Con-Tech Service Manual Rev 1 - 3 Xe Bon Tron
Con-Tech Service Manual Rev 1 - 3 Xe Bon Tron
Con-Tech Service Manual Rev 1 - 3 Xe Bon Tron
Please read carefully the following operation and service manual. It will guide you
thru the proper operation and maintenance of your new Con-Tech mixer.
As always, please follow ALL OSHA guidelines and regulations when operating on,
around or near ANY piece of equipment. Your safety is important to us.
And if you have ANY questions or suggestions regarding this manual, the operation
or maintenance of your new mixer, please do not hesitate to call us at 507-374-2239.
Thank You!
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Lock-Out / Tag-Out
Chassis Standard Operating Procedure
Anytime ANY work is to be performed on a chassis, Lock-Out / Tag-Out procedures
must be followed. Shop Lead man will be responsible to ensure that the procedures are
followed. Any questions, please contact your designated safety officer.
Lock-Out Procedure
1. After placing chassis in parking position, turn chassis off and pull key from ignition.
2. Place wheel chocks in front and back of a tire.
3. Fill out form located at the designated Lock-Out / Tag-Out station, filling in the
proper information – Make and Vehicle Identification Number. Out Of Service Date
and Time and employee signature.
4. Place Ignition key inside Red Lock Box.
5. Place lock on Lock Box and place key in a designated location.
6. Fill out Lock-Out Tag and place it on the grab handle next to the driver side door.
1. Fill out form located at the designated Lock-Out / Tag-Out station, filling in the date
and time of return to service and employee signature.
2. Unlock Red Lock box and remove ignition key.
3. Remove Lock-Out Tag from grab handle on driver side of cab.
4. Remove wheel chocks.
5. Insert key into ignition.
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IMPORTANT SAFETY INFORMATION
Safety and safe working procedures must be followed WARNING !
at all times. OSHA procedures must be followed at all Correct hoses, fittings and adapters with the correct
times when working on the mixer or the pneumatic, SAE rating must be used when replacing hoses to
electrical, or hydraulic systems. Anytime you are prevent possible serious injury. Never mix brands of
working on the mixer or its related systems, you must hose, fittings and adapters. Example: brand “A” hose may
do the following: not be compatible with a brand “B” fitting or adapter. If
you have any questions, please contact Con-Tech Mfg.
1. Inform the truck driver that the mixer is going to Inc. at (507)-374-2239.
be repaired and “locked out” and that he must not
attempt to start the truck. WARNING !
2. Remove the keys from the ignition. Never remove hydraulic lines, fittings, or adapters until
3. Place magnetic “CAUTION” signs on both doors all pressure has been relieved from the hydraulic system.
which read: “Caution – Man Working on Mixer – Contact Con-Tech Mfg. Inc. at (507)-374-2239 for
Do Not Start Engine.” assistance if required.
4. Read, Understand, and Follow the Safety
Guidelines, Dangers and Warnings listed below WARNING !
and contained elsewhere in this manual including If hydraulic pipe must be replaced be sure to follow
the lock-out procedures. the specifications in this manual. If incorrect hydraulic
5. Contact Con-Tech if you have any questions or pipe is installed the hydraulic system may fail. Serious
do not understand the procedures. Phone 507-374- personal injury could also result from hydraulic pipe
2239. failure. Inspect hydraulic pipe on a weekly basis for
abrasions, damage or rust.
A copy of the Con-Tech bulletin on Lockout Procedures
is available from Con-Tech Mfg. Inc, 67079 170th Ave, WARNING !
Dodge Center, MN 55927 Do not heat hydraulic pipe. The carbon content of
this steel tube is such that if heated for bending and
THESE SAFETY PROCEDURES ARE FOR either water or air quenched, the pipe may have lost its
YOUR OWN PROTECTION: ductility and thereby be subject to failure under high
pressure or hydraulic shock conditions.
WARNING !
