment and our hydrostatic
transmission program.
OPERATION RECOMMENDATION
The engine must have at least 600 RPM at idle
with a load of concrete in the mixer drum. When
sitting on the jobsite with a load of concrete, use
higher engine RPM (up to 1,200 RPM) to help
maintain cooling and prevent drum stall.
In cold weather, allow the hydraulic oil to warm up
before turning the drum.
Recommendations for hydrostatic lubricants

The following are approved ISO 100 specification lubricants for Eaton Transit Mixer Hydrostatics
operating in ambient temperatures in excess of 80° F:

SUS @ POUR
BRAND NAME 210 VI POINT (F)
Castrol HV100 73.6 142 -42
Castrol Blue Hydraulic 65 102 +5
Castrol Paradene AW 65.7 102 -15
Citgo AW Hyd Oil 63 96 +5
Conoco Super Hyd Oil 100 64 98 -25
Exxon NUTO H100 62.6 97 -9
Fina AW Hyd Oil 64 95 0
Kendall Four Seasons (7384) 63 95 +10
Mobil DTE10-18M 71 120 -29
Mobil *SHC500 Series 66 145 -55
Shell Tellus 65214 62 95 - 5
Sunoco Sunvis 7100 64.7 95 - 2
Texaco Rando HDZ 100 75 142 -35
Texaco Rando HD 100 63 95 0
Unocal UNAX AW 65 100 +10

The following are approved ISO 68 specification lubricants for Eaton Transit Mixer Hydrostatics
operating in ambient temperatures less than 80° F:

Castrol HV68 61.4 145 -45

Castrol Blue Hydraulic 54 105 -15
Castrol Paradene AW 54.1 95 -26
Chevron Hyd Oil AW 54 99 -22
Citgo AW Hyd Oil 55 94 -20
Conoco Super Hyd Oil 68 56 100 -30
Exxon NUTO H68 54.8 97 -17
Fina AW Hyd Oil 55 96 -15
Kendall Four Seasons (7382) 56.0 100 -5
Mobil DTE10-16M 62 120 -11
Mobil *SHC500 Series 66 145 -55
Shell Tellus 65211 54 95 -10
Sunoco Sunvis 768 54.9 98 -15
Texaco Rando HDZ 68 61 141 -40
Texaco Rando HD 68 55 103 -20
Unocal UNAX AW 55.4 102 -11

* Synthetic Hydraulic Oil

NOTE: No Tractor Fluids Are Recommended at this time

Note: Several other brand oils also meet the hydrostatic specifications. Call McNeilus for further
information.
Trmoil.005
© McNeilus Truck and Manufacturing Co. All Rights Reserved
Maintenance Periodic Inspection

**

For Steel Drum Revolution Drum

1/2" Minimum

5/8" - 2 1/4" Use Blue Loctite

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

Service ZF twice annually with 85W-140 GL5 Spec. 85W-140 can be used year round.

* NOTE: Trans. hold down bolts previous S/N 14669 had 3/4” bolts that were torqued to 310 lbs. Now S/N 14669
has 7/8” bolts that are torqued to 420 lbs.

**Call McNeilus for additional oil or filter information at (507) 374-6321.

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

DAILY INSPECTIONS WEEKLY INSPECTIONS

1. Check the pump driveshaft cap screws for

1. Hydraulic hoses, fittings, tubing, and
proper tightness.
electrical wire and cable must be inspected
on a daily basis for leaks, cuts, abrasions,
2. Lubricate the complete mixer as per the lube
damage, aging, improper clearance, and
chart supplied with the mixer.
along the frame for hidden damage. If you
find hoses, fittings, tubing, or electrical wire
3. Draw a sample of oil from the reservoir and
or cable with any such adverse conditions or
check for the presence of water. If water is
damage, they must be replaced before the
present the oil should be drained from the
mixer is returned to service! In any event, all
reservoir and replaced. The source of the
hydraulic hoses must be replaced every three
water should be found and corrected.
years. Failure to properly inspect and
maintain your mixer may result in serious
4. Inspect the water tank for damage, dents,
personal injury.
leaks, rust, and corrosion. Also inspect the
area around the water tank mounting
2. Visually inspect the roller track and roller
brackets.
alignment. Check for “snapping” or
“popping” noises while the drum is turning.
5. Check and record the drum RPM while
loading the mixer with concrete and the truck
3. Check the oil level in the hydraulic reservoir.
engine running at top governed RPM. If the
Add oil if below the sight gauge level with all
drum revolution is 2 RPM less than that
cylinders retracted. Use the correct oil.
recorded at the previous check, see the
manual for component check out.
4. Start the engine and warm up the hydraulic
system with the truck engine at approximately
6. Check the inside of the drum for concrete
1,200 RPM and with the drum turning at
build up and clean as required.
approximately 2 RPM. Warm up time
minimum is five minutes.
7. Check the mixer mounting bolts and springs
for proper tightness, wear, and damage.
5. Check the vacuum gauge on the oil filter.
Replace bolts and springs as required.
Replace the element if the reading exceeds 10
inches of vacuum after the oil has reached
8. Inspect the Debouncer for proper clearance.
operating temperature.
9. Inspect the Roller Track for cracks and flat
6. Check for and correct any external oil or air
areas. Correct as necessary.
leaks.
60 DAY INSPECTION
CAUTION: Do not tighten or loosen any
connections while the hydraulic system is under
1. Check the torque on the ZF mounting bolts.
pressure! Serious personal injury may result if
The ZF mounting bolts should be torqued to
connections are tightened or loosened while the
410 lb ft. Use only Grade 9 bolts, washers,
hydraulic system is under pressure!
and nuts if mounting bolts must be replaced.
Call McNeilus Truck and Manufacturing at
507.374.6321 and ask for mixer service if you
7. Lubricate the pump drive shaft universal
have questions or require assistance.
joints.
2. Check the torque on the ZF drum flange bolts.
8. Lubricate the roller bearings.
The drum flange bolts should be torqued to
170 lb ft.
9. Lubricate and inspect the rear cable control
box.
SIX MONTH INSPECTION
10. Lubricate the chute pivot system and inspect
1. Change the hydraulic oil and install new
the chutes and chute hardware for wear and
hydraulic oil filters. Remove filters and check
damage.
for metal particles. Replace the filters with
the correct part number filters with the proper
11. Inspect the decals on the mixer. If the decals
filter media and Beta Rating. Check with
are damaged, worn, or difficult to read,
McNeilus before using any alternate hydraulic
replace the decals immediately. No charge
oil or filters. Only few Multiple Viscosity oils
decals are available from your local McNeilus
are approved. Automatic Transmission
Parts Department.
Fluids (ATF) must not be used in this
hydrostatic system.
2. If the mixer is equipped with control cables
lubricate the control cables using the
McNeilus Cable Lube Kit.

3. On Bridgemaster systems check the indicator

gauge on the high-pressure filter when the
system is warm and the Bridgemaster trailer
is actually moving up or down (if the trailer is
not moving, the indicator will not read).

4. Service the ZF transmission. The lubricant

should be drained while the ZF drive is hot.
85W140 lubricant with a GL5 spec is the
proper lubricant. Do not overfill the drive.
Proper oil level is to the bottom of the sight
gauge.

NOTE: Call McNeilus Truck and Manufacturing at

5073374.6321 and ask for mixer service if you
have further questions or require assistance.

trmperiodicinspection.401

© McNeilus Truck and Manufacturing Co. All

Rights Reserved
Additional Information
1. REPAIRING CHUTES
A. McNeilus does not recommend that chutes be
repaired. Use caution if you decide to repair
main chutes, foldovers, and extensions for
emergency use
1. Many repaired chutes are not safe and can
result in injury or death, or present a liability
problem should an accident occur
B. Hardware and bolt holes may be elongated
C. Use only high strength bolts when replacing
main and foldover chute bolts
D. Use safety chains on main chutes and
foldovers
2. WATER TANKS
A. Inspect water tanks for damage, dents, leaks,
rust, and corrosion on a weekly basis.
1. Also inspect the area around the water tank
mounting brackets
B. Mixers should not be transported with water
tanks pressurized
1. This is a law in some states
C. Do not exceed the manufacturer’s recommend-
ed pressures
D. When replacing components on the water tank
air pressure system, the same pressure value
components must be installed
1. Specifications of the McNeilus air pressure
system components
a. Hold back valve . . . . . . . . . . . . . . 75 psi
b. Regulator . . . . . . . . . . . . . . . . . . . 55 psi
c. Relief Valve . . . . . . . . . . . . . . . . . 60 psi
d. Pressure Gauge . . . . . . . . . . 0 - 100 psi
E. Use only DOT-approved air lines when replac-
ing air lines
F. Replace pressure gauges which are defective
G. Replace any damaged or missing water tank
decals
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
3. ROLLER AND DEBOUNCER ALIGNMENT
A. Roller and debouncer alignment should be
inspected visually on a daily basis
B. Rollers should be parallel with the roller track
1. A machined surface for a straight edge is
provided on the rear of the roller on the
McNeilus mixer to check if the rollers are
parallel with each other
C. When the mixer is loaded the roller should have
maximum contact with the track
D. The debouncer should be adjusted to allow
minimum up-down drum movement
4. DECALS, WARNINGS, PLACARDS
A. Replace the decals, warnings, and placards if
the decals are damaged, worn, or painted over
B. Replace the chute warning decals when the
chutes are replaced.
C. Information may be required for rating plates,
capacity placards, etc
D. Safety decals must conform to the current stan-
dards for color, language, symbols, etc., to be
legal
5. FOLLOW OSHA PROCEDURES AND RULES
WHEN WORKING ON EQUIPMENT
A. When working on the mixer inform the truck dri-
ver that the mixer is going to be repaired and
“locked out” and that he must not attempt to
start the truck
B. Remove the keys from the ignition
C. Place magnetic caution sign on both doors
which read: “CAUTION - MAN WORKING ON
MIXER - DO NOT START ENGINE”
D. Read, understand, and follow the safety guide-
lines contained in the owner’s manual and on
the decals located on your mixer
E. McNeilus has no charge information on lockout
procedures available upon request
F. No passengers are allowed in the cab unless a
Manufacturer’s approved passenger seat and
seat belt are provided.
Additional Information 79
Pump and Universal Alignment

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Pump and Universal Alignment 53
Universal Drive Shaft
After the universal drive shaft has been assembled to
the engine and pump, be sure that the following
conditions exist:
a. The drive shaft joint are in phase (See Below)
b. The slip joint spline has ample engagement and that
at least 3/8” of clearance exists between the end of
the male spine and the bottom of the female spline.
(See Below)
Misaligned
52 Universal Drive Shaft
CAUTION: If the yoke (00700) nut is not properly
torqued to 175 ft. lbs., drive shaft failure may occur. In
most universal drive shaft installations, a slight
misalignment between driving and driven members is
desirable but in no instance should the angle of the
universal drive shaft between joints and the shaft
centerline of the driving or driven member exceed 6°.
(See Pump and Universal Alignment)
Aligned
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Fluid Power Equivalents
EXACT EQUIVALENTS: APPROXIMATE EQUIVALENTS

1 US Gallon = 231 Cubic Inches 1 Fluid Oz. (volume) = 600 drops of oil

1 Bar at Sea Level = 14.504 psi 1 Cubic Inch = 330 drops of oil
1 Cubic Centimeter (cc) = 6 drops
1 Horsepower = 33,000 Ft. Lbs. per Minute
= 2545 BTU per hour 1 Gallon = 3,785 Cubic Centimeter (cc)
= 746 Watts or 0.746 kw
1 Oz. = 28.4 Cubic Centimeter (cc)
1 PSI = 2.0416” Hg
= 27.72” Water Area of a Cylinder = Diameter Squared X .7854
= .0689 Bar
Force = Area X Pressure
1” HG = 0.490 PSI
= 1.131 Ft. Water Cylinder Volume = Area x Stroke ˜ 231
Pump Flow = Displacement x RPM ˜ 231
1 Atmosphere = 1.013 Bars
= 29.921” HG Horsepower = Flow X Pressure ˜ 1714
= 14.696 psi
BTU's per Hour = Horsepower x 2545
1 Foot Water Column = 0.432 psi
Torque (In./Lb) = Horsepower x 63025 ˜ RPM
1 Foot Oil Column = 0.354 psi
Torque in Ft./Lb = In./Lb ˜ 12
1 Barrel of Oil = 42 Gallons

1 Micro-Meter = 1 Millionth of a meter

56 Fluid Power Equivalents © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Common Abbreviations
15P: Parker Bridgemaster Filter N-M: Newton Meter
30P: Parker Bridgemaster Filter (older style) NO: Normally Open
2W2P: Two Way - Two Position (common cartridge) NPT: National Pipe Taper
3W2P: Three Way - Two Position (common cartridge( NPTF: National Pipe Taper Fuel
3W3P: Three Way - Three Position (common spool valve) OEM: Original Equipment Manufacturer
4W3P: Four Way - Three Position (common spool valve) ORS: O-Ring Seal
40CN: Parker Packer Return Line Filter PFD: Priority Flow Divider
▲ : Delta PTO: Power Take Off
P/N: Part Number
A-PAD: SAE Standard Pad for Mounting Pumps PV: Pump with Variable Swash plate
A-SPLINE: SAE Spline - 5/8”x 9 Tooth REGEN: Regeneration
AISI: American Iron and Steel Institute REL: Rear Loader
ANSI: American National Standards Institute RH: Right Hand (clockwise)
ASL: Automated Side Loader RPM: Revolutions per Minute
ASME: American Society of Mechanical Engineers RV: Relief Valve
ASTM: American Society for Testing Materials SA: Single Acting Cylinder
B-SPLINE: SAE Spline - 7/8”x 13 Tooth SAE: Society of Automotive Engineers
BTU: British Thermal Unit SE10: Mixer Hydro Filter
CB: Counter Balance SUS: Saybolt Universal Seconds
CCI: Cylinder City, Inc. TELE: Multi-Stage Telescopic Cylinder
CEC: Component Engineering Company TG: Tailgate
CFM: Cubic Feet per Minute TVS: Transient Voltage Spike
CIC: Commercial Intertech Company UNC: Unified National Coarse Threads (bolts)
C PAD: SAE”C” Pad Mount UNF: Unified National Fine Threads (bolts)
C-SPLINE: SAE Spline - 1-1/4” X 14 Tooth VA20: Commercial Intertech Spool Valve - 40 GPM
CC: Cubic Centimeters VA35: Commercial Intertech Spool Valve - 70 GPM
CD10: Muncie PTO VI: Viscosity Index
CID: Cubic Inch Displacement VIN: Vehicle Identification Number
CCW: Counterclockwise (also LH) VIP: Viscosity Index Improver
CW: Clockwise (also RH) WPRV: Work Port Relief Valve
CYL: Cylinder
DA: Double Acting Cylinder
DE: Dual Element
EOS: Electronic Overspeed
E-STOP: Emergency Stop
FE: Full Eject
FEL: Front End Loader
FF: Flow Fuse
GPM: Gallons Per Minute
GVW: Gross Vehicle Weight
GW: Gross Weight
HOC: Hydraulic Overspeed Control
HP: Horsepower
HPRV: High Pressure Relief Valve
IFI: Industrial Fasteners Institute
ISO: International Standards Organization
J20A: John Deere Oil Spec
JDM: John Deere Motorworks (oil specs)
LCD: Liquid Crystal Display
LED: Light Emitting Diode
LH: Left Hand (counterclockwise)
LORV: Lock Out Relief Valve
LPM: Liters per Minute
LPRV: Low Pressure Relief Valve
MF: Motor with Fixed Swash Plate
MIL: Military Specification
MM: Millimeter
MRV: Main Relief Valve
MS: Military Standard
MSL: Manual Side Loader
NEMA: Weatherproof Rating
NC: Normally Closed

