2024 Service Maintenance Training Book by ctmmixers

AGENDA FOR TODAY – DAY 1

Notes:

- Grab your 1 tee shirt in lobby at break or lunch

- Please make sure to fill out NDA paperwork quick and pass to RH end of rows

8:00 Introductions (Recognitions)

8:15 Safety

9:00 Main Pump - Hydraulics Theory and Application

10:00 Bridge King Hydraulic System

11:30 Cylinders (Trailer & Chute)

11:45 Gearbox

12:00 Lunch

1:00 Electrical 2:00 Air System

3:00 Parts Information 4:00 Remarks

6:00 Dinner

AGENDA FOR TOMORROW – DAY 2

Groups 1-6

7:00 am - Breakfast

7:30 am - Opening Remarks

8:00 am - Stations at Event Center

Lanyard

Colors - Brown - Dark Blue - Silver

- Red - Purple - Light Green

-Station 1: BridgeKing Cyl Maintenance

-Station 2: Elite Control System

-Station 3: Pumps & Controls

-Station 4: MAC Values

-Station 5: Standard Controls & Electrical Harness

-Station 6: Website Tutorial

11:00 am - Lunch

12:00 pm - Load Buses for Factory

12:30 pm - Stations/Tour

-Tour Group 1

-Tour Group 2

-Station 7: Drum Measuring & Roller Adjustment

-Station 8: BridgeKing Hydraulics

-Station 9: BridgeKing Axle and Pusher Axles

4:00 pm - Departure

AGENDA FOR TOMORROW – DAY 2

Groups 7-12

7:00 am - Breakfast

7:30 am - Opening Remarks

8:00 am - Load Buses for Factory

8:30 am – Factory Stations/Tour

Lanyard Colors - White - Orange - Light Blue - Yellow - Black - Dark Green

-Tour Group 1

-Tour Group 2

-Station 7: Drum Measuring & Roller Adjustment

-Station 8: BridgeKing Hydraulics

-Station 9: BK Axle and Pusher Maintenance

11:30 am - Load Buses

12:00 pm - Lunch

1:00 pm

- Stations at Event Center

-Station 1: BridgeKing Cyl Maintenance -Station 2: Elite Controls Station

-Station 3: Pumps & Controls -Station 4: MAC Values

-Station 5: Standard Controls & Electrical Harness

-Station 6: Website Tutorial

4:00 pm - Departure

EMERGENCY ACTION PLAN

LOT

CON-TECH FACTORY 65742 HWY 56 DODGE CENTER MN

Hwy 56 South

“To each there comes in their lifetime a special moment when they are figuratively tapped on the shoulder and offered the chance to do a very special thing, unique to them and fitted to their talents. What a tragedy if that moment finds them unprepared or unqualified for that which could have been their finest hour.”

Sir Winston Churchill

OSHA VIOLATIONS

SAFETY

OSHA 1910.147 (SAE 2957)

This standard covers the servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy, could harm employees

- Battery Shut Off/Disconnect

- Wheel Chocks

- Drum Roller Lock Out Wedges

- Hydraulic Pump Lever Arm Lockout Device

- Truck Keys in Pocket or Lock Box

SAFETY

Terminology

- Potential Energy: Stored energy

- Kinetic Energy: Energy in motion

- A good, consistent lockout program minimizes the risk of when potential energy turns into kinetic energy

EXAMPLES OF STORED ENERGY

WHY LEARN ABOUT SAFETY AND DANGERS??

DAY BEFORE YESTERDAY

TRUCK: 2022 OUT OF SERVICE VIOLATIONS PERCENTAGES (3 DAYS-59,000+ INSPECTIONS)

MIXER PRE-TRIP INSPECTION

XD (STANDARD) MIXER PRE-TRIP

CLEANING CHEMICALS 101

CHEMICALLY DAMAGED HYD HOSE

DRUM DRIVE COMPONENTS

- Eaton/Danfoss 54 Series Variable Displacement Pump

- Eaton/Danfoss 54 Series Fixed Displacement Motor

- Hydraulic Fluid

- Hydraulic Filters

- Hydraulic Oil Reservoir

HYDRAULIC

FLUID TERMINOLOGY

- Oil Base Stock

The base oil (ie: petroleum or mineral) that is the starting point for hydraulic fluid and other oils

- Additive Packages

Additive packages are supplemental “kits” that are added to base stocks to achieve desirable characteristics