Hydraulic hoses must be inspected on a weekly basis WARNING !
for cuts, abrasions, damage, aging and proper clearance Use the proper tools and equipment when servicing the
along the frame. Immediately replace any damaged or hydraulic system. Use only Con-Tech charging kit when
aged hydraulic hoses – See pages in this Manual for recharging the accumulator. Call Con-Tech Mfg. Inc. at
specs. Call Con-Tech Mfg. Inc. at (507)-374-2239 if you (507)-374-2239 for assistance if required.
require assistance.
WARNING !
WARNING ! Never operate the hydraulic system if a leak is present.
Hydraulic system is hot – DO NOT TOUCH – serious
personal injury may result from hot oil. WARNING !
When using the emergency jumper procedure to rotate
the drum on a disabled mixer the following must be
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IMPORTANT SAFETY INFORMATION
observed: Before removing the hydraulic motor from concrete. Position chutes while they are not loaded.
the mixer drive on both the operating and disabled A loaded chute falling on a person may cause serious
mixer, be sure the drum has been allowed to turn freely injury. All chutes must be handled with great care to
so that it is balanced with no forces transmitted to the avoid injury. Do not stand on chutes.
hydraulic motor.
WARNING !
WARNING ! Main, fold over and extension chutes must be inspected
Wearing rings, watches or jewelry while working with on a daily basis for damage, excessive wear, proper
electrical and mechanical equipment can be hazardous hardware fit, twist and overall condition to determine
and can cause serious and painful injuries if they come that they are safe to use. Do not attempt to repair chutes.
into contact with electrical wires, moving parts or Unsafe chutes must be replaced with new chutes.
hydraulic equipment.
WARNING !
WARNING ! Optional air chute lock is intended for use only on
When working on the hydraulic or electrical system the job site. The manual chute lock should always be
of a BridgeKing unit the trailer should be in the down engaged during transport. Excessive wear or injury may
position or chained if in the up position to prevent result due to improper usage.
the trailer from lowering unexpectedly. Never stand
behind the trailer axle when in the up position. If the WARNING !
BridgeKing cylinder will not lower or raise, call Con- Do not let other persons, other than the driver,
Tech Mfg Inc. For assistance at (507)374-2239. handle the chutes, unfold the fold over and/or remove
extensions, or stow and secure the extensions for transit.
WARNING ! Keep hands away from chute hardware where the chutes
Slower speeds are required when going around curves connect. Never stand in the path of the chute as it is
or corners as the unit could upset or roll. being unfolded or while in use. Failure to follow the
warnings concerning chute safety may result in serious
WARNING ! injury.
At the job site use the lowest transmission gear
and proceed at low speed, 3 MPH maximum, to the WARNING !
discharge area. No passenger may be allowed in the cab unless a
Manufacturer’s approved passenger seat and seat belt are
WARNING ! provided.
Always keep hands and feet clear of the mixer drum,
revolving parts and moving parts while checking load WARNING !
or washing down the mixer. Do not climb on ladder or The mixer and chassis should not be overloaded. Gross
platform while truck is in motion or drum is rotating. Vehicle Weights must meet Federal, State and Local
Serious personal injury may result due to a fall, or laws.
entanglement.
WARNING !
WARNING ! Never drive the truck with the water tank pressurized.
All personnel must stand clear of the chutes during
raising and lowering and when chutes are loaded with
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IMPORTANT SAFETY INFORMATION
WARNING ! WARNING !
The water tank must be operated at no more that 55 When working on the mixer the wheels must be
psi. blocked, the parking brake on, lockout procedures in
effect and the keys out of the truck’s ignition.
WARNING !
Safety decals must be replaced anytime they are WARNING !
damaged or missing or cannot be read clearly. DO NOT ROTATE DRUM while backing up on
uneven or soft terrain.
WARNING !
The mixer must not be modified in any way without WARNING !
authorization from Con-Tech Mfg. Inc. Modifications Driver / Operator of the BridgeKing mixer MUST
may not comply with safety standards and may cause consult the axle psi placard (located near the axle
serious personal injury. Please contact Con-Tech Mfg. pressure adjusting valve) to determine appropriate
Inc. at (507)-374-2239 if you require assistance. pressure setting based on the load that is being
transported. Pressure is adjusted by turning the knob
WARNING ! clockwise/counterclockwise till the appropriate pressure
Be sure everyone is clear of the area around the truck is indicated on the gauge. If unit is equipped with
before operating the mixer. Remain attentive at all auxiliary lift axles, it will also be indicated on the axle
times when operating the controls. Watch the mirrors psi placard as to whether this axle should be raised or
for activity. Never back up the mixer until you are lowered based on the load being carried. Failure to
completely sure it is safe. Thoroughly understand the properly set the axle pressure and/or the improper use
controls before operating the mixer. of auxiliary axle can result in serious injury or death.