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Common Abbreviations 57
Water Tank Measurement
Contact ______________________________________
Company Name _______________________________
Mailing Address _______________________________
City _________________________________________
State ___________________ Zip__________________
Special Notations ______________________________
____________________________________________
____________________________________________
____________________________________________
(SAMPLE of completed measurements)
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
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
Water Tank Measurement 41
Rear Pedestal Specification Sheet

42 Rear Pedestal Specification Sheet © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Fender Measurement

Contact_______________________________________ Date of Order _________________________________

Company Name ________________________________ Phone Number ________________________________
Mailing Address ________________________________ Shipping Address ______________________________
City __________________________________________ City _________________________________________
State ___________________ Zip __________________ State ___________________ Zip _________________
Special Notations_______________________________________________________________________________
_____________________________________________________________________________________________

PUSHER

A. __________________________________________ G. __________________________________________
B. __________________________________________ H. __________________________________________
C. __________________________________________ I. ___________________________________________
D. __________________________________________ ■ Driver Side ■ Passenger Side
E. __________________________________________ ■ Pair
F. __________________________________________ ■ Steel ■ Aluminum

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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Fender Measurement 43
 Hydraulic Oil
The Life Blood of your
Mixer

1
Standard and Bridgemaster
Common Rules for Hydraulic Oil
Maintenance
1. Set up a filter maintenance schedule and follow it.
2. Inspect the filter elements that have been removed from
the system for signs of failure or have oil tested for
content.
3. Keep the supply of oil and filters sealed and the area clean.
4. Never reuse fluid that hasn’t been filtered and tested.
5. Always use clean containers, hoses and funnels when filling
the reservoir.
6. Use precautions to keep contamination out of ports and
components that have been removed for service.
7. Keep all filters, sight gauges, filler caps and breathers
tight and in good shape to prevent unwanted contamination.
8. Make sure all fluids are well marked and everyone is using
the proper type of fluid in each application. 2
 HYDRAULIC FILTER
SPECIFICATIONS
• The Mixer hydrostatic pump is protected
with a 10 Micron suction filter. This tank port
is a bottom feed so the pump needs adequate
protection.
• Hydraulic tank breather is a 10 Micron
replaceable element.
• Bridgemaster high pressure filter is 10
Micron with a micro-glass element. This tank
port is not a bottom feed so we filter to
protect the hydraulic cartridges after the 3
pump.
 How Littleis a Micron or
Micro-meter
How about 39 Millionths of an inch

The smallest size you can see with the human eye is 40
Micron.
4
 Hydraulic Oil
Human Hair Magnified 100
times

5
Understanding the size of a Micron
used in Filtering Media

Sizes of other objects relating to a

Micron

Size in Micro-meters Magnified 500

times. 6
 The following oil &
filter recommendations
and Service Intervals
should be followed to
keep the hydraulic,
hydrostatic, and ZF
warranty valid.
7
 Change Your Hydraulic Oil,
ZF drive oil and Filters!!!!
After the FIRST 100 HOURS of
operation

The oil cleans up the system and

flushes out any Debris such as
metal, rubber, dirt, casting silt and
other normal contaminants in a new
hydraulic system. 8
 Hydraulic Oil
HYDRAULIC OIL
RECOMMENDATION

ISO Grade 68 (Up to 80 degrees F.)

Viscosity @ 210° F: 60 SUS or Higher
Viscosity Index 95 to 100
Pour Point -20°F to -30°F

Change your Hydraulic Oil and filters

Every 6 Months or 1,250 hours
(which ever comes first) 9
 Hydraulic Oil
HYDRAULIC OIL
RECOMMENDATION

ISO Grade 100 (80 degrees and above)

Viscosity @ 210° F: 70 SUS or Higher
Viscosity Index 95 to 100
Pour Point -20°F to -30°F

Change your Hydraulic Oil and filters

Every 6 Months or 1,250 hours
(which ever comes first) 10
 USE THE CORRECT
OIL
80% of a pump’s wear occurs
when the unit is started cold and
not yet up to operating
temperature.
REMEMBER: Heavier oil will not
perform well in cooler weather and
thinner oil will not perform well in
warmer weather. 11
 Hydraulic Oil
What is Oil Viscosity ?

ISO VISCOSITY
International Standards
Organization

SUS Saybolt Universal Seconds

A MEASUREMENT based on TEMPERATURE

The resistance to flow or the thickness of the oil.
The higher the viscosity the thicker the oil is.

Normally given as ‘SUS’ or ‘cST’

12
 What does Viscosity Index Mean
to Oil ?

VISCOSITY INDEX

VISCOSITY INDEX IS A SCALE SHOWING AN

OIL’S CHANGE IN VISCOSITY,
IN RELATION TO THE TEMPERATURE OF THE
OIL.
Oils viscosity changes as the oils temperature raises and lowers, The
higher the Viscosity Index means the oil viscosity will change less rapidly
with the temperature.
This is accomplished with a polymer additive that acts like a bunch of coils
that can stretch and retract and pull back to their original shape in relation
13
to the temperature of the oil.
 Hydraulic Oil
VISCOSITY-TEMPERATURE CHART
VISCOSITY INDEX
VISCOSITY

High VI usually found

in multi-viscosity oils.
(135)
Ideal VI for hydro-
(100) static pumps and
motors.
(65)
Low VI oil will thin
severely when it gets
TEMPERATURE hot and can’t protect
the system.

Do to the high pressure and heat that hydrostatic pumps create there is also a
high shear factor to the oil, this is the breakdown of the additive package that 14
happens in the oil after a period of time.
 Hydraulic Oil
What is Oil Pour Point ?

POUR POINT

Pour Point is the lowest temperature at

which the oil will flow when it is chilled and
undisturbed.
Normally under controlled conditions

-25°F to -30°F 15
 Hydraulic Oil

OPERATIONAL OILVISCOSITY
CONDITIONS VS. NEEDED

HIGHER LOAD

HIGHER TEMPERATURE

INCREASED SPEED
16
 HYDRAULIC OIL
ADDITIVES

What is there purpose:

! TO IMPROVE THE PERFORMANCE OF
THE BASE OIL

! IMPART ENTIRELY NEW PERFORMANCE

CHARACTERISTICS TO THE OIL.

! REDUCE THE RATE AT WHICH

UNDESIRABLE CHANGES TAKE PLACE.
17
 STANDARD HYDRAULIC OIL
ADDITIVE PACKAGE
Makes Up About 20% Of Oil
Volume
• Anti-Wear • Anti-Foam
• Anti-Rust • Anti-Corrosion
• Anti-Oxidant • Emulsifier

• Remember the additives in hydraulic oil wear out, shear,

break down and become contaminated.
• All of these factors can greatly increase the wear
factor of hydraulic components.
• For this reason oil must be changed or tested on a
regular basis.
18
Change Your Hydraulic Oil and
Filters!!!!
After the FIRST 100 HOURS of operation

19
The only time you should adjust your oil
change intervals is when you use a high
quality oil sampling program to
determine when the oil needs to be
changed.

Change your Hydraulic Oil and filters Every 6 Months or

1,250 hours
(which ever comes first) 20
 NEW HYDRAULIC OIL
MAGNIFIED

THE ANTI-WEAR ADDITIVE

MACHINED SURFACE
MOLECULES ARE ROUND .

LESS FRICTION AND HEAT IS 21

GENERATED
 6 MONTH OLD HYDRAULIC
OIL MAGNIFIED

ANTI-WEAR ADDITIVES AND

THE POLYMER CHAINS THAT MACHINED SURFACE
CARRY THEM ARE BREAKING
DOWN
22
 1 YEAR OLD HYDRAULIC OIL
MAGNIFIED

MOST ALL OF THE

MOLECULES ARE NOW
BROKEN DOWN

GENERATING HEAT, FRICTION AND

EXCESSIVE WEAR
23
 Thermal breakdown of your Oil
starts to occur at about 240° to
260°F.
Breakdown
Of Oil

1. 2. 3.
Oxidizes Additives Forms
Breakdown Varnish

SEALS in the Cartridges, Pumps, Motors and

Cylinders will start to LEAK.
24
 What happens during break-in
Lubricatio
n
of your hydraulic system

AS BREAK IN TAKES PLACE, THE MACHINED SURFACES

ARE POLISHED BY THE OIL AND MOVEMENT OF SPOOLS
AND CARTRIDGES, PEAKS WEAR OFF AND THE PARTICLES
TRAVEL DOWNSTREAM WITH THE OIL. MANY OF THESE
PARTICLES ARE SUB-MICRON IN SIZE AND WILL NOT BE
HELD EASILY IN THE FILTER AND WILL, IN TIME, CAUSE
A DOMINO EFFECT IN THE HYDRAULIC SYSTEM WEAR.

PARTICLES FLOAT ON DOWN

THE OIL STREAM 25
 Hydraulic Oil
Cause and Effect of
Contamination in the Oil

Foreign Material and Dirt from by-passing filters, dirty oil, missing
tank breathers and worn hydraulic components will be Ground into
fine microscopic particles, that will damage and stick Cartridges and
Spools downstream. 26
 Hydraulic Oil
Cause and Effect of
Contamination within a Spool

The Contamination will deposit within the spools and

Cartridges and cause them to stick.

27
 BRIDGEMASTER HYDRAULIC RESERVOIR
DESIGN
Oil cooler Control block Single point fill
return line. return line. tube.

Single Sight gauge

Oil should be in the
bottom of the sight
glass when the oil
is at operating
temperature.
BM cylinder
return line.

Tank Capacity 18
gallons

Outlet for the Parker

1-1/4” NPT Outlet for 10 Oil tank drain pump on Bridgemaster.
Micron suction filter to feed Parker pump
plug
hydrostatic pump. case drain line. 28
 OLDER BRIDGEMASTER HYDRAULIC
RESERVOIR DESIGN
Tank Capacity 18
gallons Single point fill
tube.
5TH port was used Control block
if there was a return line. Single Sight gauge
separate chute
Oil cooler
block in system return line. Oil should be in the
bottom of the sight
glass when the oil
is at operating
BM temperature with
cylinder the BM and chute
return cylinder retracted.
line.

Baffles
Outlet for the
Bridgemaster Parker
Parker pump pump.
1-1/4” NPT Outlet for 10 case drain line.
Oil tank drain
Micron suction filter to feed 29
plug
hydrostatic pump.
 STANDARD MIXER HYDRAULIC
RESERVOIR ROUND DESIGN
Single point fill tube, no
breather on standard
mixers.

Oil cooler
Chute Control return line.
block return
line.

1-1/4” NPT Outlet for 10

Micron suction filter to Single Sight gauge
feed hydrostatic pump. Oil should be in the
bottom of the sight
glass when the oil is
at operating
Tank Capacity 13 temperature with
gallons the chute cylinder
retracted.
30
 STANDARD MIXER HYDRAULIC
RESERVOIR SQUARE DESIGN
Tank Capacity 8 1-1/4” NPT Outlet for 10
Single point fill tube, no gallons Micron suction filter to
breather on standard feed hydrostatic pump.
mixers. Filter is remote mounted.
Chute Control
block return
line.

Single Sight gauge

Oil should be in the
bottom of the sight
glass when the oil is
at operating
temperature with
the chute cylinder
retracted. Oil cooler
Backside of
return line. hyd. tank
31
 Understanding your Suction oil filter
with an Internal By-Pass

Oil flows from the tank to

the inlet side of the filter
housing to the outside of the
filter media.

Your filter head is equipped with a

It is passed thru the filter media
and into the center of the filter and
out to the pump.
by-pass valve that will open at 20
in. of vacuum. Should your filter
become restricted the valve will
open allowing unfiltered oil to flow
to the pump.
32
 Troubleshooting your Suction
Hydraulic oil
Reservoir
filter
Your Vacuum gauge should
never read more than 10” for
any extended periods of time.
After the oil is warm you
should read 2 to 5 in-hg.

Suction not a pressure

filter.

If vacuum is reading high Replace your

check to make sure the filter or check
gate valve is fully your system
opened. when needle is
in the yellow
Check to make sure you or red on the
have the correct filter gauge.
installed and verify the
gauge is reading correct Remember a damaged
with another known filter housing, an inferior
working gauge. part or the wrong oil can
cause high vacuum and by-
passing of the oil through
33
the filter head.
 Understanding your Bridgemaster High
Pressure Filter Assembly

The filter head is equipped

with a Flow style by-pass
indicator. It only reads when
oil is flowing thru the head,
When operating the Trailer
axle up or down, If the
needle moves into the red
The HP filter by-pass you have a restricted filter.
becomes functional any
time the outlet pressure
is 50 psi lower than the
inlet pressure.
If you have 2500 psi
entering the housing and Inlet from Pump Outlet to Combo Block
your filter is starting to
restrict flow than when Unfiltered Oil Filtered Oil
outlet pressure drops to
2450 the by-pass will Oil by-passing
open to keep the flow
moving. 34
FILTER
DON’T forget the 10 Micron
Breather Filter
Breather filter is
on Bridgemaster
hydraulic tanks
only

Element is
replaceable separate
from breather
assembly.

5 gallons of air is drawn through the breather

every time the BM cylinder is extended.

INSPECT Monthly or Every 200 Hours /

REPLACE Every 6 Months or 1250 Hours
35
 Suction Filters for Hydrostatic Systems

High Pressure Filters for Bridgemaster trailer

Hydraulic system

36
ZF Drum Drives
ZF was founded in 1915 by Count Zeppelin (the airship
Zeppelin) and is the world’s leading manufacturer of
transmission systems including axles and steering.
McNeilus Companies has used ZF’s Drum Drive since
the 1970’s. Since that time several models of the ZF
have been developed and put into production. Over the
years the torque rating of the ZF has continually
increased to meet the demands of larger capacity mixer
drums and lower slump concrete.
The ZF drive is a double planetary reduction drive. The
input rpm (where the motor is mounted) is reduced to the
output rpm (the flange that bolts to the drum) by the ratio
of the drive. As an example, if the ratio is 144:1, the
flange rotates once for every 144 turns of the motor.
This reduction is accomplished through planetary gears
which rotate around a sun gear. There are two sets of
planetary gears which accomplish the reduction.
Planetary gears are very efficient and cool running. The
drive is around 96% efficient meaning only 4% of the
input energy is used by the drive. This compares to 80%
efficiency for many of the straight gear reduction drives.
Servicing the ZF drive is critical to the overall lifetime of
the drive. The proper lubricant for the drive is 85W-140;
the same lubricant commonly used in differentials. The
spec of the lubricant is GL-5. This lubricant is available
from nearly any oil distributor.
It is important that the ZF be serviced after the first 100
hours in service. The drive should be drained while the
lubricant is warm. This 100 hour period is considered the
“clean up” lubricant change for the drive. Any
contamination which washes from the new castings,
bearings, gear wear-in, etc. can be drained at this time.
After the initial service the drive should be serviced every
six months or 1,000 hours; whichever comes first.
Remember that the drive has a positive pressure within
the case. The drive design allows a minimum amount of
internal pressure to develop as the lubricant and drive
warm up. This positive internal pressure helps prevent
contamination from entering the internal drive
components. This internal pressure also means that
caution must be used when removing any fill plugs from
the drive while the drive is warm. Safety glasses must be
worn while servicing the ZF drive. Even though the
internal pressure is minimal, the fill plug may want to
blow from its port and spray lubricant from the port.
Loosening the four hydrostatic motor mount bolts and
then loosening the hydrostatic motor will normally relieve
any pressure in the ZF drive. Any excess pressure
developed in the drive is normally relieved by the output
flange seal.
The hydrostatic motor is bolted to the input of the drive.
54 ZF Drum Drive
The hydrostatic motor has a shaft seal which prevents
the hydraulic fluid in the motor from leaking around the
motor shaft under pressure. If this motor shaft seal
leaks, hydraulic oil and pressure can transfer from the
motor case to the ZF drive case. There is also an input
seal in the ZF input cavity around the splined receptacle.
This ZF seal is “nicked” at the factory in the 9:00 or 3:00
o’clock position. The nick allows the ZF lubricant to leak
from the drive and lubricate the spline on the motor shaft
and ZF splined receptacle. Without this lubrication, the
motor spline and ZF receptacle will wear prematurely.
Because this seal is “nicked”, there will normally be 85W-
140 lubricant in this cavity. The hydraulic fluid in the
motor case is quite “thin” compared to the ZF lubricant.
Also the ZF lubricant has its own strong odor. If there is
hydraulic fluid in this cavity, the motor seal is leaking.
Anytime the drive is overfilled - either from servicing the
drive or from a leaky hydrostatic motor seal - the excess
lubricant will exit the drive around the output flange seal
and show up on the drum head. This seal is a heavy
rubber lip seal which is quite strong. It is our experience
that a leaky ZF output seal is generally an indication of a
faulty motor seal or overfilled drive rather than a faulty ZF
output seal. The seal cavity also holds a quantity of
lubricant and may take two or three weeks for the
lubricant around the seal cavity to dry up. Changing the
seal is a difficult job which requires a 60 ton press. The
seal is one of the last items to come out of the drive
when it is completely disassembled. Never assume this
heavy rubber lip seal is faulty. It normally only leaks only
when the drive is overfilled. A ZF Repair Manual is
available from McNeilus if you are planning on working
on the drive.
When changing the ZF drive it is important to retain the
flange in its normal centered position that it is in when the
drive is mounted on the mixer. Allowing the weight of the
output flange to put its weight on the output seal may
damage the seal; especially if it’s left in that position for
any length of time. For this reason a bracket with a 90∫
bend should be fabricated. One end of the bracket
should be bolted to the flat on top of the drive and the
other to the flange. This bracket is especially important
when storing a ZF drive for any length of time.
There are flange bolts around the output flange which
secure the drive flange to the mixer drum socket. The
flange bolts should be torqued to 170 lb. ft and checked
on a weekly basis. There are threaded holes in the ZF
flange which are unused. When removing the ZF flange
from the drum socket, bolts can be threaded into these
extra threaded flange holes around the flange and
pressure applied from the flange to the drum socket by
tightening the bolts. This will help separate the ZF
flange from the drum socket. The bolts work like a
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
ZF Drum Drives
puller to help separate the flange from the drum socket.
Heat may have to be applied to the flange and drum
socket area to separate the flange from the drum socket.