Anti-Wear (AW): Usually Zinc

Emulsifiers: Water dissipation

VII: Viscosity Index Improver

HYDRAULIC FLUID SPECIFICATIONS

- Fluid Recommendations from Eaton

- ISO = International Standards Organization

- Average ambient below 80’F = ISO68 Fluid

- SUS @ 210’F = 55-60

- Viscosity Index (VI) = 100-120

- Pour Point = -25’F Avg

- Average ambient above 80’F = ISO100 Fluid

- SUS @ 210’F = 60-70

- Viscosity Index (VI) = 100-120

- Pour Point = -5’F – +10’F

HYDRAULIC FLUID VISCOSITIES

Avg Temp>80’F

Avg Temp<80’F

HYDRAULIC FLUID CLEANLINESS

- ISO Cleanliness Coding System

- Eaton Target ISO Code: 18/15/13

- 4m/6m/14m

- 18 = 1300 - 2500 ppMl 4 micron & larger

- 15 = 160 - 320 ppMl 6 micron & larger

- 13 = 40 – 80 ppMl 14 micron & larger

- Example of difference of 1 step up the scale

- 19/16/14

- 19 = 2500 – 5000 ppMl 4 micron & larger

- 16 = 320 – 640 ppMl 6 micron & larger

- 14 = 80 – 160 ppMl 14 micron & larger

* 1m=.00004”

4 100,000th’s

* Grain Salt=100m .004”

* Hair = 70m .0028”

* See > 40m .0016”

* Blood Cell=25m .001”

KEYS TO LONG LIFE OF HYDRAULIC SYSTEM

- Recommended Service Intervals

- After initial 100 hours

- Every ~ 1000 hours there after

- Keep Cool

- Check fan cooler operation often

- Operator should be discharging at 1200-1400 engine RPMs & control drum speed with controls

- Use the Correct Filters

- Suction (Spin On)Filter Rating: B10=2 (catches 50% of x<10m 1st pass)

- Could go to lower filter rating but would be in bypass MUCH longer!!

- Also @ 5m rating, strips the additive package from oil base stock

- High Pressure Filter Rating: B10=200 (catches 99.5% of x<10m 1st pass)

- Watch filter vacuum gauge

- X<10” at start up, 2”<x<5” after oil is warm

- If x>10”, filter is in bypass

Note: Tighten filter till contact with head and then ½ turn

Vacuum Generator #799613

Screws on top of hydraulic reservoir and hooks to shop air. Creates vacuum inside tank which allows hydraulic repairs to be made with minimal oil loss.

HANDHELD KIDNEY LOOP FILTER

POTENTIAL OR NO?

• Times to use?

• Replacing Parker or Chute Pump

• Maintenance intervals don’t line up

• For you that only change oil every OTHER filter change

HYDRAULICS – PUMP/MOTOR

- Eaton (now Danfoss) 54 Series Pump

- Variable Displacement Rotary Piston Pump

- Commonly referred to as “Closed Loop”

- Closed loop means that fluid travels in the high pressure circuits in a “circular” motion between the charge & discharge loops (hi/low side)

- 8 pistons rotating on swash plate create displacement (0-5.4 cu in)

- Swash plate angle determines displacement

- Controller (on side of pump) determines swash plate angle via pressure applied to servo cans

- Type of controllers (Manual, RE, EP)

- Right hand (clockwise)rotation – REAR of cab UNLESS Cummins X-12

- Left hand (counter clockwise) – Front REAR Cummins X-

EATON CHARGE PUMP

- Charge pump – Gerotor Style (real heart of system)

- Generates control pressure to shift servo cans

- Old=220 psi, New=280psi

- Charge Pressure Relief Valve controls PSI

- Makes up for leakage (5% of displacement) in rotating groups (high press circuit leakage)

- Leakage referred to as “case drain”

- Originates in motor (top), flows to bottom of pump & out top of pump thru cooler back reservoir

- Purposes: Cool & clean

MAIN PUMP – CHECKING CHARGE PRESSURE

- Without adequate charge pump pressure, cannot shift servo cans, create displacement and turn drum

- Charge pump pressure test procedure:

- With engine turned off, install #500 gauge

- Start truck engine and run at idle

- Pump in neutral: x > 280 psi (Con-Tech)

- Pump in full stroke: x > 220 psi (Con-Tech)

Notes

CHARGE PRESSURE RELIEF VALVE

• When testing charge pressure with gauge, charge pressure reading should NOT vary with engine RPM