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 workers.
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.
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1.0 Controls - Electrical Page #
Cab Controls............................................................................................................13
Proximity Switches for Trailer Arm / Chutes......................................................18
Omnex Wireless Controller...................................................................................20
Omnex Reset............................................................................................................22
Extreme Duty Harness............................................................................................24
BridgeKing Harness................................................................................................26
Rear Control Pendent.............................................................................................28
Deutsch/Weather Pack/Fuse Kits..........................................................................30
Counters, Panel Meters, Tachometers and Timers.............................................32
Omnex Installation / Configuration Manual.......................................................35
Honewell Sensing and Control..............................................................................51
2.0 Air System
MAC Valves..............................................................................................................54
Coalescing Air Filter...............................................................................................61
Water Tank Controls...............................................................................................62
Auxiliary Air Tank / Controls................................................................................64
Chute Lock...............................................................................................................65
Hopper Lift Cylinder...............................................................................................66
Pusher / Tag Axle Quick Release Valves...............................................................67
BridgeKing Trailer Brakes......................................................................................68
Flow Control Valves................................................................................................69
Coalescing Filters....................................................................................................72
Mac Valve - Application Intallation and Service.................................................73
Mac Valve - Air Valve Lubricants..........................................................................77
3.0 Chute Pivot
Chute Pivot Maintenance.......................................................................................78
4.0 Hydraulics
Hydrostatic Pump and Motor Maintenance........................................................80
Hydraulic Test Kit....................................................................................................85
Troubleshooting Pumps and Motors....................................................................86
Pump and Motor Steps and Actions.....................................................................90
Hydraulic Pump.......................................................................................................92
Hydraulic Motor......................................................................................................94
“RE” Pump Controls...............................................................................................96
Hydraulic Reservoir................................................................................................98
Chevron Rando HD................................................................................................ 99
Hydraulic Suction Filter..........................................................................................101
Hydraulic Fan Cooler..............................................................................................103
Eaton Hydraulics.....................................................................................................105
Eaton Heavy Duty Hydrostatic Transmissions....................................................137
Eaton Hydrostatic Variable Pumps.......................................................................185
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5.0 Extreme Duty Chute Lift System
Standard Chute Block.............................................................................................191
Auxiliary Hydraulic Gear Pump............................................................................193
6.0 BridgeKing Axle / Chute Control System
Troubleshooting BridgeKing Hydraulics..............................................................195
BridgeKing Hydraulics Steps and Action.............................................................206
High Pressure Filter Assembly...............................................................................210
Parker Auxiliary Pump...........................................................................................211
BridgeKing Main Control Block............................................................................213
BK Cyl. High Flow Block........................................................................................215
BK Cyl. CB4 Block...................................................................................................217
7.0 BridgeKing Trailer System
Pivot Bushing Maintenance...................................................................................219
Trailer Axle Service Manual...................................................................................221
Charging The BK Accumulator.............................................................................223
Hendrickson Bridge Axle Technical Procedure..................................................225
Bendix LQ-5 Bobtail Ratio Valve..........................................................................242
8.0 Drum Drive - Gearbox
ZF Maintenance.......................................................................................................255
P/PK/CML................................................................................................................256
ZF Hydrostatic Mechanical & Electric Drive Systems Lubricants....................258
ZF Spare Parts Catalog............................................................................................260
ZF Repair Manual....................................................................................................292
9.0 Drum Roller Maintenance
Roller Adjustment / Maintenance.........................................................................309
10.0 Pusher Axle
Pusher Axle Maintenance.......................................................................................314
Hendrickson Technical Procedure........................................................................314
Hendrickson Parts List...........................................................................................339
11.0 PTO Info
PTO Shaft.................................................................................................................347
Spicer Driveline Installation...................................................................................349
12.0 Decal Info
Decal Placement......................................................................................................373
Note:
Page numbers on the vendor supplied spec sheets may not be in sequence of the service manual.