Normal maintenance of the ZF drive includes checking

the torque of the mounting bolts. It’s important to check
these mounting bolts that hold the ZF drive to the front
pedestal on a weekly basis. Acid wash and moisture can
get into the area where the six bolts pass through the ZF
mount and pedestal. Over a period of time the bolts can
deteriorate in these areas of the ZF drive mount and front
pedestal which can’t be readily seen or inspected. If a
bolt has deteriorated, it will break when torqued. If one
bolt breaks, all six should be replaced as all mounting
bolts should be considered to be in the same condition.
If only one bolt comes loose, the ZF drive mount may
crack. Should this happen, the entire drive will have to
be replaced. The correct bolt for the application and
which is installed at the factory is a Bowman product
called “Bowmalloy”. This Bowmalloy bolt is a Special
Ultra Hi-Strength Alloy Steel Quenched and Tempered
Bolt. The proof load of this bolt is 165,000 psi and the
tensile strength is 185,000 psi. No lesser bolt can be
installed in this ZF mount application! This Bowmalloy
bolt is readily available locally or from the McNeilus
branches (McNeilus P/N 020.100990).

If your mixer is S/N 14,669 or previous, the ZF mount

bolts will be a 3/4” bolt and should be torqued to 310 lb.
ft. If your mixer serial number is 14,670 or higher, the ZF
mount bolts will be a 7/8” bolt and should be torqued to
420 lb. ft.

Please call your McNeilus branch or McNeilus Truck and

Manufacturing’s Corporate Headquarters at 507-374-
6321 if you require assistance with the ZF drive or have
questions. We’re glad to help.

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved ZF Drum Drive 55
SYNTHETIC LUBRICANTS APPROVED BY ZF:

! Chevron Delo Gear Lubricant 80w-90 or 85w-140

! Castrol BOT 188/95 75w-90

! Castrol Syngear 75w-140

! Castrol Syngear 80w -140 (Warm Climates)

! Castrol Syntrans HT

! Mobilube 1 SHC 75w-90

! Mobilube XHP 75w-90

 P-7300 ZF DRUM DRIVE

Oil fill port

Oil Sight and dipstick
glass
When checking
When oil remove plug
checked slowly. Case is
cold oil not vented.
should show Pressurized oil
in the may blow out
bottom of of port when
the glass. opened.

Oil drain plug

Oil capacity is
17 quarts or
4.2 gallons.

The ZF drum drive must be serviced after the first 100 hours. After the initial
service, the oil must be changed every 1250 hours or 6 months; Whichever comes
first.
37
THE PROPER LUBRICANT FOR THE ZF DRIVE IS 85w-140. THE SPEC IS GL-5
WHAT SHOULD YOU LOOK FOR IN
YOUR GREASE ?
PERFORMANCE:

• Provide Adequate Lubrication Surface

• Prevent Corrosion and Rusting
• Seal Out Contamination and Water
• Resist Change in Consistency
• Tolerate Some Contamination
• Seal Compatibility
• Suitable Method of Application

38
 SOME RECOMMENDED
GREASEING INTERVALS
Daily or Every 10 hours:
Lubricate Drum Roller Bearings.
Check Hydraulic Oil level and add if necessary.
Check Hydraulic hoses, pipe and fittings for any damage or external
leaks.
Weekly or Every 50 hours:
Lubricate PTO Shaft and U-Joints.
Lubricate Rear chute pivot Assembly and inspect for any damage.
Lubricate Bridgemaster Trailer pivot bushings.
Lubricate Bridgemaster Axle tie rod ends and upper and lower
kingpins.
Check Bridgemaster Wheel hubs for proper level and leakage.
Lubricate Bridgemaster 3 Axle Cylinder Spherical Bearings. 39
40
41
42
43
44
MC NEILUS HYDROSTATIC DRUM DRIVE
SYSTEM

1
Bridgemaster Hydraulic Troubleshooting
PUMP NOISE DUE TO CAVITATION

Suction Filter Suction Filter Reservoir Gate

Plugged OK Plugged OK Valve Closed
1 2 3

Change to Correct Service Filter Open Gate Valve

Oil OK

Improper Hose Reservoir Vent Reservoir Outlet

Installation OK Clogged OK Plugged
6 5 4

100R4 Spec Vent reservoir Unplug Reservoir

OK Required Outlet

Call
McNeilus
Check Pump
OK for further
7-15
assistance
10

(507) 374-6321
Mixer Service Dept.

PUMP NOISY DUE TO AERATION

Air Leaking Into

Oil Supply Low Foaming Oil
OK Suction Lines OK
1 1-6
6

Fill to Proper Level Replace 100R4 Refill with Correct

Suction Line Oil
OK

Call
McNeilus
Check Pump
for further OK
7-15
assistance
10

(507) 374-6321
Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
PUMP WON”T DEVELOP ADEQUATE PRESSURE

Check Pump Excessive Internal Compensator

Pressure OK Leakage OK Spool Sticky
12 8 13

Measure Leakage Clean Spool or Replace

Compensator

Excess Flow Replace Pump

Adjust Pump
7
12 OK

Adjust Pump
12

Call
McNeilus Check “A” Pad
Check Pump Shaft
For Further OK Receptacle OK
14
Assistance 15
10

(507) 374-6321 Replace if Worn Replace if Worn

Mixer Service Dept.

PUMP NOT DEVELOPING ADEQUATE FLOW

Excessive Internal Compensator

Leakage OK Spool Sticky OK Pump Cavitating
12 13

Measure Leakage Clean Spool or Replace Clean Spool or Replace

Compensator

Excess Leakage Replace Adjust Pump

Pump 12
7 OK

Adjust Pump
12

Call
McNeilus Check “A” Pad
Check Pump Shaft
For Further OK Receptacle OK
14
Assistance 15
10

(507) 374-6321
Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
BRIDGEMASTER SYSTEM OVERHEATING

Measure Oil Hydraulic Oil Too

Oil Supply Low
Temperature Light
1
11 1

Drain and Refill

Fill to Proper Level
with Correct Oil

Case Drain Excess Internal

Aeration of Oil
Incorrect Pump Leakage
6
9 8

Correct Plumbing Check Hose and Measure Leakage

Fittings

Excess leakage
See “Pump Noisy Replace Pump
Due to Cavitation” 7

Adjust Pump
12

Call
McNeilus
HPRV Leaking
for further
21
assistance
10

Clean or Replace (507) 374-6321

HPRV Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
BRIDGEMASTER SYSTEM WON’T DEVELOP ADEQUATE PRESSURE IN TRAILER DOWN MODE

Isolate
Check Pump Check PRV2
OK Components OK
7-15 20
31

See Pump Section Clean or Replace

PRV2 OK

Call
McNeillus
Check PTS BM Cylinder
for further OK OK
24 28
assistance
10

(507) 374-6321 Clean or Replace HPRV

Mixer Service Dept. PTS 21

CB
27,29

BRIDGEMASTER SYSTEM WON’T DEVELOP ADEQUATE PRESSURE IN TRAILER UP MODE

Isolate
Check Pump Check PRV2
OK Components OK
7-15 20
31

See Pump Section Clean or Replace

PRV2
OK

Call
McNeillus
Check PTS BM Cylinder
for further OK OK
24 28
assistance
10

(507) 374-6321 Clean or Replace CB

Mixer Service Dept. PTS 27,29
Bridgemaster Hydraulic Troubleshooting
BRIDGEMASTER TRAILER WON’T LOWER OR LOWERS SLOWLY

Check Dash
Do Chutes Work? Truck in Reverse
Gauge OK OK
25 26
16

Check Axle Stop Put Transmission

25 in Neutral OK

Operate Trailer Chutes off Center

OK Manually OK or Raised
23 17, 18, 19

Directional Valve Center or Lower

Check PRV2 Check HPRV CB Cartridge

OK OK
20 21 27

Clean or Replace Clean or Replace Clean or Replace

PRV2 HPRV CB

OK
Check CB Drain
Line

Check PTS and

Check Pump BM Cylinder
OK OK Trailer Lock
7-15 28
24

Pressure and Checker Cylinder Clean or Replace

Leakage Test Bypass PTS

OK
Replace if
Required

Call
McNeillus
for further
assistance
10

(507) 374-6321
Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
BRIDGEMASTER TRAILER LOWERS SLOWLY OR HESITATES BEFORE LOWERING

Check Dash Check

Check HPRV
Gauge OK OK Accumulator
21
16 30

Clean or Replace Recharge

HPRV Accumulator OK

Check Chute
Check Pump CB Cartridge
OK Function OK
7-15 27
22

Clean or Replace
OK CB Cartridge

Call
McNeillus
for further
assistance
10

(507) 374-6321
Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
CHUTES WON’T RAISE - SINGLE ACTING

Check Dash Check 12 Volt Check up Flow

Gauge OK Coils OK Control
16 32 33

Check Mid Replace Coils If Adjust as Required

Position Valve Required
OK
25

Call
McNEilus Check 3W2P
P.O. Check
for further OK OK Cartridges
35
assistance 34
10

(507) 374-6321 Clean or Replace Clean or Replace

Mixer Service Dept. as Required as Required

CHUTES WON’T LOWER - SINGLE ACTING

Check Dash Check 12 Volt Check Down Flow

Gauge OK Coils OK Control
16 32 36

Check Mid Replace Coils If Adjust as Required

Position Valve Required
25 OK

Check 3W2P
Check Return Line P.O. Check
OK OK Cartridges
37 35
34

Clean or Replace Clean or Replace Clean or Replace

OK as Required as Required as Required

Call
McNeillus
Flo-Fuse Tripped
OK for further
38
assistance
10

Reset Flo-Fuse (507) 374-6321

Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
CHUTES WON’T RAISE - DOUBLE ACTING

Check Dash Check 12 Volt Check Up Flow

Gauge OK Coils OK Control
16 32 33

Check Mid Replace Coils If Adjust as required

Position Valve Required
OK
25

Call
McNeillus Check 3W2P
Cross Check
for further OK OK Cartridges
39
assistance 34
10

(507) 374-6321 Clean or Replace Clean or Replace

Mixer Service Dept. as Required as Required

CHUTES WON’T LOWER - DOUBLE ACTING

Check Dash Check 12 Volt Check Up Flow

Gauge OK Coils OK Control
16 32 33

Check Mid Replace Coils If Adjust as required

Position Valve Required
OK
25

Check 3W2P
Check Return Line Cross Check
OK OK Cartridges
37 39
34

Clean or Replace Clean or Replace Clean or Replace

OK as Required as Required as Required

Call
McNeillus
Flo-Fuse Tripped
OK for further
38
assistance
10

Reset Flo-Fuse (507) 374-6321

Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
CHUTE DRIFTS UP OR DOWN - SINGLE ACTING

Check 12 Volt
Check 3W2P
Coils OK OK P.O. Check
Cartridges
32

Replace Coils If Clean or Replace Clean or Replace

Required as Required as Required OK

Call
McNeillus
for further
assistance
10

(507) 374-6321
Mixer Service Dept.

CHUTE DRIFTS UP OR DOWN - DOUBLE ACTING

Check 12 Volt Check 3W2P

Cross Check
Coils OK Cartridges OK
39
32 34

Replace Cols If Clean or Replace Clean or Replace

Required as Required as Required OK

Call
McNeillus
for further
assistance
10

(507) 374-6321
Mixer Service Dept.
Bridgemaster Hydraulic Troubleshooting
CHUTE LIFTS WHEN DOWN BUTTON DEPRESSED - SINGLE ACTING