• If reading LOW, remove and inspect valve

• DO NOT REMOVE WITH OUTER ¾” CAP, ONLY REMOVE WITH 1.25” WRENCH/SOCKET ON INNER HEX HEAD

• Inspect oring

• Hold valve up to the light and make sure you CANNOT see daylight between the cage and poppet holes. This is a CLOSED valve so if you can see daylight, something has it stuck open

Flow From Pump To Motor and Motor Back To Pump (ie: High Pressure “A” & “B” circuits)

Case Drain Flow

PUMP ANIMATION

- Go to live animation

MANUAL CABLE CONTROLLER

- Drum Start-Stop is normally CLOSED cartridge

- Take 12V power to open and stop drum

- Connects pathway between charge -discharge servo cans and “neutrals” swashplate in pump

- NOTE: If valve sticks OPEN, drum will not turn no matter what

- Remove valve and plug ports if suspect

EATON RE PUMP CONTROLLER

Charge/Discharge Cart/Coil Manual Override Valve

- RE Controller

EATON RE CONTROLLER

- Utilizes 12V coils to shift pump

- Charge/Discharge coils control pressure to either side of piston which shifts and just “drags” outer control valve

- Start-Stop valve opens to equalize pressures between servo cans (allows swash plate to neutral)

- NOTE: If drum fades to stop – O-rings worn on control piston in controller

- NOTE: Set drum to charge and watch arm on outer control valve. Does it move (on it’s own) back to the neutral position & the drum slows to a stop???

- O-Rings #725049 (x2)

- RE Gaskets #740005 (x2)

- Spool (if req’d) #725037

- Note: While in there, clean screen!!

Charge-Discharge

Emergency

Start-Stop

Cavity Plug #740044

RE SPOOL O-RING INSTALLATION

EATON RE CONTROLLER

- Controller Inlet Screen/Orifice

- Symptom: Slow controller motion from charge to discharge

- Causes

- Partially Open Override Valve

- Plugged Orifice Screen

- Low Charge Pressure

MANUAL OVERRIDE-VERY IMPORTANT!!!

#2

#1

1. Loosen inner “jam” knob CCW out till touches outer knob

2. Turn outer knob CCW (out) until it stops

3. Control pump/drum with arm

#3

Notes:

• On wireless remote units, the drum STOP function is activated when the ignition key is turned ON

• A shorted out coil will fault the Omnex receiver upon key ON

• Easy way to tell is that the charge-discharge and chute up-down will still work from cab box switches

DID NOT OPEN MANUAL OVERRIDE

Added Slide

MOTOR SHUTTLE VALVE

• The shuttle valve in the motor is the last component that controls the direction of the drum.

• The valve controls the flow of hydraulic fluid around the rotating group (pistons) in the motor

• How to diagnose

• Is the arm on control valve on the pump moving normally but the drum will not respond

• Remove shuttle and check for contamination

MYSTERY SERVICE CALL

Customer had full charge and only partial discharge…………..hmmmmmm

EATON EP (MTM/SCHWING,ETC.) CONTROLS

- EP (Electronic Proportional) Controller

- Uses .5 - 1.5 Amps to control (balance) spool position inside controller

- Utilizes “maestro” controller to manage spool position based on setting input from toggle switch (by varying current to coils)

- Coil Ohms (resistance) = ~6.5 -7.0

- Initial diagnosis steps anytime drum control issues are present

- Check resistance in coils

- Remove coils and clean coil and cartridge stem/tube

EATON EP (MTM/SCHWING,ETC.) CONTROLS

“Maestro” Control Module

12V+ Inputs from front and rear discharge switches

- Charge

- Discharge

Check with test light or multi-meter/power probe while depressing switches

EATON PUMP – COMMON SERVICE ISSUES

Trunnion Cover Oring #725000

Servo Can Socket #740100

Servo Can O-rings

Sm #725000

Lg #725004

If drum creeps when stop activated, adjust servo can in/out

Note: ALWAYS mark servo cans prior to adjusting or removing!

Shaft Seal Driver #799616

Input Shaft Seal Kit #725015

Torque=320 ft/lbs

Then to next slot for cotter pin

Note: There is NO backstop for seal!!