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Daily Pre-Operational Inspection
1. Inspect hydraulic system for leaks. Please inspect all hoses for cuts, abrasion or rubbing that could cause a
hose failure. If ANY leaks are present, please repair, tighten or replace as needed. Please make sure system has
sufficiently cooled and is NOT under ANY pressure!
2. Check all hydraulic oil sight gauges for adequate oil level and fill as needed to the correct level. When filling
hydraulic fluid, the oil MUST meet J20A specifications.
3. Start engine and allow adequate time for system warm up (5 minute minimum).
4. Rotate drum and inspect for proper roller operation. If any snapping or popping is heard from rollers or roller
track area, stop drum immediately and check for proper roller alignment. Any damaged rollers MUST BE replaced
to eliminate potential damage to the drum.
5. Visually check hydraulic vacuum gauge located on suction filter housing. If gauge reads above 10” of vacuum
after system has reached operating temperature, replace filter.
6. Test run all mixer functions electrically to make sure the mixer is fully operational before putting into service.
Any repairs should be made before the mixer is put on the road!
1. Initial change of fluid and filters at 100 hours (this is the normal break in period and will also allow for an initial
visual inspection of the hydraulic fluid/filter for contaminants). Failure to perform this service may adversely effect
performance of your Con-Tech mixer & void any warranty.
2. After this oil change, replace oil and all filters every 6 months or 1000 hours to insure the optimum performance
from your mixer. (See recommended lubricants on next page)
Weekly Inspection
1. Lubricate necessary components per Table 1 (at end of this section) Failure to follow recommended
maintenance will result in premature failure of certain components & Void any warranty.
2. Re-Torque bolts per Table 2 (at end of this section). Maintaining bolts (and torque) is considered a maintenance
item. Failure to routinely check bolts may result in component failure & void your Con-Tech warranty.
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3. Inspect oil (at operating temperature) for the presence of a milky substance and/or any foam. This would
indicate a suction leak or the presence of water in the system. Call Con-Tech Service at 507-374-2239 for further
information.
4. Inspect drum for proper max charge RPM (16-18 RPM at governed engine RPM).
5. Inspect drum and fins for concrete build up and excessive wear. Concrete build up can cause the drum to be out
of balance and will affect the mixing capabilities of your Con-Tech Mixer.
6 Month Inspection
1. Change Hydraulic Fluid as per specifications on Table 1 (at end of this section)
2. Change Gear Lubricant in main gearbox as per specifications located in Table 1 (at end of this section)
3. All filters and hydraulic fluid must be replaced every 6 months or 1000 hours to maintain your warranty and
keep your Con-Tech Mixer operating at maximum performance. All filter O-rings must be pre-lubricated prior to
installation. Inspect filters for presence of foreign materials such as copper or brass filings. Call Con-Tech Service
at 507-374-2239 for more information.
Lubrication
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8 7 6 5 4 3 2 1
D 10 D
B
8
11 7 12
2 4
6 5
C C
UNLESS OTHERWISE SPECIFIED: NAME DATE CON-TECH MANUFACTURING.INC
DIMENSIONS ARE IN INCHES
BEND .5°
DRAWN AJB 8/21/2014
TITLE:
1-507-374-2239
3
FRACTIONAL 1/32 CHECKED
ANGULAR: .1° MACH .01
ENG APPR. A
TWO PLACE DECIMAL .01
THREE PLACE DECIMAL .001 MFG APPR.
B
DRAWING IS THE SOLE PROPERTY OF
CON-TECH MNUFACTURING INC. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
FINISH
XD SERVICE
LAYOUT
1
CON-TECH MNUFACTURING INC. IS
B PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:64 WEIGHT: SHEET 1 OF
B 1
6 5 9 4 3 2 13 1
Pour or Pump
FRACTIONAL 1/32 CHECKED Change oil after first 100
TITLE:
A ANGULAR: .1° MACH .01 A
Drum Drive-Z.F. hours. Thereafter, change
ENG APPR.