Call
Mcneilus for
P.O. Check
OK further
35
assistance
10

Clean or Replace (507) 374-6321

as Required Mixer Service Dept.
Troubleshooting Action Steps

1. Oil viscosity incorrect , low or wrong specification

a. Change to proper ISO spec oil for outside temperature
b. ISO68 (SUS 55-60 below 80 degrees F)
c. ISO100 (SUS 60-65 above 80 degrees F)
d. Change oil and filters after first 100 hours in service and every six months thereafter
e. Refill reservoir to proper level
f. Use only approved Hydraulic Fluid – Do Not Use ATF OR ENGINE OIL
g. Contact McNeilus for complete oil information (507) 374-6231
2. Bridgemaster PC pump Inlet filter (if installed – optional since 1988)
a. Optional 100 mesh filter (141 micron) is used for BM pump (optional since 1988)
b. Replacement 100 mesh filter P/N: 140.00429
c. Vacuum gauge on the optional inlet filter(street side of truck) should not exceed 4-5 in. of
vacuum when oil is warm
d. Read Parker high pressure filter indicator only when BM trailer is lowering (maximum
flow condition)
3. Gate valve on reservoir closed
a. Turn counterclockwise until fully open
b. When fully open install tie wrap to prevent vibration from closing gate valve
4. Reservoir outlet plugged
a. Oil must flow freely from reservoir outlet
b. On composite reservoirs, check filters for plastic film material from reservoir (caused
from overheat situation)
Note: Composite reservoirs, which have been overheated and damaged, should be replaced with steel
reservoir
5. Reservoir vent clogged
a. Clean or replace 10 micron breather cap on reservoir
b. 10 micron cap P/N: 140.100855
c. If breather cap is not installed on your older BM reservoir, install the P/N: 140.108555
breather cap and a NPT bell reducer to properly vent the reservoir. This will replace the
old style breather on older BM systems. Contact your MTM Branch for details.
6. Check for proper hose
a. SAE100R4 suction hose should be installed between the reservoir and pump
b. Hose should be the same diameter and length as original hose
c. Improper hose size or rating may collapse under suction
d. Inspect for air leaks on suction side
e. Inspect fittings for air leaks
f. Inspect spin on filter gasket for air leaks
7. Install new pump
a. Lightly lubricate spline on pump with moly grease or equivalent before installing
b. Compressor will require adjustment (see step #12)
8. Excessive internal leakage
a. Remove case drain line pump and measure volume flowing from case drain when pump
is at operating temperature
b. Measure volume for 15 seconds and multiply by 4 to get your flow per minute
c. Normal case drain is 1.0 gpm on a new pump
d. Maximum allowable case drain is 2.5 gpm
e. Call McNeilus for assistant if required
9. Case drain incorrectly plumbed
a. A 1995 Eaton product update tees the Cessna pump case drain into the hydro case drain
coming from the top of the hydro
b. The 1995 Eaton product update allows Cessna pump to case drain to pass through the oil
cooler on the way to the reservoir
c. Current plumbing routes the pressure compensated pump case drain directly to the
reservoir
d. All BM pump case drains must ago direct to the reservoir
10. Call McNeilus for assistant
Troubleshooting Action Steps

a. (507) 374 – 6321

b. Ask for the mixer service department
c. Give us a call if we can be of help!
11. Measure oil temperature
a. Measure oil temperature in the reservoir with an infra red heat gun or candy thermometer
b. Determine if the heat is caused by hydrostatic system or BM hydraulic system
c. Maximum temperature should be outside temperature plus 100 degrees F
d. Ideal oil temperature should be 170 degrees F- 180 degrees F
12. Check pump pressure
a. Deadhead pump pressure line at Parker Filter inlet with a 0 – 5,000 psi gauge
b. Pressure should be adjusted at the compensator
c. Pressure should be the maximum required + 100 psi
13. Compensator spool sticky
a. Remove spool and clean with WD40 or equivalent
b. Check compensator spring
c. Compensator spool should move freely in bore
d. LH and RH PC compensator are the same but mounted opposite
e. Use new o-ring for the installation
14. Check pump shaft
a. Check spline for worn spline
b. Replace shaft if worn
c. A-Pad receptacle on the Eaton A-Pad may also be worn
15. Check A-Pad receptacle
a. Check for worn receptacle
b. Replace receptacle if worn
c. PC pump shaft will also be worn
16. Check cab gauge pressure
a. 1,000+ psi minimum pressure typically required to move trailer up and down
b. This is approximately the minimum setting of the PRV2
c. If there is no pressure in the cab gauge, the optional mid position valve may be activated
and neither the trailer or chutes will function (see #25)
17. Check red chute light
a. If chute light is on, chute is not centered or fully lowered
b. See the section on trailer electrical troubleshooting
18. Chute light activated
a. Unplug Weather-PakR connection on chute pressure switch – if light goes out the chute
pressure switch is activating the light
b. Be sure chute is fully lowered
c. Check for binding hardware on the chutes
d. Air in the chute lines or cylinder can activate the light – bleed air as required
e. Check o-ring on 3W2P up cartridge
f. Replace chute switch if required
g. Check for restricted or obstructed tank return line
h. Use dielectric grease on the connectors
i. See the section on trailer electrical troubleshooting
19. Chute light remains on – pressure switch unplugged
a. If the light stays on when the chute switch Weather PakR connection is unplugged the
prox switch for the chute centered function is activating the light
b. Be sure the chute is centered
c. Check prox connections
d. Replace prox is defective
e. Use dielectric grease on the connections
f. See the section on trailer electrical troubleshooting
20. Check adjustment PRV2 valve
a. The pressure should reach compensated pressure when the PRV2is turned fully clockwise
with trailer in the up position
Troubleshooting Action Steps

b. Minimum pressure when PRV2 is turned fully counterclockwise should be approximately

1,000 psi
c. Maximum pressure should be the maximum pressure on the BM placard plus 100 psi
d. The PRV2 can be cleaned and flushed with WD40 (do not use a parts washer!)
e. Replace the PRV2 if necessary
21. Check High Pressure Relief Valve (HPRV)
a. The HPRV is located on the High Flow Block on the barrel end of the BM trailer cylinder
b. If the HPRV is leaking, partial flow may be going to the reservoir and preventing full
pressure from building up in the down mode - this condition will typically cause heat and
slow trailer down speed
c. The HPRV can be cleaned and flushed with WD40 (do not use a parts washer!)
d. Replace the HPRV cartridge if it is leaking
22. Check chute function
a. If the chute lift section malfunctions, oil flow can flow to the reservoir which can also
cause trailer up/down movement problems
b. Turn the chute up speed flow control fully clockwise to shut off the flow of the oil to the
chute system – this will isolate the chute lift system from the BM trailer system
c. See the section on the closed center chute lift block
23. Operate trailer manually (PRV2 should be adjusted no higher that 1,000 psi)
a. Shift the directional valve manually
b. If trailer operates, problem is probably electrical
c. If trailer doesn’t operate, problem is probably hydraulic
d. If trailer safety latch operates, directional valve is sending a hydraulic signal to the high
flow block
24. Check PTS and trailer lock
a. On later models the PTS is located on the manifold on the barrel end of the block
b. Earlier models have the PTS located in the control block
c. The PTS should receive a signal when the directional valve is shifted
d. The PTS signal also unlatches the trailer lock – the lock should open when PTS shifts to
the down position or the lock should relax in the up position
e. If the PTS doesn’t shift fully, the trailer speeds may be slow of the pressure low
f. Inspect the PTS o-rings and orifice behind PTS
g. You should be able to push in against the spring on the center spool of the PTS and it
should return freely
h. The PTS can be cleaned and flushed with WD40 (do not use a parts washer!)
i. Replace the PTS if necessary
25. Do chutes work?
a. Optional mid-position valve activated
b. Activated mid-position stops all flow to system including chutes
1. Trailer won’t operate
2. Chutes won’t operate
26. Truck in Reverse
a. Putting truck in reverse automatically raises axle (chutes must be centered and down)
b. Putting truck in reverse bypasses chute down or chute centered interlocks
c. Back up lights on or truck in reverse will prevent axle from going down
27. CB (counter balance) cartridge
a. If CB cartridge is stuck closed, oil cannot leave the rod end of the cylinder and cylinder
will move down slowly or stop
b. If CB cartridge is stuck closed , dash gauge will not drop when trailer is lowered
c. The CB cartridge controls the trailer down speed of 30 – 45 seconds
d. Check drain line from CB cartridge - only occasional drops should enter drain line from
CB cartridge
e. If there is pressure in the drain line (which is a tank line), the CB cartridge will not open
and trailer will not lower
f. The CB cartridge can be cleaned and flushed with WD40 (do not use a parts washer!)
g. Replace the CB if necessary
Troubleshooting Action Steps

28. BM Cylinder
a. If oil bypasses at the piston the trailer may be slow, not develop adequate pressure, or not
move up or down
b. When the cylinder barrel end is pressurized, only drops should bypass to the rod end
c. Check with McNeilus Companies for the proper procedure to check oil bypass in the BM
cylinder
29. CB one way check valve
a. the CB Manifold assembly has a one way check valve to allow oil to flow to the rod end
of the cylinder when the trailer is being raised
b. The one way check can be cleaned and flushed with WD40 (do not use a parts washer!)
c. Replace the one way check if necessary
30. Check Accumulator
a. Accumulator pressure should be 1150 psi
b. Low accumulator pressure may cause trailer down hesitation of up to 20 seconds before
trailer starts down
c. Other symptoms of a low or flat accumulator include dash gauge fluctuates and a rough
ride for the driver
d. A low or flat accumulator will cause damage to the cylinder pin eye bearing, cylinder
mounts, and trailer mounts
e. See the section on charging the accumulator for the proper safety procedures
31. Isolate Components
a. The trailer and chute lift systems can be isolated from the main control block on the BM
hydraulic system
b. The hydraulic hoses going from the control block to the cylinder can be removed and
capped off and the manifold ports plugged at the cylinder or control block – whichever is
easiest
c. The chute system can be isolated by turning the up flow control fully off on later systems
d. BM systems with a separate chute lift block can isolate the block by removing the hose
from the “ P AUX” port and plugging the port
e. Isolating the cylinder and chute lift systems one at a time provides a “process of
elimination” to help locate problems
f. Call McNeilus for further information
32. Check 12 volt coils
a. When the chute up button is depressed, the up coil will be energized
b. When the chute down button is depresses, the down coil will be energized
c. An energized coil will be an electromagnet and will attract a piece of metal such as a
knife blade
d. You can also hear a “clicking” noise when the coil is energized if the cartridge is shifting
e. If neither coil is energized when the chute up/down button is depressed, check the
electrical circuit
f. If both coils energize correctly when the chute up/down button is depressed, check the
hydraulics
g. Most coils have an o-ring seal which must be in place when a coil is reinstalled
h. If an electrical circuit malfunctions, partial voltage may cause a cartridge to shift slightly
resulting in chutes drifting up or down
33. Check up flow control (chute up speed)
a. If the chute up speed control is turned entirely off, no oil will be available for the chutes
b. If the up speed control is out of adjustment, turn both the up and down speed control to
the center of their adjustment range as a place to start again
c. If the up speed control is adjusted to approximately maximum up chute speed, the chute
may go up when the down button is depressed
34. Check 3W2P cartridges
a. Both 3W2P (three way/two position) cartridges are the same and are interchangeable
b. The coil can be removed from the cartridge and the 3W2P cartridges removed for
inspection and cleaning
c. Inspect the o-ring on the cartridge to be sure they are not chipped or damaged
Troubleshooting Action Steps

d. Clean the cartridge with WD40

e. Because both cartridges are interchangeable, they can be swapped into the other cavity
which may reverse the problem - the chute that wouldn’t go up probably won’t lower
35. P.O. Check
a. A pilot operated check valve holds the chute in the up position
b. If the P.O. check leaks, oil can pass to the reservoir rather that raise the chute
c. If the P.O. check leaks; the chute will drift down
d. The P.O. check can be cleaned and flushed with WD40 (do not use a parts washer!)
e. Replace the P.O. check if necessary
36. Check down flow control
a. If the chute up speed control is turned entirely off the chutes will not lower
b. If the down speed control is out of adjustment, turn both the up and down speed control
to the center of their adjustment range as a place to start again
c. The down flow control cartridge be cleaned and flushed with WD40 (do not use a parts
washer!)
d. Replace the cross checks if necessary
37. Check return line
a. An obstructed return line to the reservoir will prevent oil from leaving the chute lift
system
b. An obstructed return line will result in a chute which won’t lower
38. Flo-Fuse Tripped
a. Excess chute speed will trip flo-fuse and chute will not lower
b. If flo-fuse is tripped. The chute must be lifted to reset the flo-fuse
c. If new chute lift cylinder is installed the air must be thoroughly bled from the chute lift
cylinder and hydraulic hose or the air (which is compressible) may trip the flo-fuse
39. Cross checks
a. the newer BM Control block has two pilot operated cross checks which can affect the up
or down performance of the chute
b. The cross check can be cleaned and flushed with WD40 (do not use a parts washer!)
c. Replace the cross checks if necessary
Troubleshooting Your Mixer Hydrostatic System

Today’s new generation mixer pumps and motors are
the result of extensive field testing, customer input, and
the latest technology. They offer greater durability,
increased power density, and greater efficiency. They
also require proper lubrication, filtration, and good
maintenance to deliver the years of service designed
into them. Should a problem develop good
troubleshooting procedures can help you identify and
correct a problem before the problem becomes critical.
We’ll divide the hydrostatic troubleshooting into four
steps which will cover the test procedures. The area
discussed in this update will be analyzing the vacuum
readings. Upcoming updates will discuss and analyze
the remaining troubleshooting steps.
Most hydrostatic oil filters have a vacuum gauge which
indicates the amount of vacuum required to draw the oil
through the filter. As the filter becomes contaminated
more vacuum will be required to draw the oil through the
filter media. This filter vacuum gauge will not detect a
problem between the filter and the charge pump. For
this reason a reading is always taken at the charge
pump inlet. A continuous high vacuum reading at the
charge pump inlet will result in pump failure and will
require immediate attention.

Gauges, fittings, adapters, and hoses are required to

troubleshoot the hydrostatics. McNeilus markets a hydro
test kit (P/N 260.00483) which includes all of the
required components organized in a portable carrying
case. Contact your local McNeilus branch for details on
the test kit.

STEP #1—THE VACUUM CHECK

The charge pump develops the amount of vacuum

required to move the oil from the reservoir to the charge
pump. The normal oil route is from the reservoir, through
the filter, and into the charge pump. Anything that
restricts this oil route will increase the amount of vacuum McNeilus Hydro Test Kit 260.00483
required to move the oil to the charge pump. The
amount of vacuum required to move the oil can be
measured with a vacuum-pressure gauge.

The vacuum-pressure gauge is installed directly into the

charge pump inlet. Remove the inlet hose and install a
tee fitting into the charge pump inlet. Reattach the inlet
hose to the tee. Plumb the vacuum-pressure gauge into
the tee (see photo #1).

The vacuum reading should be taken when the oil is

warm. Cold oil will require more vacuum and result in a
higher than normal reading. Vacuum is measured in
inches of mercury (HG) rather than pounds per square
inch (PSI) like pressure. A hydro system with a new filter
and everything correct will normally read approximately
two inches or less of vacuum. The maximum allowable
vacuum on a continuous basis is 10 inches of mercury.

Photo 1

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Troubleshooting Your Mixer Hydrostatic System 17
 Cause Remedy
Contaminated oil filter Install new filter
Suction hose not used Use SAE 100R4 Spec
suction hose
Obstruction in hose or
reservoir Remove obstruction
Sharp hose bends
restrict flow Reroute hose
Oil too heavy Install proper weight oil
Oil not warmed up Let system warm up and
recheck
Suction hose too small Install correct size hose
Fitting ID too small Install proper fittings
Filter element incorrect Use 10-micron suction filter

The following areas are common causes of high vacuum

readings:

STEP # 2 - CHARGE PRESSURE Photo 2

The charge pump is the heart of your hydrostatic
system. If the charge pressure is low or nonexistent, the
hydrostatic pump will not provide the flow to turn the
drum. The duties of the charge pump include:
1. Develop the vacuum to move the oil from the
reservoir through the filter to the charge pump.
2. Provide flow under pressure to the control valve to
allow the servo system to stroke the pump to charge
or discharge modes.
3. Provide cool oil from the reservoir to the pump case
to assist in cooling the hydrostatic system.
4. Provide make up oil to replace oil lost through
normal leakage within the pump.
5. Provide flow under pressure to the rotating group
(piston and slipper assembly) to maintain pressure
and oil flow to the rotating group while the pump is in
neutral.
test kit is required to clear the cable. A 0 - 400 PSI
gauge should be plumbed to the end of the hose.
BE SURE EVERYONE IS CLEAR OF THE AREA.
Start the truck and warm up the system. The gauge
should read 220 ∆ PSI in neutral. The ∆ means 220 PSI
(the setting of the relief valve on the charge pump) plus
the pressure in the case of the pump. An example: If
the pump case pressure is a normal 40 PSI your gauge
would read 260 PSI in neutral (220 PSI charge pump
pressure plus 40 PSI case pressure). Remember each
system is unique and the gauge readings may vary
slightly from pump to pump.
When the pump is put into charge or discharge the
charge pump pressure will decrease by approximately
60 PSI. As an example: A 260 PSI reading in neutral
should drop to 200 PSI when the pump is put into
charge or discharge. These gauge readings are normal
and indicate good charge pump performance.
If your charge pump pressure is low check the following
areas:

The charge pump pressure check is easy to perform. 1. Be sure your vacuum readings are normal. If
With the truck engine off remove the o-ring plug from the vacuum readings are high, the pump may not be
top of the pump (see photo #2). Normally the control receiving the supply of oil required to achieve the
cable is routed across the area of the o-ring plug and a pressure to operate the system. (See Step #1 for
90-degree adapter and a short hose from the McNeilus vacuum information).

18 Troubleshooting Your Mixer Hydrostatic System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
2. Both the charge pump and motor bolted to the mixer
drive have low pressure relief valves. If your charge
pressure is OK in neutral but low in charge and
discharge positions you probably have a problem
with the motor’s low pressure relief valve. If your
charge pressure is low in neutral but OK in charge
or discharge your problem will most likely be the
charge pump’s low pressure relief valve. The
quickest way to verify this is to exchange the relief
valve cartridge with a known good cartridge from
another mixer.