GEARBOXES

- ZF was the primary US supplier for gearboxes

- Lubricant 85w90 gear lubricant that meets the GL5 specification (4.2 gal)

- Recommended lubricant change intervals

- After initial 100 hours, every 1000 hours thereafter

- If output seal found leaking:

- Check dipstick for correct fluid level

- Raise output seal (umbrella) and clean behind it with quick clean. Re-inspect after 20-30 hours of operation

- Do NOT recommend synthetic gear lube (cost, service intervals, leakage, internal damage)

• Manufactured in Italy

PMP GEARBOX

• Most mixer manufacturers have moved to PMP due to product availability issues w/ ZF

• Gearlube:85W90 or 85w140

• Oil Capacity: 14L (3.7 gal)

• Gear Ratio: 127.6:1

• Interchangeable w/ZF

Sight glass locate on driver side

PMP GEARBOX CONT’D

ZF-PMP GEARBOX NOTE: DO NOT INSTALL INPUT SHAFT SEAL IN GEARBOX!!

FAN COOLER

- The fan cooler is an integral part of the hydraulic system.

- Con-Tech uses an ASA fan cooler

- Cooler flow TOTAL capacity = 35 Gpm

- Hydraulic fluid flow at WOT = 13.5 Gpm (case drain only)

- Utilizes a single temp switch set @ 157’F

- 30 Amp relay controls on-off power

- Simple installation and retro fit as only need power & ground

- Has 3rd wire for “fan on” output (to turn on a light in cab or elsewhere

Temp Switch #740013

Relay #715065 Fan Motor #740009

COMING LATE 2024 (PRODUCTION)

HYDAC COOLER

Improved leg design Less Bends

Thicker Material

Fan Cooler Assembly #740500

Note: Has 50 psi bypass to keep case pressures low ie: cold weather/thick oil

Fan/Motor Assembly #740502

Fan Temp Switch #740501

Fan Cooler Power Relay #715065

ASA/HYDAC FAN COOLER HARNESS SCHEMATIC

BRIDGE KING HYDRAULIC SYSTEM

- Parker Pump

- Pressure compensated piston pump (1 cu in)

- Pump is “self adjusting” to comp setting

- Testing

- Deadhead pressure hose (that goes to filter) into 5000psi gauge & start truck

- Failure indicators: No pressure or pressure fluctuates up/dn with engine RPM

- Also can check case drain volume. Place case drain line in bucket, at idle should be about ½ gpm (new), 2 ½ GPM on used pump

- If pressure is only slightly off, then adjust using compensator adjustment screw (in= psi increase) to 100 psi above highest setting on placard

- Pressure on gauge should be set to 100 psi over maximum setting on axle psi placard

Case Drains

- Right hand (clockwise)rotation –

REAR of cab UNLESS Cummins X-

- Left hand (counter clockwise) –

Front bumper mount OR REAR

Cummins X-

BRIDGE KING HYDRAULIC SYSTEM PARKER PUMP

How does it work?

• Compensator “self-regulates” pressure to set pressure

• Bias spring keeps pump at full stroke/pressure till outlet pressure matches comp setting and then destrokes the pump

PARKER PUMP QUICK TEST

1. With truck shut off, disconnect -8 pressure hose from high pressure filter

2. Install #5000 gauge

3. Start truck engine

4. At idle, should go immediately to #3000

5. Should NOT vary dependent on engine RPM

BRIDGEKING HIGH PRESS FILTER AND NOTES

- Bridge King Mixers

- Inspect high pressure filter bypass indicator daily

- By pass indicator trips at 50 psi pressure drop across filter

- The bypass filter indicates pressure DROP & will only read when raising/lowering trailer or raising/lowering chute

- Notes:

- Oil Capacities

- Standard Mixer: 13 gallons + 2 gallons in system

- Bridge Mixers: 18 gallons + 5 gallons in system

- Lefthand Pump Rotation: Front Engine AND Rear Engine Cummins X-12

- Rear (REPTO) mount pumps = Right hand pumps

Parker Filter Assy

O-Ring #725019

Cartridge #735003

Can Torque 30-35 ft lbs

Drain Torque 15-20 ft lbs

Schroeder Filter

Assembly #735019

Cartridge #735003

By-Pass Ind #760094

Round O-Ring #735021

Square O-Ring #735022

Canister Torque 45 ft lbs

BK Axle

BRIDGE KING HYDRAULIC SYSTEM

- Main Control “Combo” Block

Up/Dn Valve Axle Mid-Stop Valve (Option)

PRV2

Chute Lift Pilot Checks

Chute Up Flow Control

Setting: Bottom out and ¼ turn out

Chute Down Flow Control: ½ way out

Chute Down Manual Override

Chute Up Manual Override

BRIDGEKING® AXLE & CHUTE OVERRIDES

Notes:

• Overrides located under coil caps

• Overrides dis-regard ALL safeties and proximity switches

WHAT

DO I

DO…………WHAT

ARE THE POSSIBLE CAUSES

COMBO BLOCK – PORTING PLUGS

- Parker Valve Machine Screw Torque = 50 in lbs

COMMON SYMPTOM IS SLOW/NO BUILDING OF BRIDGE AXLE PRESSURE WHEN ATTEMPTING TO MOVE

TRAILER UP OR DOWN

System speed orifice located under axle mid-stop Parker valve

• Remove axle mid-stop valve

• Unthread orifice from manifold

• Remove Parker pump pressure hose AND fitting from “P” port

• Flush out port from top down

• Reassemble and test operation of trailer

HIGH FLOW BLOCK

- High Flow Block Contains:

- 3300 psi Relief Valve: 75 Gpm valve that clips pressure above 3300 psi ONLY on the downside of bridge circuit

- Check this valve if you can build trailer pressure in the UP pos but not in the down

- Pilot to Shift Valve: This valves tells which end of the bridge cylinder to apply flow/pressure to based on whether it sees signal pressure or not (from axle up/down valve

Signal pressure

HIGH FLOW BLOCK

Regulated Pressure

Signal pressure

Up = 0 psi

Down = 3000 psi

Regulated Pressure from PRV2 Valve

Extend Cyl (Down)

Retract Cyl (Up)

PILOT TO SHIFT VALVE ORIFICE

Symptom: Trailer won’t react to up/down command but pressure stays up

• Remove “PP” hose and fitting

• Located under fitting is orifice plug

• Remove orifice and inspect

COUNTERBALANCE BLOCK

- Located on rod end of bridge cylinder barrel

- The counter balance block is simply a safety valve (ie: metered check valve) for controlling the lower of the trailer should there be a loss of hydraulic pressure

BRIDGE KING HYDRAULIC SYSTEM

HYDRAULIC HOSE INFORMATION

- Con-Tech uses Danfoss hoses and fittings

Dash system for hose sizing is base on 1/16”

Gauge Hoses -4 = ¼” ID (GH781=6500 psi)

Chute Hoses -6 = 3/8” ID (GH781=5300 psi)

BK Parker Pump/XD Pony Pump Press -8 = ½” ID (GH781=4500 psi)

BK Cyl (short hose) -12 = ¾” ID (GH781 = 3500 psi)

BK Cyl Return -12 (FC619 = 305 psi)

Main Pump to Motor High Press -16 = 1” ID (EN856 = 5100 psi)

Main Pump Suction -16 (FC619 = 245psi)

STANDARD XD MIXER CHUTE LIFT PUMP

- .67cu in gear pump powers chute system

- Right hand (clockwise)rotation – REAR of cab UNLESS Cummins X-12

- Left hand (counter clockwise) Front bumper mount OR Cummins X-12

NOTE: Larger port is AWAYS the sucton port

Shaft: 5/8” x 9

Spline

STANDARD XD MIXER CHUTE LIFT

- Open center manifold manifold (#765100)

- Up-Down Coils/Cartridge (Cart #765092/Coil #765093)

- 2200 psi relief valve (#765095)

- Down flow control (#765097) In=Faster / Out=Slower (PFC)

- Up flow control (#765091) In=Slower / Out=Faster (Needle)

- Base Line Settings for Both - ½ way out

- Pilot Check Valve (#765096)

CON-TECH XD CHUTE MANIFOLD - RAISE

CON-TECH XD CHUTE MANIFOLD - HOLD

Key: Pilot check valve is what holds the chute up in the air (back pressure from cylinder pushes check valve shut

Troubleshooting

• If chute fades back down, remove and inspect check valve

• If just replaced block and chute fades, check chute hoses!!

CON-TECH XD CHUTE MANIFOLD – LOWER

CON-TECH XD CHUTE MANIFOLD – TESTING

Testing: The ONLY place you can install (deadhead)a pressure gauge is in the chute lift hoses (to test pressure)

System pressure is set to 2200psi

NEVER install a test gauge here unless you are Tee’d into the hose

CHUTE

- Con-Tech uses ALL double acting cylinders for the chute lift applications

- All Con-Tech cylinders have internal

- This flow (velocity) is set @ 4.0 4.0 gpm to leave the cylinder unrestricted & allows the cylinder to lower

- Any flow > 4.0 lock up and stops the dropping of the chutes

- Causes of cylinder locking up include: broken hydraulic hose, flow control open too far, air bubble trapped in cylinder

CHUTE CYLINDER

BRIDGEKING

- Internal Nitrogen Accumulator

- Use nitrogen because dry, stable and NOT flammable

- Accumulator located INSIDE rod

- Charge to 1100 psi

- Utilize Atro bushings

- Must be greased via zerks

NOTE!