TWO PLACE DECIMAL .01
B
DRAWING IS THE SOLE PROPERTY OF
CON-TECH MNUFACTURING INC. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
BK SERVICE
LAYOUT
Drum Drive-ZF-CML ZF EcoMix-X Synthetic Gear Lube Change Every 10,000 Hours
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
CON-TECH MNUFACTURING INC. IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:96 WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
6 Hyd. Reservoir Chevron Rando HD Fill to sight gauge Change every 1000 hours or
level six months
8 Sec. hold down bolts Bolts just snug Check 1000 hours
9 Trans. hold down bolts Torque to 420 lbs. – 7/8” bolt Check Weekly
12 Drive flange bolts Torque to 170 lbs (5/8” bolt) Check Weekly
Bridge King
13 BK Pivot Bushings General Purpose EP #2 Lithium Zerk Fitting Weekly
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Recommendations
for Hydrostatic Lubricants
The following are approved ISO 68 specification lubricants for Eaton Transit Mixer
Hydrostatics operation in ambient temperatures less than 80º F:
The following are approved ISO 100 specification lubricants for Eaton Transit
Mixer Hydrostatics operating in ambient temperatures in excess of 80º F:
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Controls - Electrical
Cab Controls
BridgeKing Harness
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Cab Control Box
Referance Pages 16 & 17
Drum S/S: Activates Pause-Resume (start-stop) of drum rotation. Activating this switch
will cause the drum to stop rotating. When function is de-activated, drum speed and
rotation will resume to where it was set previously.
Fan ON Indicator: Indicates hydraulic oil fan cooler is running. The fan sensor is set to
activate at when the oil temperature reaches 150°F. It is normal for this indicator light to
be on when ambient temperature is above 50°F or during times of extreme use.
Lock: Activates the Air Chute Lock. LED indicator light will be on when chute is
UNLOCKED.
Hopper: Raises and Lowers the material loading hopper. LED indicator will be ON if
hopper is in raised position. All CTM mixers are equipped with auto down in reverse
so the hopper will lower automatically if the truck is put in REVERSE. In order to reset
hopper function (after truck is put in reverse), you must toggle this switch off-on.
Drum Counter: Indicates the number of drum revolutions (since last reset).
Pusher Axle: If chassis is equipped with Con-Tech installed auxiliary air suspensions,
this switch will raise and lower the axle. Please note, all trucks with factory mounted
suspensions will have the controls mounted in the dash, on the driver’s frame rail or both.
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Cab Control Box
Activate: This switch (on the Con-Tech BridgeKing Mixer) must be held down prior to
pressing the Up/Dn switch for raising and lowering the BridgeKing Auxiliary axle.
Up/Down: This switch will activate (after pressing and holding the Activate switch) the
motion of the BridgeKing axle in the up or down direction. Motion of the trailer will
only be started if the main discharge chute is in the CENTERED and DOWN position.
The Chute Hazard indicator lamp will be ON if either of these two criteria are not met.
Start/Stop: When pressed in STOP direction, this switch will stop the travel of
BridgeKing axle in either the up or down direction. The LED indicator light will be ON
when the axle is in STOP mode. Axle will continue in the direction of previous travel
when pressed to START unless the Activate & Up/Dn switch has been pressed.
NOTES: When axle STOP is activated, the CHUTE UP/DOWN functions will NOT
operate. In order utilize chute up/down functions, the switch must be pressed to START
ALL BridgeKing mixers are designed so the BridgeKing axle will raise automatically
when the truck transmission is put in reverse. If the axle is in the DOWN mode,
stopped AND the truck transmission is put in reverse, when axle travel is started
(switch pressed to START), the axle will RAISE. If the chutes have been moved from
the original position (when trailer was lowered), damage may occur. If any further
clarification is required, please call the Con-Tech service department.
It is the responsibility of the operator to make sure all areas around the travel range of
the BridgeKing axle trailer are clear for safe operation!!!!