3. If the pressure is low or non-existent in any control

valve position the charge pump should be removed
and inspected. It should rotate freely. Look for
contamination, excess wear, or broken parts. If the
charge pump is contaminated or has broken pieces
the hydro system will require flushing to remove the
contaminates from the system. If the pressure is low
from a worn charge pump you may be able to
change just the charge pump and continue.
Remember - if the charge pump has enough hours
to be worn out, the pump and motor may be in the
same condition!!

4. If a pump is operating with oil which is too thin or

operating at excessive temperatures, the charge
pump may not be able to maintain the required
pressures — especially at low RPM’s.

It is important that the flow of oil from the motor and

STEP #3 - CHECKING CASE PRESSURE
The hydrostatic pump and motor are designed to have
internal oil leakage. This internal leakage occurs
between the piston and piston sleeve which the piston
travels in, between the slipper and piston where the
slipper is wedged on the piston, and between the slipper
and the swashplate. This normal internal oil leakage
allows the oil to clean, lubricate, and cool as it passes
through these close tolerances. Internal leakage collects
in the motor case and flows out of the motor housing
through a smaller low pressure hydraulic return line to
the bottom of the hydrostatic pump case. The leakage
flows into the pump and joins the internal pump leakage
and other accumulated oil in the pump case. The total
volume of leakage from the motor and pump then pass
out of the top of the pump, flows through the oil cooler
and returns to the oil reservoir.
pump cases have a free unobstructed flow to the
reservoir. If anything obstructs this flow of oil, the
pressure required to move the oil increases. Increased
pressure can cause problems with external leakage for
your motor and pump around the shaft seals and control
valve seals - especially if the case pressure approaches
100 PSI.
Checking the case pressures on the hydros is easy! A 0-
400 PSI gauge is plumbed into the return line hose
which is routed between the top of the hydrostatic pump
and oil cooler. The return line which is plumbed into the
top of the pump should be removed and a tee plumbed
into the line. The gauge is plumbed into the third port of
the tee. (See photo above)
When the hydrostatic system is operating at normal
temperatures, the gauge pressure should read 40 - 60 PSI.
If the pressures are higher than this, the system should be

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Troubleshooting Your Mixer Hydrostatic System 19
checked to determine why the pressures have increased.
Two common causes of high case pressure on mixer
applications are obstructed oil coolers and return lines
which are pinched due to tight radius turns.
Approximately 25 PSI is required to force the oil flow
through the oil cooler. If you case pressure is high, you
simply remove the two return lines from the oil cooler
and join the hose ends with a union. If the case pressure
dropped from a high reading to a low reading (example:
100 PSI with the cooler in the circuit dropping to 20 PSI
with the cooler out of the circuit), the system is telling
you that the cooler is obstructed internally. Most coolers
can be reverse flushed with flushing fluid or diesel fuel to
remove the contaminants. If the cooler can’t be properly
flushed it should be replaced with a new cooler
assembly (normally around $100.00). If a return line
hose is pinched, it must be replaced and rerouted if
necessary to eliminate tight bends and turns. A 3/4” ID
return line may have only a 1/4” ID if pinched or in a
bend which is too tight.
STEP #4 - CHECKING HYDROSTATIC HIGH
PRESSURE
forced through the main relief valve generates heat at
the rate of one degree per second for each one
thousand pounds of pressure!
More modern systems with the “power limiters” in the
pump (used by McNeilus since 1988) allow the pump to
destroke when pressures reach maximum. With the
pump destroked, there is no oil flow to the motor and no
heat is generated in the closed loop circuit.
Checking the high pressure circuit requires a 0-10,000
PSI gauge be installed in the charge circuit port in the
manifold of the motor (see the inset). When the
hydrostatic system is turning the drum, the gauge will
read the amount of hydrostatic pressures required to
perform that function. A typical mixer system will require
around 500 PSI to turn an empty drum and from 2,500 -
3,500 PSI to turn a drum with a load of mixed concrete.
The lower the slump of the concrete, the harder the
drum turns and the higher the pressures will be. (If you
have a slump meter installed, you already have a high
pressure gauge in the circuit).

Two high pressure relief valves on older style

hydrostatic systems are typically found in the manifold
on the rear of the hydrostatic motor. On later style
systems, the relief valves have been replaced by “power
limiter” valves which are located on the front of the pump
rather than on the motor manifold. The job of these
relief valves or “power limiter” valves is to protect the
closed loop circuit and components (including the pump
and motor) from excess hydrostatic pressures during the
charge, mix, and discharge modes or if a problem
develops which would cause the pressures to increase
above the normal limits.
New Style
In older systems with the relief valves located in the Motor Without Manifold
motor manifold, considerable heat can be generated if Normal Reading - Varies with Load
any significant amount of oil flows through the relief
valves. As an example: a mixer with a drum drive
locked up may prevent the motor from turning. If a
driver placed the controls in charge or discharge, the
pump will send a flow of oil to the motor in an attempt to
turn the drum. Because the drive can’t turn the drum,
the high pressure will immediately intensify to the relief
valve setting and force the oil through the relief valve
and back into the circuit. This situation causes
tremendous amounts of heat to be generated in the
hydrostatic system; enough to destroy the motor, hoses,
and the pump if it is allowed to continue. Oil which is

20 Troubleshooting Your Mixer Hydrostatic System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
If the drum won’t turn and the high pressure gauge
reads low or zero while the pump is delivering oil flow
to the motor, the high pressure relief valve or “power
limiter” valves may be stuck in the open position and
allowing oil flow with little or no resistance. Remove
the valves and examine them for contamination,
damaged o-rings, etc., and thoroughly clean the
valves with WD-40 or an equivalent product. Normally
the two valves can be interchanged to unload the
drum.

Pressure Gauge for

Checking System Pressure
10,000 psi

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Troubleshooting Your Mixer Hydrostatic System 21
 HYDROSTATIC PUMP MOUNTING ON
McNEILUS MIXERS
CLOCKWISE OR RIGHT HAND COUNTER-CLOCKWISE OR
ROTATING (CW) LEFT HAND
HYDROSTATIC ROTATING
PUMPS ARE ALWAYS PTO SHAFT (CCW)
DRIVEN HYDROSTATIC PUMPS ARE ALWAYS
AND MOUNTED BEHIND THE CAB FRONT MOUNTED AND DRIVEN BY
ON McNEILUS MIXERS A CRANKSHAFT PTO

2
 Understanding Delta Pressure
Readings
These are normal operating system
pressures at normal operating
The pressures in this training are temperature.
gauge pressures or Delta pressures. •Inlet pressure or vacuum,

Delta pressure is the difference of 2

gauge pressures in a hydraulic system.
•Case drain pressure.
Approximately 40 to 60 psi
Should not exceed 100 psi for an
extended period of time.
•Low or charge pump pressure

Plus case drain pressure or Delta

•System or high pressure.
Due to mechanical and individual
applications. These pressures will
vary from system to system.
3
Eaton Fixed Displacement Motor with High
Pressure Relief Valve Used through 1987

Not to
exceed 40
psi.
The motor
high pressure
relief valves
were 5000 or
5500 psi.

160 psi +
case drain
pressure

4
Eaton Fixed Displacement Motor without High
pressure Relief/With Integral Shuttle used
since 1988

Not to
exceed
40 psi.

160 psi +
case drain
pressure
5
 FIXED DISPLACEMENT MOTOR LOW
PRESSURE RELIEF VALVE AND
SHUTTLE SPOOL
54 series fixed displacement motor
Gauge ports Gauge ports
for charge for charge
and discharge and discharge
pressures pressures

Low pressure
160 psi Low by-pass spool
pressure relief or Shuttle
valve Motor
Quadrature
speed sensor
6
Eaton Fixed Displacement Motor without
High pressure Relief/With Integral
Shuttle used since 1988

Low pressure
by-pass spool
or Shuttle

160 psi Low

pressure relief
valve

When the main pump is stroked to charge or discharge the low

pressure relief valve in the motor takes control of the charge pump
pressure. When the by-pass spool shifts it allows pump oil to flow
7
through the motor to help cooling and lubrication of the motor.
Eaton Variable Displacement pump with Internal
High Pressure Relief Valve used since 1988

Charge pressure
should be 220 psi +
Case drain pressure
in Neutral. Not to exceed 10”
And 160 psi + case while running with
drain pressure in warm oil.
charge or discharge.

8
6000 psi Clipping valves.
 Eaton Hydrostatic Pump Power limiter or
Clipping Valves

1988 through current production are the # 57 6000 PSI Clipping

Valves 9
TO CHANGE ROTATION PLATES MUST BE
REPLACED, PUMP MUST BE TORE DOWN.

10
TO CHANGE ROTATION, PLATES MUST BE
REPLACED, PUMP MUST BE TORE DOWN.

11
Early style Eaton Pump Input Shaft Seal
Removal

12
Early style Eaton Pump Input Shaft Seal
Installation

13
 Eaton Hydrostatic Pump Shaft Yoke
Change and Nut Torque
Specifications
In February 1998 PTO
Shafts and Yokes were
increased from 1310 series
to 1350 Series.

In September 1998 Eaton

Stated the Shaft Nut torque
should be 320 Ft.lbs plus
torque required to align
slotted nut with shaft cross
hole, NOT to exceed 415
Ft.lbs. Or Nut and Shaft
damage May occur.

14
 Eaton Pump and Motor Shaft
Seal Change
The 3 piece Mechanical shaft
seal was replaced with a single
Lip seal.

Motors received the New style seal in

October 1999 and Pumps received the
New Style seal in January 2000.

3 piece Mechanical shaft New Single Lip Seal.

seal

Old and New Seal Parts are NOT Interchangeable.

15
Tapered Shaft Yoke Puller for the 1310 and
1350 Series Pump Yokes

To Help in the Removal of the Yoke Eaton Suggests using a

Tapered Shaft Yoke Puller Tool.
16
Eaton Hydrostatic Control Valve Removal

17
 NEW STYLE
CONTROL VALVE
SHAFT

18
Pump Control Valve installation and removal of Plate
and Plug Style Orifices

19
Eaton Hydrostatic Control Valve
Installation

20
Eaton Hydrostatic Charge Pump Removal

21
Eaton Hydrostatic Charge Pump Check Valve
Removal

22
Eaton Hydrostatic Charge Pump Check
Valve Installation

23
Charge pump
Installation

24
Eaton Charge Pump breakdown and
Rotation

25
 Charge Pump Counter
Clockwise/Left Hand Rotation

Rotation is shown
standing at the
rear of the pump
facing the charge
pump rear cover

Ridges are aligned on the body and pump section. 26

 Charge Pump Clockwise/Right
Hand Rotation

Rotation is shown
standing at the
rear of the pump
facing the charge
pump rear cover

Ridges are not aligned on the body and pump section. 27

COMMON STYLES OF EATON CHARGE
PUMPS
Optional duel-element
charge pump used on
Standard Mixer with engine
driven pony pump to operate
chute lift.

Standard charge pump used

on Std. Mixer with remote
mounted pump for chute
lift.

Standard charge pump used on

Bridge Master, optional style for
standard mixers with auxiliary
pony pump driven off of
hydrostatic pump for chute lift.

28
Eaton Dual Element Charge pump used for Motor
driven chute lifter on Standard Mixers.

29
Eaton Dual Element Charge pump used for
Motor driven chute lifter on Standard
Mixers.
Charge
pump
relief
Suction valve 220
line from PSI.
tank to
feed the
charge Pressure
pump and line to
chute Chute
lifter lift
pump. control
block.

30
Cessna Pressure Compensated Pump Used on
Tuck-A-Ways, BM 2 and BM 3 Mixers up til
October1997

31
 Anatomy of a Pressure Compensated Pump
Pump Housing Swash Plate Servo Piston

Bias Spring Compensator

Spool

Piston Slipper

Input Shaft
Seal

Input Shaft
Bearing

Rear Cover

Trunion Cylinder
Bearing Barrel Case Drain 32
 Compensator Pressure Flow Diagram
Compensator
Assembly

Compensator
Notice that Spool
the swash
Servo Piston
plate is fully to Case drain
stroked. oil
And the Pump Outlet to
Pistons are Compensator
reaching Spool Sense line
there full
travel in the
cylinder.

Pump is operating below Compensated Pressure

There is no flow to the back side of the servo piston from the outlet 33
side of the compensator.
 Compensator Pressure Flow Diagram

Notice that Servo Piston

the swash to Case drain
plate is fully oil
Centered
and not
stroked. Pump Outlet
to
And the Compensator
Pistons are Spool Sense
Even and line
away from
full travel in
the cylinder.

Pump is operating Above Compensated Pressure

There is flow to the back side of the servo piston from the outlet side
of the compensator and the case drain port is plugged. 34
Understanding the PVP 16 Pressure
Compensated Control

35
 The Parker PVP Series 16 Pressure
Compensated Pump Replaced the Cessna
Pump in October 1997

36
Illustration shows a Right-hand Clockwise
Rotation Pump.
Counter-clockwise Pumps will have inlet and outlet
ports reversed with the compensator on the outlet
side.

Parker PVP
series 16 Pump
37
The Parker PVP Series 16 Pressure
Compensated Pump

38
Pressure Compensating Pump
Troubleshooting

39
Understanding the
Hydraulic Powered
Chute System of
your Mixer
Standard Mixers
OPEN CENTER SINGLE ACTING
CHUTE BLOCK

2200 psi Relief

Valve

Chute Raise coil

Down Speed Flow
and Normally Open
Control
cartridge

Chute lower coil

and Normally
Closed cartridge
 OPEN CENTER SINGLE ACTING
CHUTE BLOCK IDENTIFICATION

Note:
there is a Pressure line
5 psi from pump
check
valve on
the back
side of Return line to
the block tank

200 psi Check valve with Output line to the cylinder

.062 orifice behind check
valve.
OPEN CENTER SINGLE ACTING CHUTE
BLOCK

Drawing
shown with
valve in
lower
position
.062 orifice behind
200 psi check valve.

Return flow
Pump flow
OPEN CENTER SINGLE ACTING CHUTE
BLOCK

Drawing
shown with
valve in
Raise
position
.062 orifice behind
200 psi check valve.

Raise pressure
Return pressure
Hold pressure
OPEN CENTER SINGLE ACTING CHUTE
BLOCK

Drawing
shown with
valve in the
neutral non
activated
hold position .062 orifice behind
200 psi check valve.