Cylinder MUST BE installed on truck AND trailer MUST BE in down position before charging the bridge cylinder

ATRO BUSHINGS

LOCATED IN CYLINDER AND TRAILER PIVOT

Bushing: 750051

Notes:

• Grease required to flush out contaminates

• WATCH for alignment “dots” to ensure entire bushing gets greased

• Some play/gap is normal between poly material and pin

• Bolts: 6” x 1” GR8, 450 ft/lbs

Press Tool: 740101

BRIDGEKING AXLE CYLINDER

- Set screws located here

- There are TWO in there (inner/outer)

BRIDGEKING AXLE CYLINDER

- Forgot to remove head gland set screws located in barrel !!!!!

PHOTOS OF DAMAGE CYL ROD DUE TO ACID

BRIDGEKING AXLE CYLINDER

- ACID DAMAGE!!!!

BRIDGEKING AXLE CYLINDER

• Cylinder ran with Kevlar® protective boot

• Evidence of concrete slurry underneath rod clamp

BRIDGEKING CYLINDER HOSE

- ACID DAMAGE!!!!

BRIDGEKING® AXLE CYLINDER SLIDE OF SHAME

ATRO BUSHINGS LOCATED IN CYLINDER AND TRAILER PIVOT

Trailer Pivot Bushings

• Zerk and “Divot” align towards front of truck with trailer down

Cylinder Bushings

• Zerk and “Divot” align as shown so to line up with trailer down

ATRO BUSHING: EVIDENCE OF LACK OF GREASE

Lack of grease causes rusting and pitting of pin. Formation of rust “locks” pin to polyurethane and tears polyurethane from the outer sleeve

BRIDGEKING TRAILER AXLE MAINTENANCE

Causes of trailer issues/tire wear

• Toe In (1/8” Toe In)

• Steer Stop Adjustment

• Side Loading

• Tire Scuffing

BRIDGEKING AXLE – OEM SPINDLE LOCKNUT

• Locknut Part #791020

• Inner Seal #791050

• Inner Bearing #791024

• Inner Race #791023

• Outer Bearing #791022

• Outer Race #791021

NOTE: Bearing preload after nut adjustment .001”-.005” (end play)

BRIDGEKING AXLE – SPINDLE LOCKNUT & SEALS

Inner Wheel Seal #791050 (New)

Stemco Pro-Torque Spindle Nut #791053

See installation instructions on following pages or google “Stemco Pro-Torque Spindle Nut Torque Chart”

Inner Wheel Seal with Repair Sleeve #791014

SUSPENSION & AXLE MAINTENANCE

MIXER ELECTRICAL

• Con-Tech Harnesses

• Pre-Aug 2018: Standard 1-piecebraided harness bottom of cab to rear pedestal

• Post-Aug 2018: Armor Tech Harness System

• 1 piece braided from cab to front pedestal only

• Segmented (red, orange, green)rubber cables from front pedestal to rear pedestal

PROX SWITCHES 101

How Do They Work….

When prox switch is “made”, it fires a12V+ out When prox switch is NOT made, output signal is 0V+

Where are they…..

Chute Center (at bottom of main chute)

Bridge Trailer Motion (located inside driver frame rail near trailer pivot casting

BRIDGEKING® UP-DOWN SCHEMATIC

REMOTE THROTTLE SWITCH

- Only on mixers with corded rear pendants!

- If mixer is wireless, turning ON the handheld activates the PTO mode

- If PACCAR w/ MX engine, when PTO mode is activated, the accelerator pedal is “ dead”

THROTTLE BRAKE PRESSURE SWITCH

• In park brake signal (yellow) air line

• Paccar = Firewall or Driver Frame Rail (back of cab

• MACK = Inside driver frame rail (back of cab)

• Others = Typically behind park brake hand valve

• Normally Closed (NC) switch at 0 psi

• Opens at 40 psi when park brake is held OFF (not applied)

• For diagnostic purposes ONLY, you can place a jumper wire between the two terminals on the harness plug and re-test

• KW/Pete chassis, located on firewall, engine side/driver side

• Mack chassis, located inside driver’s frame rail, back of cab

• Western Star are located behind the trim panel in front of the passenger seat (where the glove box would typically be)