In the event you need to replace any of the switches or drum counter, you must remove
the 2 bolts (located on passenger side of console) at the top of the access door. The door
will swing down after removal of the bolts. Remove the white harness plug from the
switch to be replaced. Be sure the remove the connector by pulling firmly on the white
housing and do NOT pull on the wires. To remove the switch, press inward on the
locking tabs located on the ends of the switch. Push the switch up thru the panel. Snap
new switch into panel, re-install connector in the same orientation (as it came off the
old switch) and verify operation.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 15 www.ctmmixers.com
Cab Control Box
799757
Part # 715550
Fuse Box
Located on
Cab Control
Box
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Cab Control Box
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Proximity Switches for Trailer Arm / Chutes
Proximity Switch for Chute:
On your Con-Tech BridgeKing mixer (located below the main chute) is the CHUTE
HAZARD proximity sensor. This sensor indicates to the electrical system and the driver
if the chutes are off center or raised. If the chutes are off center or raised, the system will
not allow the BridgeKing trailer arm to be raised OR lowered.
During normal operation, when the chute is centered and down, the proximity switch
light (located on the back of the proximity switch) will indicate yellow, when the chutes
are raised or off-center, there will be no indicator light present).
NOTE: If the chutes are raised or off center and the emergency overrides (located on
the Parker directional valve) are used, you may damage the discharge chutes and/or
rear pedestal if the chutes are not centered and down.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 18 www.ctmmixers.com
Proximity Switches for Trailer Arm / Chutes
Main Chute
Prox Switch
Target
Main Chute
Prox Switch
# 715008
BridgeKing
Trailer BridgeKing
Prox Switch Trailer
# 715008 Prox Switch
Target
# 245143
Page 19 www.ctmmixers.com
Omnex Controller
As an option, Con-Tech offers Omnex Wireless Control Systems. This allows the
operator to operate the mixer via wireless within 50’ of the vehicle. It is imperative that
the operator become familiar with the controls of the wireless unit prior to use on the
job site. In the event of a lost or inoperative wireless transmitter, the mixer controls (on
the console) will still operate normally.
If access is required to the receiver unit, it is located inside the floor mounted cab
console.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 20 www.ctmmixers.com
Omnex Controller
Omnex Omnex
Transmitter Transmitter
# 765031 Cradle
# 765033
Always Keep The Transmitter In Its Charging Cradle While Not In Use To
Insure Charging and Protection
Page 21 www.ctmmixers.com
Omnex Controller Reset
Resetting a R160 receiver for a new T110 transmitter code.
Before starting this procedure, remove the R160 “board ” from the case. Release the clip
on either side with a flat blade screwdriver and pull down. Keep the receiver connected
to the truck power.
1. Power up the Receiver. The (E-Stop) light and the (Link) light will come on red
(provided the Transmitter is off), and the (Status) light will come on green.
2. Turn on the Transmitter by pressing and holding the red [E-Stop] button and the
green [Power] button, and then releasing first the red [E-Stop] button and then the
green [Power] button. This will power up the Transmitter into Download Mode. The
yellow (Active) light will begin flashing slowly (once per second).
3. Press and hold the [SETUP] button (yellow button on left side just above the left
connector) on the Receiver. The (Status) light (far right LED-Green ) will flash slowly.
Continue to hold the [SETUP] button (approximately 5 seconds) until the (Status) light
starts flashing rapidly and then release; it will now remain on steady. NOTE: If left idle
in Setup Mode for over 30 seconds, the Receiver will time out, indicated by the red
(Status) light flashing rapidly. To return to Setup Mode, repeat step 3.
4. Press and release the green [Power] button on the Transmitter to start sending the
ID Code to the Receiver. On the Transmitter, the red (Battery) light will come on and
the yellow (Active) light will flash rapidly; on the Receiver, the (Link) light will become
green. Once the ID Code has been downloaded, the red (Battery) light and the yellow
(Active) light on the Transmitter will go out. The (Link) light on the Receiver will
change from green to red.