Pump pressure
Hold pressure
OPEN CENTER CHUTE VALVE
TROUBLESHOOTING

200
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK

Pilot
Check
Valve

4 way 3 position open center

2200 psi relief valve cartridge and coils
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK IDENTIFICATION

Chute speed Priority flow control

The other Chute speed flow control is located on the
flat side not showing.
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK

Shown with valve in raise

position
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK

Shown with valve in Lower

position
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK

Shown with valve in raised

by-passing position
OPEN CENTER DOUBLE ACTING
CHUTE BLOCK

Drawing shown with

valve in the neutral non
activated hold position
CHUTE CYLINDER INTERNAL
FLO-FUSE
 Understanding the
Hydraulic System of
your Mixer
Bridge Masters

1
Bridgemaster III Hydraulic System
COMPONENT DESCRIPTIONS
1. Control Block
A. Bridgemaster Directional (Parker Valve)
Function: Directs pressure and flow to latch cylin-
der and pilot-to-shift directional valve to allow
Bridgemaster to raise or lower. Also used on Flow
Stop Block or can be added to current block for
flow stop function.
Failure symptom: Bridgemaster will not change
direction. Valve will not shift because of bad switch
connection, failed coil or sticking spool.
B. Adjustable Pressure Regulating Valve (PRV2)
Function: Adjusts and maintains correct down
pressure (regulated pressure).
Failure symptom: System will not develop desired
pressure. Pressure erratic or unstable caused from
sticking or binding spool. Can be cleaned with
WD40™ or equivalent and reused.
C. Chute Up or Down Solenoid and Cartridge
(Current Block) (3W2P Cartridge)
Function: (Up Cartridge): Allows oil flow to raise
chute when coil is energized. (Down Cartridge):
Allows oil flow to unseat Pilot-Operated Check so
oil can leave the chute-lift cylinder.
Failure symptom: Chutes won’t move up or down
depending on cartridge affected. Can be cleaned
with WD40™ and reused. Also check coil for
magnetism when energized.
D. Pilot-Operated Check (PO CK)
Function: Holds chute in position.
Failure symptom: Chute drifts.
E. Chute Speed Control (See page 11)
Function: Control chute up and down speed.
• UP Speed Control - CW = slower
CCW = faster
• DN Speed Control - CW = faster
CCW = slower
Failure Symptom: Chute speed non adjustable
F. Chute Pressure Switch
Function: Senses chute not fully lowered.
Failure symptom: BM trailer won’t move, red dash
light on. (Red dash light may also be caused by
faulty chute swing Prox or chute not centered.)
16 Bridgemaster III Hydraulic System
2. High Flow Block (Barrel end of BM Cylinder)
A. Pilot-to Shift Orifice
Function: Provides smooth shifting of pilot-to-shift
directional valve spool.
Failure symptom: Bridgemaster will not change
direction because of plugged orifice.
B. Pilot-To-Shift Valve (PTS)
Function: Normal position connects barrel end of
cylinder to tank, allowing Bridgemaster trailer to
raise. Shifted position connects regulated pressure
to barrel end of cylinder, forcing Bridgemaster trail-
er down.
Failure symptom: Bridgemaster trailer will not
change direction. Spool not shifting because of
plugged pilot orifice, binding or jammed spool from
system contamination.
C. High Pressure Relief Valve
Function: Prevents pressure in barrel end of cylin-
der from exceeding 3300 PSI in abrupt grade
changes and rough roads or if accumulator charge
is low or flat.
Failure symptom: System will not develop desired
pressure if spool is stuck open.
3. Rod End Control Block (CB4)
A. Check Valve
Function: Allows free flow during Bridgemaster up
mode. Blocks flow in Bridgemaster down mode.
Failure symptom: Bridgemaster will not stop or
hold in mid-stroke position, or Bridgemaster moves
too fast in down mode. Failure is caused by system
contamination holding check valve open. If check
valve fails in the closed position, the axle will not
raise.
B. Counterbalance Valve
Function: Prevents Bridgemaster from being
lowered or dropping when truck is turned off, and
limits the speed the Bridgemaster can be lowered.
Failure symptom: Bridgemaster will not stop or
hold in mid-stroke position, caused by contamina-
tion holding the valve open. If check valve fails in
the closed position, the axle will not raise.
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
CB4 Conversion
A pre-1988 Bridgemaster ll or Tuck-A-Weigh can be
retrofitted to a new style motion control valve (CB4).
Should a problem arise with the motion control valve on
a Bridgemaster ll (CB1) or a Tuck-A-Weigh (CB3), this
CB4 conversion would not only save the customer
money, but provide to be more efficient. All Bridgemaster
lll units built after 1/2/88 incorporate a CB4 as a standard
equipment.
To convert a CB3 on a Tuck-A-Weigh to the CB4 unit the
following steps should be followed:
1. Unplumb and remove existing CB3.
2. Eliminate the pilot line which runs between the
high pressure relief valve assembly. (HPRV) and
the CB3.
3. Install a plug in the pilot port on the HPRV as this
will no longer be required.
4. Install new CB4 to rod end of cylinder with the
ports pointing toward the HPRV.
5. Plumb the drain line from the HPRV to the end of
the CB4 cartridge (the end cap of the cartridge is
threaded to accept a fitting). A -4 to -6 adapter
will be required .
6. Plumb the large “CR” hose which was removed
from the CB3 to the CB4.
7. Check trailer performance on a scale. The new
CB4 is more efficient and may require recalibra-
tion.
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
To convert a CB1 on a Bridgemaster ll to the CB4 unit the
following steps should be followed:
1. Unplumb and remove the existing CB1.
2. Eliminate the pilot line which runs to the CB1
from either the HPRV or the “P aux” port of the
“C” block (control block).
3. Install a plug in the port which the pilot pressure
line came from. A pilot line is no longer required.
4. Install new CB4 to the rod end of the cylinder
with the ports pointing toward the HPRV.
5. Install a drain line from the CB4 cartridge end
(threaded to accept a fitting) to the reservoir (or
HPRV drain if equipped).
6. Plumb the large “CR” hose which was removed
from the CB1 to the CB4.
7. Check trailer performance on a scale. The new
CB4 is more efficient and will require recalibra-
tion.
The CB4 is quite simple to install. It has only three ports:
the port which attaches directly to the cylinder via a fitting
which is included with the CB4, a port for high flow which
allows oil to enter or leave the cylinder, and a cartridge
drain line which is designed to thread directly into the car-
tridge.
CB4 Conversion 41
Hydraulic System - How It Works
1. Pressure Compensated (PC) pump a. COMPENSATED PRESSURE flows into the
control block and moves into 3 areas within
a. The PC pump draws oil from the reservoir
the block:
as required
1. One route directs compensated pres-
b. The PC pump develops pressure respective
sure to the closed center chute lift block
to the compensator setting
section
1. This is called COMPENSATED PRES-
2. One route directs a flow of oil at com-
SURE
pensated pressure to the Directional
2. Compensated pressure has a +3,000 Valve.
PSI range capability
3. One route directs a flow of oil at com-
3. The compensator is fully adjustable pensated pressure to the PRV 2 valve
c. With the exception of internal leakage, the b. COMPENSATED PRESSURE to the direc-
pump only develops flow when the large tional valve
cylinder is in motion or the chute is being
1. When the down position is activated,
raised
the Directional Valve directs a flow of oil
1. You can check the bypass gauge on the at compensated pressure to the trailer
hi-pressure filter ONLY when the large latch and PTS. The trailer latch opens
cylinder is being extended or retracted. and the spool of the PTS shifts against
the PTS spring. This flow is via hose as
a. This would be a maximum flow situ-
the PTS is located in the hi-flow block
ation
on the barrel end of the large cylinder
d. The PC pump develops approximately 1
c. COMPENSATED PRESSURE to the PRV 2
GPM of leakage which is routed back to the
reservoir 1. The PRV 2 REDUCES COMPENSATED
PRESSURE from the Cessna pump to
e. Oil flows at compensated pressure from the
the setting of the PRV 2
PC pump through the hi-pressure filter
2. This new lower pressure from the PRV
2. Hi-Pressure Filter
2 is called “REGULATED” or
a. The oil flow flows through the Bridgemaster “REDUCED” pressure
filter element trapping particles of contami-
d. This flow of reduced pressure travels to the
nation
hi-flow block on the cylinder barrel end via
b. If the element becomes full, the bypass will hose between the control block and hi-flow
open. This allows oil to flow directly through block
the filter head without flowing through the
4. Hi-Flow Block
filter.
a. The PTS valve receives an oil flow of
1. The bypass becomes functional any
REDUCED PRESSURE from the PRV 2
time the OUTLET PRESSURE IS 50
flow and directs it to the barrel end of large
PSI BELOW THE INLET PRESSURE.
cylinder. This happens when the down trail-
At the same time, the indicator will read
er position is selected and an oil flow of
“bypass”. You can only read the indica-
pilot pressure from the directional control
tor when the large cylinder is being
valve shifts the PTS’s spool against its
extended or retracted.
spring
c. The oil flow continues to the Bridgemaster
1. With no pilot pressure, the spring holds
III control block at compensated pressure
the PTS spool in its normal position
3. Control Block - COMPENSATED PRESSURE which blocks off regulated pressure and
TO REGULATED PRESSURE exposes the large cylinder barrel end to
tank (trailer up)

© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Hydraulic System - How It Works 1
Hydraulic System - How It Works
b. At any time there is pressure in the large c. A hydraulic hose is routed from the end of
cylinder barrel end, the pressure is also the CB 4 cartridge to the hi-flow block. This
exposed to the Hl-PRESSURE RELIEF hose accumulates any normal leakage from
VALVE. Should the pressure exceed 3,300 the CB 4 cartridge and routes it to tank
PSI, the hi-pressure relief valve will open through the hi-flow block.
and dump directly to the reservoir. This pro-
6. Trailer Down Operation
tects the systems from damage due to high
pressure. a. A flow of oil travels from the pump through
the filter (compensated pressure) to the
c. An oil flow of COMPENSATED PRESSURE
control block. The PRV 2 reduces the pres-
also flows from the hi-flow block to the
sure to the amount required by the system.
LATCH CYLINDER. This flow is tee’d from
The reduced pressure oil flows through the
the PTS pilot flow inside the hi-flow block
PTS which was shifted by pilot pressure
which arrives from the directional control
from the directional valve. Oil which flows
valve. The latch cylinder responds to
through the PTS valve flows directly into the
approximately 50-60 PSI whereas the PTS
barrel end of the cylinder. Because of a dif-
spool responds to 175 PSI. Thus the latch
ference of area exposed to reduced pres-
cylinder will open before the PTS shifts to
sure, the cylinder extends and the
let the trailer down.
Bridgemaster III trailer goes down
d. A drain line from the CB 4 cartridge also
b. Reduced pressure flow in the rod end of the
joins the tank drain internally in the hi-flow
cylinder leaves the cylinder through the CB
block
4 cartridge and returns to rejoin the oil flow-
5. CB 4 Block ing to the cylinder through the PTS in the
hi-flow block.
a. The CB 4 block mounts on the rod end of
the large cylinder c. The check valve remains closed during trail-
er down cycle
b. The CB 4 block contains a CB 4 cartridge
and a check valve 7. Trailer Up Operation
1. The CB 4 cartridge is sensitive to pres- a. There is no flow through the directional
sure differences between the cylinder valve when the trailer up switch is activated
rod end and regulated pressure port on so the PTS in the hi-flow block drains the
the CB 4 block assembly. If the regulat- barrel end of the large cylinder to tank. A
ed pressure on the CB 4 block is lower flow of oil travels from the pump through the
than the regulated pressure in the cylin- filter (compensated pressure) to the control
der barrel end, the CB 4 cartridge will block. The PRV 2 reduces the pressure to
close. This traps oil in the cylinder rod the amount required by the system.
end and terminates cylinder movement.
b. A flow of oil at reduced pressure travels
Previous CB 1 and CB 3 valves
through the hi-flow block from the control
requires pilot pressure for operation. All
block to the CB 4 block. The CB 4 is closed
CB cartridge installations or replace-
as oil cannot flow through the CB 4 in that
ments should utilize the CB 4 block
direction.
assembly.
c. The reduced pressure oil flow opens the CK
2. The CHECK VALVE allows a flow of
valve in the CB 4 block and flows into the
reduced pressure toward the cylinder
rod end of the large cylinder. The cylinder
rod end only. For the oil to flow from the
barrel end is drained to tank through the
cylinder rod end, it must flow through
PTS. With oil flowing into the rod end of the
the CB 4 cartridge. The CB 4 also con-
cylinder at reduced pressure, the cylinder
trols the down speed of the cylinder as
retracts and the trailer goes up.
the opening through the CB 4 cartridge
is a specific size. This is not adjustable.

2 Hydraulic System - How It Works © 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
BRIDGEMASTER COMBO BLOCK
Used in production since January 1996 with double
acting chute lift cylinder.

This block controls the up and down movement of the

trailer axle, concrete placement chute and Hyd. Oil
flow to the block. 2
BRIDGEMASTER DIRECTIONAL
CONTROL VALVE
(PARKER VALVE)

New style coils with out

spacer block 3
 BRIDGEMASTER DIRECTIONAL
CONTROL VALVE (PARKER VALVE)

Old style coils with

spacer block

Trailer up/down valve and mid-position valve are interchangeable, as

long as port orifices are in the correct position. 4
 MID-POSITION OR START/STOP
VALVE

Trailer up/down valve and mid-position valve are

interchangeable, as long as port orifices are in the
correct position.

5
 ADJUSTABLE PRESSURE
REGULATING VALVE (PRV-2 VALVE)

6
CHUTE PILOT OPERATED CHECK
VALVE (PO CHECK VALVE)
PO check valves are
interchangeable
Pressure must be relieved from
chute lift cylinder before
servicing

7
 BRIDGEMASTER COMBO BLOCK
LINE ROUTING
G is gauge port
showing
regulated
pressure
C2 is Chute
down port
RP is
regulated
pump
C1 is Chute pressure to
up port high flow
block

Chute pressure P is pressure PP is pump

switch used in non- or pump port pressure to T is tank or drain
EP and older to feed block high flow port
systems operation block 8
CHUTE UP AND DOWN CARTRIDGE
(3W2P VALVE)

Both the coils and cartridges

are interchangeable in the up
or down port.

9
DOWN SPEED FLOW CONTROL

10
UP SPEED FLOW CONTROL

11
 BRIDGEMASTER HIGH FLOW BLOCK
ASSEMBLY (Barrel end port)

HPRV PTS
cartridge cartridge

The high flow block is located on the barrel end of the BM cylinder. This
block contains 2 cartridges; the High pressure relief valve (HPRV) and Pilot-
to-Shift (PTS) cartridge. A .025 orifice is located in the block in the PTS
cavity to control the shift speed of the PTS spool. 12
 BRIDGEMASTER HIGH FLOW BLOCK
LINE ROUTING

PP Compensated DR Drain from

pump pressure counterbalance
form Combo cartridge
block
RPR Regeneration
line from the CB-4
T Return line Block controlled
to tank from by the PTS
cylinder cartridge

L Pressure feed RPP Regulated

to the trailer pump pressure
safety latch form Combo 15
block
HIGH FLOW BLOCK HIGH PRESSURE
RELIEF VALVE (3300 PSI)

13
HIGH FLOW BLOCK PILOT TO
SHIFT VALVE

14
PILOT TO SHIFT VALVE
OPERATION

16
 ROD END CONTROL ASSEMBLY
(CB-4 BLOCK)

Counterbalance
valve Check
Valve

The CB-4 is located on the rod end port of the BM

cylinder. It has 2 cartridges; the counterbalance
valve and a check valve. 17
COUNTERBALANCE VALVE
(CB-4 cartridge)

WARNING: Do not remove CB4 cartridge with

any pressure in the BM cylinder, or if the
trailer is in mid-position. SERIOUS INJURY
OR DEATH COULD RESULT!

18
CB-4 CHECK VALVE
WARNING: Do not remove CB4 cartridge with
any pressure in the BM cylinder, or if the
trailer is in mid-position. SERIOUS INJURY
OR DEATH COULD RESULT!

19
ROD END CONTROL BLOCK OPERATION
(CB-4 block)

WARNING: Do not remove CB4 cartridge with

any pressure in the BM cylinder, or if the
trailer is in mid-position. SERIOUS INJURY
20
OR DEATH COULD RESULT!
 SIMPLIFIED BM HYDRAULIC
DIAGRAM
Vented Hydraulic
reservoir
BM cylinder

Parker pressure
compensated pump
BM counterbalance
block (CB-4)

BM high pressure oil BM High-flow block

filter
BM trailer safety
BM hydraulic control latch
block (combo block)

Chute lift cylinder

This diagram depicts a system that is not in use single acting
anymore, drawing is for parts reference only! 21
22
23
24
BRIDGEMASTER SYSTEM
TROUBLESHOOTING

25
BRIDGEMASTER SYSTEM
TROUBLESHOOTING

26
 BRIDGEMASTER V LATCH
ASSEMBLY WAS UPDATED IN JUNE
OF 2001

A new heavier return spring with a greater angle to pull.