• Freightliner and others, typically behind park brake hand valve

ELECTRICAL – THROTTLE TIE IN (PRE NOV. 2018) PACCAR

Set-Resume Switch

Located in Dash

POWER AND THROTTLE – LOCATED

BEHIND CAB IN MAIN MIXER HARNESS

2 pin (12ga) power & ground

3 pin throttle

PACCAR (POST DEC 2018) THROTTLE 12 PIN BODYBUILDER CONNECTOR (FIREWALL)

Remote bodybuilder plug contains throttle up/down wires as well as the remote PTO enable signal wire

PACCAR THROTTLE 12 PIN BODYBUILDER PLUG

(BACK OF CAB)

PACCAR THROTTLE – POST NOV 2018 WITH PENDANT & MX ENG

GROUND (Pin 3)

UP=5V+ (Pin 2)

DOWN=5V+ (Pin 1)

GROUN D

DOWN=3V+

UP=3V +

PACCAR THROTTLE – POST NOV 2018

WITH WIRELESS REMOTE & MX ENG

PACCAR THROTTLE – POST NOV 2018 WITH PENDANT & CUMMINS

PACCAR THROTTLE – POST NOV 2018 WITH WIRELESS AND CUMMINS

PACCAR MAIN MIXER THROTTLE HARNESS

PACCAR POWER HARNESSES

(LOCATED IN BATTERY BOX)

PACCAR BATTERY BOX – POWER RELAY

Relay is triggered by accessory power from chassis (wire located under dash) above driver’s left foot

50 Amp relay & 40 Amp Fuse

PACCAR BATTERY BOX – POWER RELAY

MACK MIXER POWER AND THROTTLE

MACK IMPORTANT NOTES: IF NO MIXER POWER

• Make sure ignition switch is springing back to “RUN” position. MACK bodybuilder plug will NOT go hot (12V+) till the ignition cylinder returns to the RUN position. If ignition cylinder remains in START position, starter will kick out and everything will work just fine.

• Check MACK harness connector under dash. There is a single wire connector that connects the fuse box harness to the bodybuilder plug harness located above steering column in dash. VERY common for this to come disconnected!!!

MACK POWER/THROTTLE TIE IN

THROTTLE & POWER TIE IN’S

LOCATED BEHIND CAB-DRIVER’S FRAME

RAIL

Main power(12ga wires) coming from power relay in battery box or BodyLink III connector (if MACK)

Throttle (3 wires)

WESTERN STAR THROTTLE/POWER

Located at Back of Cab (Driver Side)

Throttle & Ign Power

EMERGENCY POWER JUMP

Run jumper wire direct from pos battery stud to power stud on back of fuse panel (located in center mixer console)

REAR PENDANT DAMAGE (2 DAYS OF DIAG)

Throttle would raise on engine as soon as PTO switch was turned ON (on the mixer console)

DRUM COUNTERS (2 DIFFERENT STYLES)

2 wires that come from pencil prox switch are hooked to terminals 2 & 6

= Jumper wire from terminals 4-6 to enable front reset button

DRUM COUNTERS

MIXER LIGHTING

Module located inside driver’s side of rear pedestal under cover as shown

LIGHTING - CHASSIS TIE IN

• ALL chassis manufacturers give us a lighting output connector inside the driver’s side frame rail behind the rear dual.

• We hook directly into these outputs and run into our lighting distribution “module”

• This module replaces the old “spider” harness

LIGHTING – CHASSIS ADAPTER HARNESS

To Light Distribution Module

Chassis Harness End

XD (STANDARD MIXER) LIGHT HARNESSES

BRIDGEKING LIGHT HARNESSES

LIGHTING J-BOX SCHEMATIC

CONSTANT SPEED “LOGIC”

“Quad Sensor: Relays drum speed and direction back to controller

Sets drum speed while in constant speed

CW=Faster

CCW=Slower

Located in lower mixer console

Constant Speed Module: Process drum speed/directio n info from quad sensor

Configurator: Fuse location sets software for interlocks, hyd motor and truck mph for constant

Constant Speed Valve: Bleeds off charge pressure to charge servo can to destroke pump

CONSTANT SPEED MODULE PRE JAN 2020

CONSTANT SPEED MODULE

POST JAN 2020

• Vehicle speed for activation

• Type of hydraulic motor

• Discharge switch operation

STANDARD CONSTANT SPEED

• Maintains constant drum speed regardless of engine RPM

• Drum speed can be set to 1-3

• May or may not come with optional discharge signal lock out

Rheostat (inside cab box) sets drum speed while IN constant speed mode

QUAD SENSOR LOCATED IN MOTOR

• Senses speed and direction of motor shaft (drum)