Page 22 www.ctmmixers.com
Omnex Controller Reset
Omnex
Status
LED
Setup
Button
Unclip and Pull
Board out of Case
Page 23 www.ctmmixers.com
Extreme Duty Wire Harness
Your Con-tech mixer wiring harness is designed with durability in mind. It is wound
in a nylon wrap to withstand to resist abrasion and incorporates Deutsch electrical
connectors to combat moisture and corrosion. Please refrain from focused acid use in
the areas in/around the wiring harness, electrical connectors and solenoids.
It is also recommended that you inspect the entire harness during preventative
maintenance work on the mixer/chassis. Over time clips, clamps and zip ties can
corrode and break. This will allow harnesses to rub/chafe on frame rails, brackets and
hoses. This rubbing over time can wear thru the protective covering and possibly cause
electrical shorts in the system.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 24 www.ctmmixers.com
8 7 6 5 4 3 2 1
Page 25
D D
Extreme Duty
Cab Harness
# 715210
Tri-Bar
Harness
C
# 715111 C
B B
Spider
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Harness
# 715114
License Plate
UNLESS OTHERWISE SPECIFIED: NAME DATE CON-TECH MANUFACTURING.INC
DIMENSIONS ARE IN INCHES DRAWN AJB 8/21/2014 1-507-374-2239
BEND .5°
FRACTIONAL 1/32 CHECKED
Harness
TITLE:
ANGULAR: .1° MACH .01 A
A ENG APPR.
TWO PLACE DECIMAL .01
Extreme Duty THREE PLACE DECIMAL .001 MFG APPR.
# 715138
INTERPRET GEOMETRIC Q.A.
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
Harness DRAWING IS THE SOLE PROPERTY OF SIZE DWG. NO. REV
Extreme Duty Wire Harness
# 715113 # 715112
BridgeKing Wire Harness
Your Con-tech mixer wiring harness is designed with durability in mind. It is wound
in a nylon wrap to withstand to resist abrasion and incorporates Deutsch electrical
connectors to combat moisture and corrosion. Please refrain from focused acid use in
the areas in/around the wiring harness.
It is also recommended that you inspect the entire harness during preventative
maintenance work on the mixer/chassis. Over time clips, clamps and zip ties can
corrode and break. This will allow harnesses to rub/chafe on frame rails, brackets and
hoses. This rubbing over time can wear thru the protective covering and possibly cause
electrical shorts in the system.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 26 www.ctmmixers.com
8 7 6 5 4 3 2 1
Page 27
Tri-Bar
Harness
# 715111 D
D
BridgeKing
Cab Harness
# 715250 Trailer
Harness
# 715116
C
BK Fender
C
Harness
# 715117
B B
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Spider
Harness
License Plate # 715114
UNLESS OTHERWISE SPECIFIED: NAME DATE CON-TECH MANUFACTURING.INC
BridgeKing DIMENSIONS ARE IN INCHES DRAWN
Harness
AJB 8/21/2014 1-507-374-2239
BEND .5°
FRACTIONAL 1/32 CHECKED TITLE:
ANGULAR: .1° MACH .01
BridgeKing Wire Harness
A ENG APPR. A
TWO PLACE DECIMAL .01
Harness THREE PLACE DECIMAL .001
# 715138
MFG APPR.
Front Fender Stop-Tail-Turn
INTERPRET GEOMETRIC Q.A.
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
# 715115 THE INFORMATION CONTAINED IN THIS
Harness MATERIAL
SIZE DWG. NO. REV
Harness
DRAWING IS THE SOLE PROPERTY OF
CON-TECH MNUFACTURING INC. ANY BK SERVICE
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON B LAYOUT
CON-TECH MNUFACTURING INC. IS
# 715113
PROHIBITED.
# 715112
APPLICATION DO NOT SCALE DRAWING SCALE: 1:96 WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
Rear Control Pendant
Your Con-Tech rear pendant is designed with durability and function in mind.