Bottom of bracket was cut out to allow contamination to

drain away from cylinder. 27
BM-III CYLINDER WITH INTERNAL
NITROGEN ACCUMULATOR

IMPORTANT INFORMATION
• Cylinder rod head is torgued to 1,500 ft. lbs.
• Do not attempt to disassemble this cylinder wnless you
have received proper instructions !
• Accumulator must be entirely discharged before cylinder
is removed from the mixer. 28
 BM-V CYLINDER WITH INTERNAL
NITROGEN ACCUMULATOR
New style mount Do Not Grease BM-V Mount New style mount
ends with poly
ends with poly
bushings. Bushings ! bushings.

4.5 inch rod and 6 inch Accumulator piston External nitrogen

barrel pressure indicator.

IMPORTANT INFORMATION
• Cylinder rod head is torgued to 1,500 ft. lbs.
• Do not attempt to disassemble this cylinder
wnless you have received proper instructions !
• Accumulator must be entirely discharged before Accumulator
charge stem
cylinder is removed from the mixer. 29
 THE ACCUMULATOR QUICK-CHARGE
CHECK
CAUTION: Always Block the truck wheels to prevent the mixer form rolling away when
the axle is lowered for service purposes.

CAUTION: Never raise PRV2 pressure above 1000 psi with an empty
drum, chassis could be lifted and roll away!

30
ACCUMULATOR CHARGING PRECAUTIONS

NOTE: Always follow OSHA

lock/out Tag/out procedures
while servicing the BM system! 31
 CHARGING THE BM CYLINDER
ACCUMULATOR
The nitrogen charge in the accumulator must be checked on a regular basis. We
recommend the accumulator be checked every 60 days. The accumulator will normally lose
some nitrogen over a period of time and must be recharged. Recharging the accumulator
requires a McNeilus accumulator charging kit (P/N 160.85455). Before the accumulator is
charged, the following procedures must be followed. Failure to follow these procedures
may result in serious personal injury or death.

CHARGING GAUGE AND MANIFOLD

NOTE:
Always follow
OSHA
lock/out
Tag/out
procedures
while servicing
the BM
system!
32
CHARGING THE BM CYLINDER
ACCUMULATOR

33
CHARGING THE BM CYLINDER
ACCUMULATOR

34
 BRIDGEMASTER 5 HUCK BOLT
REPLACEMENT

Always use correct grade of bolts and properly

torque ! 35
Westport Axle Information

Westport Axle Information 43

Westport Axle Information

44 Westport Axle Information

Westport Axle Information

Westport Axle Information 45

Westport Axle Information
46 Westport Axle Information
Westport Axle Information
Westport Axle Information 47
Westport Axle Information

48 Westport Axle Information

Westport Axle Information

Westport Axle Information 49

Westport Axle Information

50 Westport Axle Information

Westport Axle Information

Westport Axle Information 51

Westport Axle Information

52 Westport Axle Information

Westport Axle Information

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Westport Axle Information

54 Westport Axle Information

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Westport Axle Information

56 Westport Axle Information

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Westport Axle Information

58 Westport Axle Information

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Westport Axle Information

60 Westport Axle Information

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Westport Axle Information

62 Westport Axle Information

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Westport Axle Information

64 Westport Axle Information

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Westport Axle Information

66 Westport Axle Information

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68 Westport Axle Information

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70 Westport Axle Information

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72 Westport Axle Information

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74 Westport Axle Information

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76 Westport Axle Information

Understanding the
Air System on your
Mixer

1
Standard and Bridgemaster
 D.O.T regulation Pressure
Protection valve, 75 psi not
to be changed.

Mixer Simplified air Schematic

and Component Diagram 2
Complete Mixer
Pneumatic
Diagram with all
Options.

D.O.T regulation Pressure

Protection valve, 75 psi not
to be changed.

3
 Air Tank Connections for all
Standard Mixers
Located on Factory Tank second from Wet Tank
Supply air to filter

0 to 60 psi
regulator to
control Water Supply air from
tank pressure. Filter to Mac valves

D.O.T. Pressure
protection valve
Supply air to
closes under 75
Water tank valve.
psi to protect
brake system.

Never install a Higher Pressure Regulator

4
on the water system
 Pre 2000 MAC VALVES located in
Rear Pedestal

Air Hopper Chute Lock

Mac Valve Mac Valve

900
Series
Mac
Valves

Mac Valves are the same used in current production on

5
Non-EP controlled Mixers.
 Air filter and Mac valve Assembly
mounted on front pedestal since
Jan. 2000

The filter
element should
900
Be inspected or Series
changed every 6
months or 1250 Mac
hours.
Valves

Filter bowl Mac Valves are unchanged

If filter shows any signs except for being moved
should be of discoloration or oil in
drained from the rear pedestal to
the bowl, element should the front.
Dailey be changed and chassis air
drier inspected. Excludes the EP system 6
 Air filter and Mac Valve Assembly
mounted on front pedestal With EP
Control System

92
The filter
element should
Series
Be inspected Mac
Monthly and
changed every 6 Valves
months or 1250
hours.

Filter bowl
should be
drained
Dailey If filter shows any signs of discoloration or oil in the bowl,7
element should be replaced and chassis air drier inspected.
 Chute lock and Air Hopper valve
plumbing
Front or rear mounted Mac Valves.
Chute lock Mac Air hopper Mac valve
valve assembly. assembly.

Yellow air line is

Hopper down.
Red air line is the
feed to the chute
Orange air line is
lock actuator.
Hopper up.

Green Supply jumper

to feed the Chute Green Air line is the
lock valve. supply to the Mac
valves from the
coalescing filter.

Air line colors are standard on all trucks.

Black Air lines are Pilot and Main valve exhaust
8
 Mac valve wiring and exhaust ports
Mac Valve
Mac Valve pilot exhaust
pilot exhaust

Main valve
exhaust
Main valve
exhaust

Chute lock valve plumbed normally Air hopper valve plumbed normally open to
open to cyl. B so that when the coil cyl. B so that when the coil is not powered
is not powered the air flows to the the air flows to the rod side of the
chute lock actuator to keep it hopper lift cylinder to keep it in the down
locked. position.
Note that all Mac Valves have a red and black wire, Red wire must always be
connected to 12 volts positive and black to ground. Reversing the polarity of
these wires will result in SERIOUS DAMAGE to the Mac valve coil. 9
Series 900 Mac Valve Exploded
View
Applications chute lock & charge hopper

Coil and Armature

assembly.
Spool valve assembly
060.82523
and return poppet.
100.82524 Pilot valve
Assembly
260.72555
Each of these
assemblies are
replaceable as
individual pieces
The Coil/Armature and pilot valve assemblies are
interchangeable for the 800 and 900 series valves. 10
With the design of the EP Control system,
a new Mac Valve Assembly was introduced.
Pusher Mac
2nd Pusher or valve assembly.
Tag Axle Mac
Valve.

Pusher air
Pusher air regulator and
regulator and gauge.
gauge.

Red led’s to
signal valve
Manual
operation.
Overrides

Less contamination
Single location issues and easier
Air Hopper Mac Chute lock Mac
mounting for 4 Valve Valve. Serviceability.
different 11
functions.
 Series 92 Mac Valve Identification
Part # shown is stamped on Mac Valve Label for
location verification.

The Charge
Hopper Mac Valve
is a 3 position
double acting The Chute Lock
control Mac Valve is a 2
92B-FAH-000-DP- position single
DDBP-1DM=4118 acting control.
92B-AAH-000-
DP-DDBP-
Both of the 1DM=4118
Pusher Mac
Valves are 2
position double
acting controls
92B-DAH-000-DP-
DDBP-1DM=4118

These valves are different, don’t just swap, they all

work differently!! We have Double versus Single Coil,
12
and 2 versus 3 Position Spools!
Backside of EP Control Air Manifold
Assembly
Manifold Supply Short Yellow line is
from filter is Pilot Exhaust for all
Green. the Mac valves.

Orange down
Orange down
2nd Pusher Axle
Pusher axle
or Tag Axle
Blue up
Blue up

Chute lock Chute lock

Red line. Yellow down exhaust
Short Green Air Hopper
line is main Orange up
only
valve exhaust. 13
 Air line Diagram as listed on 92
Series Valve
P = Main Air
Supply
CL= Chute Lock
E= Main Exhaust
for all valves
Except the Chute
Lock & Valve Pilot
exhaust.
HD= Hopper down
HU= Hopper up
BD= Axle down
BU= Axle up

If you receive a New or Replacement valve this label will

14
be attached to the back to aid installation of valve
 Series 92 Mac Valve 2 Position
Double Acting Exploded View
Used on Tag Axle and Pusher Axles with EP Control
System

This is the Pusher Mac, the spool is the same on both ends and can be
inserted either direction. Coils can be swapped to either side.

This exact 92 Series valve operates the same as the 800

15
Series valve used as an optional axle control valve.
 Chute lock air can assembly with
Quick release air valve.

Quick release air valve

used to speed up
reaction time of
Actuator supply
actuator
Line from Mac
Valve.

Spring return air

actuator

Chute lock clamp and

actuator rod
17
 Air Hopper lift Cylinder and Air
Connections
Yellow air
line is hopper
down.

Note cylinder
down air line is
pressurized
whenever air Orange air
tank is over 75 line is hopper
psi. up.

Note that the cylinder air fittings are not standard

fittings, they have orifices to provide smooth 18
controlled operation of the air hopper.
 Water Tank Air System
Components
Air pressure gauge.
Feed line from the
tank control valve.

Overpressure safety valve

or POP OFF valve will open
if the pressure in the
tank exceeds 60 psi.

3 position control
valve for air
pressure to tank.
Off, pressurize
and exhaust.

Do not remove or replace this valve

without checking its pop off pressure,
And never exceed 60 PSI. 19
 Air Tank control valve plumbing

Upper tank
Air tank sight gauge
control tube.
valve.

Blue air line is supply from
the pressure regulator that
is set to no more than 55
psi.
Black air line is the feed
from the control valve
through the pressure pop
off valve to the tank.
20
 Throttle Advance Safety Cut
Out
Signal line
Normally Closed out of the
pressure switch. parking
brake valve
in the cab.

Pressure Switch has a Normally Closed Circuit that opens when the Parking Brakes
are released on the Chassis. This cuts the signal to the throttle circuit.

If the Chassis Parking Brakes are released the

Mixer Throttle Advance will be inoperative. 21
The Mac valve Pilot
feed is ported from
unregulated inlet #4
if you reverse # 4 and
# 5 and the pressure
regulator is turned
down below 20 PSI
the Valve will quit
functioning.

Axle Down Position

Unregulated Pressure
Regulated Pressure
Exhaust Air
Axle Up Position 22
 Pusher axle Quick release valve
The small quick release valve
plumbed in blue air line
controls the Air bags to lift
the pusher axle.
The large quick release valve
plumbed in orange air line
controls the air bags to
lower the pusher axle.

Main air Main

supply air
from supply
the from
raise the
Mac lower
Valve. Mac
Valve.

Feed to the right and Feed to the right and

left raise air bag. left lower air bag. 16
 Tag Axle and Pusher Air
Control Valve

Blue air line is to Red air line is to

Up Air Bags down Air Bags
Mac Valve
Unregulated Air Exhaust Port Regulated Air from
from Tank to Input Pressure Regulator
Side of Up Mac to Input Side of 23
Valve. Down Mac Valve.
 Tag Axle and Pusher Air
Control Valve Blue air line is to
Red air line is to
down Air Bags Up Air Bags
Unregulated Air
Regulated Air out Non EP Control System from Mac Valve to
of Mac Valve to
Input Side of Down Input Side of Up
QR Valve. QR Valve.

Up
Quick
release
valve

Down
Quick
release
valve
Pusher or Tag axle Brake Quick release valve 24
 Mac Valve 800 Exploded View
Used on tag and pusher axles without EP Control System

Pilot valve assembly 260.7255 Spool Kit K00016C Coil 060.82523

The Coil/Armature and Pilot Valve assemblies are

interchangeable for the 800 and 900 series valves. 25
 Mac Valve Features
• Mac Quality
– Margins of force pilots
• with 120 psi inlet there is 40 #’s force to activate the
Spool and there is 20 #’s of return force in place.
– Balance
• Air pressure changes don’t effect the valve
– Wiping
• Helps keeps internals free of contamination.

– HSN Compound Viton o-rings

• Best resistance available to other chemicals.
– 4 Way pilot -- Extra shifting forces
26
1
Bridgemaster Circuit
26 Bridgemaster Circuit © 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
 McNeilus

CHUTE PROXIMITY SWITCH AND PRESSURE SWITCH DIAGRAM

5 Amp Fuse Chute Proximity
Battery Switch
WHITE D
RED C
N/O GREEN A
N/C BLACK B
P/N 060-110201A

Green

Chute up light in the console.

Light is red in color.
Back Up Axle Direction
Lights
White Black
UP

Common
N/C N/O
DOWN Axle Activate Drum Speed Controls
12 Volts with 1 Electronic Proportional (2003)
chutes centered 2 RE (2002 and newer)
and down. 3 Cable (For Ever)
4 Hydro Force (2000 and newer)
5 Delta Force (1999 and older)

Chute Pressure Switch

P/N 060-108015
UP DOWN
Unplug pressure switch, if the light is on in the cab, check the
Coil Spool Coil pressure switch and the proximity switch. If the light is still on
then check the chute proximity switch.
Directional Valve
P/N 260-108105
Simplified Bridgemaster Trailer Schematic