• Wiring colors

• Red (pin 1) = 12V+

• Black (pin 2) = Ground

• Blue (pin 3) = Drum Speed

• White (pin 4) = Drum Direction

Testing

Drum Speed: With multimeter set to Hz

• Back probe pin 3 (blue) to pin 2 (black) and turn drum

• 1 Drum RPM = 58 Hz

• 18 Drum RPM = 1044 Hz

Drum Direction: With multimeter set to 12V

• Back probe pin 4 (white wire) to pin 2(black ground)

• Should toggle on-off (0-3.4V)when drum changes direction

QUAD SENSOR TESTING

QUAD SENSOR – THINGS TO WATCH FOR

STANDARD CONSTANT SPEED

MOTOR QUAD SENSOR ADJUSTMENT

Post-2018 Armor Tech Schematic (on USB stick)

USB PORT ON BACK OF DISPLAY

NOT A PHONE CHARGER!!

IF used as a phone charging port, have seen:

- Multiple Chassis Codes

- Multiple Elite Codes

- Drum inadvertently go into discharge

AIR SYSTEM

- Con-Tech uses MAC air solenoid valves

- While a very good valve, they do require a certain amount of care

- During summer months or if you are in the south, you MUST drain the coalescing filter DAILY

- The drain is a twist valve at the bottom of the filter bowl

- Main Components

- Manual overrides

AIR SYSTEM

- Overrides ONLY work if NO Power

- 0-160 psi pusher axle gauge

- Pusher regulator

AIR SYSTEM

- MAC valves require very little maintenance

- For colder climates OR for trucks that will be parked for a considerable amount of time, MAC recommends the following

- Remove air supply line and place approximately 1 Tbsp (cap full) of ATF in air inlet airline

- Cycle all valves with manual overrides

AIR SUPPLY TANK

PRESSURE PROTECTION (HOLD BACK) VALVE

• Will NOT release air to mixer system until truck tanks build to 75 psi

• Regulated (non-adjustable 60 psi)air goes to water tank

• Non-Regulated air goes to MAC valves

AIR SYSTEM

- Mixer air functions will NOT operate till 85 psi reached in truck tanks

- Holdback valve is responsible for this

AIR SYSTEM

- Electrical pin layout on back of manifold connector

AIR SYSTEM

Air porting on back of manifold

AIR SYSTEM

Air porting on back of manifold

AIR SYSTEM

Air porting on back of manifold

HOW IMPORTANT IS THE POP-OFF VALVE ???

MUST

Part # 760030 (60 psi)

BE INSTALLED ON EVERY WATER TANK!!

BRIDGE AXLE BRAKE RELAY VALVE

Park Brake Signal

DRUM ROLLER INSPECTION

- Proper drum roller adjustment is critical for noise reduction & bearing life

- Rollers are to be greased weekly

- Use a quality EP#2 Lithium Grease

- Grease roller till you see a continual flow of CLEAN grease come OUT of seals

- Seals are installed backwards to allow grease to come OUT of roller & to keep contaminants OUT

DRUM ROLLER INSPECTION

- If drum roller noise is noticed, DO NOT grease roller track

- Spray water or WD-40 on roller & roller track

- If noise remains, most likely a bearing failure

- If noise goes away, then roller adjustment needs to be made

DRUM ROLLER ADJUSTEMENT

- If roller adjustment is needed, adjust as per below

- Align rollers with back edge of track

- Using straight edge or roller adjustment tool, “X” back edge of roller to drum track

- Using shims, shim roller to allow .010-.020” gap on front of roller between roller and track

DRUM ROLLER INSPECTION

- Evidence of drum not rotating while in transit

DRUM ROLLER INSPECTION

“Potter’s Wheel” Effect

HOW LONG DID THIS GO?

DRUM DAMAGE FROM NITROGEN

PUMP DRIVESHAFT

- Recommended Lubricants

- Use a quality EP or lithium synthetic high temp grease

- Min. Timken Load of 50

- Meets NLGI Grade 2 specifications

- Operating range of -10’F - +325’F

- Inject grease till clean grease comes from all 4 caps on the u-joint

- For slip yoke, apply grease to zerk till grease appears at the pressure relief hole. Then cover hole with finger and apply grease till it appears and slip yoke seal

- DO NOT USE LUBRICANTS WITH MOLY ADDITIVES! will cause premature failure of u-joints.