Proximity Switch
Battery 5 Amp Fuse

- - - - D
+ + + + C
A
B

Back-Up Lights Axle Direction

y


Up
R
CAB

y
Down Axle Activate

Chute Pressure Switch

y
y

Up

Directional Valve
Down

© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved. Simplified Bridgemaster Trailer Schematic 25
Bridgemaster Trailer System Electrical Troubleshooting
! WARNING
Before lowering the Bridgemaster trailer, turn the
PRV-2 (Pressure Reducing Valve) fully counterclock-
wise to itís minimum gauge pressure of approxi-
mately 1,000 - 1,100 psi.
! WARNING
Anytime you are working on this equipment or its
related systems, you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that he
must not attempt to start the truck.
2. Follow all OSHA and Mixer Lock Out procedures.
Remove the keys from the truck’s ignition.
3. Place magnetic signs on both doors of the truck
which read:
“CAUTION - MAN WORKING ON MIXER - DO
NOT START ENGINE”
4. Lock out supplies are available from McNeilus
Truck and Manufacturing. Call (507) 374-6321 for
assistance.
! WARNING
Always be sure the area behind the mixer is clear of
people or other obstacles when raising or lower the
trailer.
NOTE: The chutes must be in the full down position or
the trailer will not raise or lower.
NOTE: The chutes must be centered or the trailer will
not raise or lower.
NOTE: Always use Dielectric grease on Weather-PakÆ
connections.
THE ELECTRICAL CIRCUIT
The electrical power for the Bridgemaster trailer
raise/lower function begins at the control console. Older
Bridgemaster units have a 5 amp resettable circuit
breaker on the front of the console. Current production
units have a 5 amp ATO fuse inside the passenger side
of the console.
12 volts travels directly from the console to the proximity
switch located at the main chute pivot. If the chutes are
not centered, the proximity switch opens eliminating the
electrical circuit and the Bridgemaster trailer will not
raise or lower. If the red indicator light on the in-cab
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
console is on, this indicates that the chutes are not cen-
tered or are not fully lowered.
Provided that the chutes are centered, the electrical cur-
rent next travels to the chute pressure switch located on
the rear of the main control block. This block is located
directly behind the cab on the driverís side Bridgemaster
frame rail.
If the chutes are raised, the resulting pressure in the
chute hoist hydraulic line will activate the chute pressure
switch, opening (eliminating) the circuit, and the
Bridgemaster trailer will not lower. If the red indicator
light on the in-cab console is on, the chutes are not fully
lowered or are not centered.
If the chutes are both centered and in the full down posi-
tion, the electrical current next travels to the
Bridgemaster activate switch located on the in-cab con-
sole.
With the in-cab control console activate switch pressed,
move the up/down switch in the direction that you want
the trailer to move.
When all of the above circuits are active, the electrical
current is sent to the hydraulic solenoid directional valve
(the Parker valve) located on the top, driverís side of the
main control block (the Combo block). The trailer will
then raise or lower as directed by the up/down switch.
THE OPTIONAL MID-POSITION START/STOP SWITCH
The optional mid-position start/stop switch allows you to
stop the trailer during the up or down cycle. This is
accomplished by interrupting the hydraulic flow prior to
the Bridgemaster up/down hydraulic solenoid directional
valve.
NOTE: When the mid-position start/stop switch is in the
stop position, the Bridgemaster trailer and the chutes will
be inoperative. The in-cab hydraulic pressure gauge will
read zero pressure and placing the transmission in
reverse will not raise the Bridgemaster trailer. As an
example: If the trailer was moving down before the
Bridgemaster mid-position switch was activated to stop
the trailer, the trailer will continue to move down when
the Bridgemaster mid-position switch is moved to the
ìonî position. If the trailer is moving down and the truck
transmission is placed in reverse, the trailer will change
direction and will go up.
Bridgemaster Trailer System Electrical Troubleshooting 23
Bridgemaster Trailer System Electrical Troubleshooting
! WARNING
Anytime the mid-position start/stop switch is in the
“on” position and the truck transmission is placed in
reverse gear, the Bridgemaster trailer will raise
bypassing the proximity centering switch and the
chute pressure switches. This can cause severe
damage to the chutes and other components unless
the chutes are centered and fully lowered.
BRIDGEMASTER TRAILER WILL NOT RAISE OR
LOWER
Quick Checks if the Red Light is On:
A. Are the chutes in the full down position?
B. Are the chutes centered (pointing directly to the
rear)?
IF THE RED LIGHT STAYS ON:
A. Unplug the Weather-PakÆ connector for the chute
pressure switch located on the passenger side of the
main control block.
1. If the Red Light goes out after unplugging the
Weather-PakÆ connector, the problem is in the
hydraulic chute system or the chute pressure
switch.
a. Remove the pressure switch and check for
“open circuit” with ohm meter. If the switch
checks good, proceed to step B.
b. Change the “up” and “down” chute car-
tridges around, reconnect pressure switch,
and check for proper operation of the sys-
tem.
c. Bleed all air from the chute hydraulic line by
loosening the line at the cylinder (has any-
one changed the cylinder?)
2. If the Red Light stays on after unplugging the
Weather-PakÆ connector, the problem is in the
proximity switch on the rear chute pivot or asso-
ciated wiring.
a. Disconnect the wiring for the proximity
switch.
b. Check for 12 volts DC at terminal “C” (red
wire).
24 Bridgemaster Trailer System Electrical Troubleshooting
1. If there is no voltage present, check the
fuse or check the wire.
2. If voltage is present, check the position
of the proximity switch (1/4” air gap) or
replace proximity switch.
IF THE RED LIGHT IS OFF:
A. Make sure the mid-position switch is in the “on” posi-
tion.
1. There should be pressure showing on the cab
gauge.
2. The chutes should move up and down.
B. Make sure the truck transmission is not in reverse.
C. If there is no hydraulic pressure on the cab gauge:
1. Make sure the pump drive shaft is turning.
2. Remove the PRV-2 valve (pressure reducing
valve) and push the end of the valve “in” and
ìoutî several times while spraying with WD-40.
Reinstall the PRV-2 and check for system pres-
sure (older systems may have an orifice under
the PRV-2).
3. Remove the hose from the inlet side of the high
pressure filter located behind the cab of the
truck. Install a 0 - 5,000 psi gauge in the line
and ìdeadheadî the pump into the gauge. Start
the truck and check the pressure reading
(approximately 2,800 - 3,000 psi). If the pres-
sure is low, call your nearest McNeilus branch
for assistance.
Anytime you have questions on troubleshooting or repair
of your McNeilus Bridgemaster, please contact your
McNeilus branch or call the McNeilus Corporate
Headquarters at (507) 374-6321 and ask for mixer ser-
vice.
© 2/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
 McNeilus

Chute Centering Switch / Bridgemaster 3

Limit Switch - N/O and N/C

Part Number 060 - 00680 M

Weather Pak 3 1

Wire
Positions POSITION WIRE Green 16/4 12 Volt Supply

A White Red 16/4 12 Volt Supply

B Black
C Yellow Yellow 16/4 Console Warning Light N/C
D Brown
Brown 16/4 Wire N/O

4 2

Locate original prox switch
setup.
Tack weld the bar stock to the
bottom of the main chute.
Make sure that the bar stock is
centered in the hole of the
prox bracket.
Notice the orange and green
lights on the prox switch. The
orange light will go out if the
chute is not centered or if
removed from the “down”
position.
1. Prox Switch- 1109629
2. Prox Harness W/Relay-1145714
3. Pressure Switch Jumper-1145715
4. Main Chute Bar Stock-1132352
5. Chute Center Bracket-1144206
Locate the weather pack plug
at the end of the original prox
and disconnect it.
This is
what the
gap should
look like
Once you have everything
welded, install prox switch in
the bracket and tighten it up.
It should look like this when
you’re finished.
Unplug the weather pack
connector at the end of the
pressure switch.
Plug this female weather
pack jumper in place of the
pressure switch.
Complete Kit - 1145717
Weld bracket to here
at an angle
Plug the female end of the Tack weld this prox bracket
relay pack into the male to the pivot tube at an angle,
weather pack that the old as shown in this picture.
prox was plugged into.
Should have 1/4”
Minimum & 3/8”
Max. Clearance
There will be two lights lit up
Clearance between the prox on the prox at all times while
and the bar stock should look the chute is centered and in
like this. the “down” position.
WARNING
!
Anytime you are working on this equipment or its
related systems; you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that
he must not attempt to start the truck
2. Follow all OSHA and Mixer lock out
procedures. Remove the keys from the
ignition.
3. Place magnetic signs on both doors of the
truck which read: “CAUTION- MAN
WORKING ON MIXER – DO NOT START
ENGINE”
4. Lock out supplies are available from
McNeilus Truck & MFG.
Call (507) 374-6321 for assistance.
READ, UNDERSTAND, AND FOLLOW THE
SAFETY GUIDELINES, DANGERS, AND
WARNINGS LISTED ABOVE AND IN THE
McNEILUS PARTS BOOK AND OPERATORS
MANUAL TO PROMOTE RELIABLE
OPERATION AND PREVENT SERIOUS
PERSONAL INJURY
If you have any questions or need any assistance
with this procedure feel free to call our product
support department at (507)-374-6321
An Oshkosh Truck Corporation
Trouble Shooting Guide McNeilus

Eaton / Constant Speed Drum Control

( Correct readings on the 3 switch positions.)

The blue and orange wires are the ground wires.

Switch Wire Switch Positions
Position Colors Voltage OFF NORMAL AUTOMATIC
Blue Ground No
White Drum Speed Yes 12 Volts
OFF
Orange Ground No
White Start / Stop Yes 12 Volts

Blue Ground Yes

White Drum Speed Yes 12 Volts
NORMAL
Orange Ground No
White Start / Stop Yes 12 Volts

Blue Ground Yes 10 m ohms

White Drum Speed Yes 12 Volts
AUTOMATIC
Orange Ground Yes 9.9 ohms
White Start / Stop Yes 12 Volts

Comments: The blue and white wires go to the drum saver coil.
The orange and white wires go to the drum stop coil.

The white wires always have 12 volts.

The Blue and Orange wires carry ground signals.

The coils are energized or turned on and off by ground signals from the 3 position controller in the cab.
 JP3
7
1
Upper control + 16 GA PINK

8
2
Lower control +

9
3
12 Volts / Fan Power / Lower control + 16 GA PINK

4
5
BM stop solenoid (58) 16 GA PINK Ground 16 GA BLACK

6
Hopper up output

10 11 12

(
8
1

Power to PCB,Chute Lock,Drum S/S. BM Start. BM Up 9 Hopper up input (19) 16 GA BROWN

2

Power to tag up, pusher up, BM alarm output Hopper down input (20) 16 GA TAN
3

Power to work light output

4

Power to hopper output

5

Power to rear pendant output

6

Power to fan output

McNeilus

wires on the later units.

These are all 16 Gauge Red
7

Power to front pendant output

10 11 12 13 14

)
JP2
9
1

Chute lock output (45) 16 GA YELLOW Chute lock input (23) 16 GA GREEN
2

Drum stop output (30) 16 GA PINK Drum stop input (29) 16 GA BLUE
3
Mixer Control Board

BM strart output 16 GA PURPLE From OEM Reverse 16 GA BLUE

4

BM up output 16 GA BLUE BM S/S (11) 16 GA PINK

5

Tag up output 16 GA GREEN

6

Pusher up output 16 GA GREEN Chute unlock input (24) 16 GA GREEN

7

BM alarm output (49) 16 GA YELLOW BM alarm input (44) 16 GA GREEN

8

Work light output 16 GA BLUE To work LT SW 16 GA ORANGE

10 11 12 13 14 15 16
JP1
These are the 3 Molex Connectors on the Mixer Control Board
 McNeilus

Digital Drum Counter

Magnet
Back Side Of Drum Counter
Sensor

1 4

2 5 Jumper wire
installed at the Gear Box DRUM
3 6 factory.

Brown Wire No.2

Blue Wire No.1

Pedestal
 Optional Drum Start/Stop
Control System

The drum start/stop system is designed to stop the drum in charge or

discharge. By energizing the coil on the valve, the pressure in the pump servo’s
is equalized. This causes the drum to stop. By de-energizing the coil, the valve
closes causing the servo to re-pressurize and stroke the swash plate. This will
start the drum turning in the same direction and speed as before it was
2
stopped.
Optional Drum Start/Stop Electrical
Simplified wiring schematic

5 Amp

On/Off

The coil is also diode protected the Red wire must

be connected to 12 volts and the black wire must
be connected to ground. Reverse wiring of the coil
could cause immediate damage. 3
 2001 Hydra Force
Drum Control
System

Circuit shown with cylinder

extended
4
Note: When truck engine is off, CV3 allows control oil to drain to tank.
 2001 Hydra Force
Drum Control
System

Circuit shown with cylinder

retracted
5
Note: When truck engine is off, CV3 allows control oil to drain to tank.
 2001 Hydra Force
Drum Control
System

Circuit shown with cylinder not

activated and holding.
6
Note: When truck engine is off, CV3 allows control oil to drain to tank.
 Hydra Force Component location and
identification
NV – Adjustable
flow regulator for CV 2 – check valve
the speed of the for retract or rod
cylinder. end of cylinder.

CV 1 - check valve for

extend or barrel end
of cylinder.
CV 3 – 100psi Bias
pressure check valve to
CV-1 and CV-2 are interchangeable but keep cylinder from
CV-3 is not. hydraulically locking.
7
Note: When truck engine is off, CV3 allows control oil to drain to tank.
Hydra Force hydraulic connections and
port locations
P port - pump charge
pressure to operate block.

T port - block oil drain to case

S1/S2 - Charge/Discharge drain on the main pump.
Coils and dual acting
cartridge. A/B port – actuating cylinder
extend and retract. 8
EATON RE (REMOTE ELECTRIC) DRUM
CONTROL SYSTEM

USES THE SAME CONTROL VALVE WITH 9

EXTENDED ARM
 EATON RE (REMOTE ELECTRIC) DRUM
CONTROL SYSTEM COMPONENTS
Manual
override for
component
failure.

Charge/Discharge
coils and
cartridge.

Start/Stop coil and cartridge. 10

11
 REMOTE CONTROLLER
(RE CONTROLVALVE SECTION)

12
 REMOTE CONTROLLER
(RE CONTROLVALVE SECTION)

13
 REMOTE CONTROLLER
(RE CONTROLVALVE SECTION)

14
 REMOTE CONTROLLER
(RE CONTROLVALVE SECTION)

15
Hayden Fan Cooler Components

180
degree
sensor

140
degree
sensor

Motor and diodes for High and low temp. N/O 16

back feed. Switches.
 96 thru 99 Oil Temperature Sending Unit
and Fan Motor Control
96 thru 99 Mixers with a Hayden Electric Fan, used 2 thermostatic sensors screwed
directly into the inlet side of the oil cooler. The lower sensor would activate the fan
motor and the green light in the console at 140 degrees. The upper sensor would
activate the fan motor and the red light in the console at 180 degrees. If one sensor
would fail the other sensor would still operate. There are also 2 diodes built into the
harness of the fan motor to protect the system from back voltage.

17
Hayden Fan Cooler Wiring built before 2000

18
 2000 Oil Temperature Sending Unit
NOTE: 1996 thru current production use the same temperature sensors to activate
the Cooling fan motor, just different ways to sense the oil temperature.

The 2000 mixers used a thermister type sending unit, It uses a logic board to
convert resistance into a temperature. The in cab console light would remain off until
the sensor seen 140 degrees, than the green light would come on, when the sensor
sees 180 degrees the red light would come on to alert the driver that the second
switch is now in operation. The red light does not mean the system is overheated, it 19
just indicates the oil should be checked to verify it has not reached 220 degrees.
2001 and Later Oil Temperature Sending Unit
NOTE: 1996 thru current production use the same temperature sensors to
activate the Cooling fan motor, just different ways to sense the oil
temperature.

Sending unit operates separate from the fan cooler, using a bi-
metal switch, when the oil leaving the tank reaches 215 degrees
the switch closes and the red light on the in cab console will 20
turn on.
Hayden Fan Cooler Wiring 1/2001 thru
Current Production

21
 1995 and Earlier Mixer Fan Control
1995 and earlier mixers used a
Temptroller Fan Cooler. It had 2 sensors
that turned on at 170 degrees and off at
140 degrees. Both sensors were teed into
the outlet of the cooler and if one sensor
failed the other sensor would continue to
operate.

Diode
Fan Motor and
cooler assembly.
Sensors 170
degree
170 degree sensors

22
Chassis supplied Ignition power Pre-wired
in the Cab

72A is a 12 volt power with

a relay control from the Most all Chassis supplied powers
main fuse panel. come from the fuse panel run
down the side panels and exit the
back wall into the Cab.
This particular picture is an International Chassis 23
that was ordered pre-wired.
Rear Pendant to Chassis Harness connections

Rear Control
Pendant

MC 79 connected to the rear

pendant control box.

MC 79 connector from Chassis

Harness thru the rear pedestal.
24
 STANDARD CAB CONTROL BOX WITH
CHASSIS SUPPLIED POWER AND
GROUND IN CAB

Chassis supplied
power and
ground

25
 STANDARD CABLE CONTROL BOX
WITH FUSE BOX IN CAB

Main
Harness
Ground

Main
Harness
Power

26
 Bridgemaster in Motion Warning alarm Prox for
EP System

Prox switch
is used to
Relay to Power signal a
alarm relay in the
cab console
to activate
a separate
Striker plate alarm.
to signal prox
when BM is in
motion.

The alarm is mounted between the frame rails on a

cross member near the rear pedestal.
Bridgemaster in Motion Warning alarm Prox for EP
System

Short Prox
switch

BM rear pivot
assembly.
 Bridgemaster Chute Centered and Lowered Prox
Switch for EP System

Main Chute Prox

pivot switch
Assembly. target.

Prox
Switch.

Manual Chute Lock.

 Chute Center BM up /down Relay
BM Alarm Prox Prox Relay
Work Light Relay Relay
 Control Box Fuse Panel and Maestro
Identification
Maestro Control Module controls Drum start/stop, charge /discharge,
constant speed and transit mode.

Black Connector has

charge/discharge Reverse Signal
input from front thru Diodes to
and rear controls, Pusher and BM
output to Charge Axle to Raise.
and discharge coils,
Quadrature sensor
input, and discharge
lamp operation.

Gray Connector Contains

Maestro power and ground, #1
constant speed, transit plug Ignition
connections and drum stop Power
control.
 Chassis Harness to Cab Harness Connections thru
Cab floor

Chassis
Harness
Connector
MC 24

Chassis
Harness
Connector
MC 27

Chassis Harness
Connector MC 25