Con-Tech offers two lengths 5’ and 25’. A wiring diagram is shown for a fully loaded
pendant. If you are experiencing issues with your pendant and need to service it, use
OEM replacement parts.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Pendant Wiring
A Drum Start/Stop Blue/White M Hopper Orange/Black
B Drum Start/Stop Blue/Black N Drum Charge White/Red
C Drum Start/Stop Signal Blue O Drum Discharge White/Black
D Chute Down Black/Red P Throttle High Green/White
E Pendant Power Black Q Throttle Common Green
F Chute Up Black/White R Throttle Low Green/Black
G Chute Lock Red/Black S Plug
H Chute Lock Signal Red T Plug
X
J Chute Lock Red/White U Plug W K
K Hopper Orange/Red V Plug
V J L
L Hopper Signal Orange W Plug
U H B M
X Plug
G A C
T N
F D
E
S O
R P
Q
Page 28 www.ctmmixers.com
Rear Control Pendent
Throttle
Q - Green
R - Green/Black
P - Green/White Hopper
Orange - L
Orange/Black - M
Orange/Red - K
Chute Lock
H - Red
G - Red/Black
J - Red/White Chute Up/Dn
Black - E
Black/Red - D
Drum Chg/Dchg Black/White - F
E - Black
JUMPER
O - White/Black
N - White/Red
Drum Start/Stop
Blue - C
Blue/Black - B
Blue/White - A
Page 29 www.ctmmixers.com
Deutsch, Weather Pack, & Fuse Kits
Deutsch Connector Kit - Part # 761061
Page 30 www.ctmmixers.com
Deutsch, Weather Pack, & Fuse Kits
Fuse Kit - Part # 761062
Maintain your Con-Tech mixer using the same OEM Parts used to build your truck
with these kits. They come in stackable bins that can be easily and conveniently stored.
For more information, or to purchase any of our kits, please call the Con-Tech sales
department.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 31 www.ctmmixers.com
1.1 Counters, Panel Meters, Tachometers and Timers
Totalizers
1
Technical Data and Specifications
1
1/32 DIN LCD Totalizers
1 Description Specification
1 Power supply Non-replaceable lithium battery (lifetime approximately eight years at 68°F (20°C)
Display LCD, eight-digits
1 Figure size 0.31 in (8 mm) high
Mode Adding or subtracting (selectable), counting direction, differential counting or phase
1 discriminator single or dual evaluation (selectable)
Display range –9999999 to 99999999, with overflow display
1 Reset Manual and electrical
1 Interference emissions
Housing
EN 55011 Class B, EN 61 000-6-2, EN 61010 Section 1 (only AC versions)
Dark gray RAL 7021
1
1
1
1
1
1
(22.2 +0.3) 1
1
1
1
1
1
1
1
≤
µ
≤
≤
30 1335 ±25
27 65 ±2
End of Wire
M30 x 1.5
LED
5
36
BN
L+
BK
BU
L-
T110 Transmitter
R160 Receiver
Version 6
DMAN - xxxx - xx
#74-1833 Coast Meridian Road, Port Coquitlam, BC, Canada • V3C 6G5
Ph# (604) 944-9247 • Fax# (604) 944-9267
Toll Free 1-800-663-8806
DMAN-XXXX-XX (Rev x.x) www.omnexcontrols.com call toll free: 1-800-663-8806
1
Table of Contents
System Overview .......................................................................................................................................................3
Features ......................................................................................................................................................................3
T110 Dimensions and Controls ..................................................................................................................................3
Installing the Receiver.................................................................................................................................................4
Special Functions........................................................................................................................................................5
Installation Considerations..........................................................................................................................................5
Power the Transmitter.................................................................................................................................................6
Test the Transmitter / Receiver Link...........................................................................................................................6
Download ID Code......................................................................................................................................................7
Changing Start Up and Shutdown Configuration........................................................................................................9
Diagnostics—T110 Transmitter ..................................................................................................................................10
Diagnostics—R160 Receiver ......................................................................................................................................11
Troubleshooting Guide................................................................................................................................................12
Parts & Accessories....................................................................................................................................................16
Specifications..............................................................................................................................................................16
Warranty Information ..................................................................................................................................................16
NOTE: These instructions are intended only for installing and operating the remote control equipment described here. This is not a
complete Operatorʼs Manual. For complete operating instructions, please read the Operatorʼs Manual appropriate for your
particular machine.
Safety Precautions
READ ALL INSTRUCTIONS
CAUTION: Changes or modifications not expressly approved by the party responsible for compliance could void the
user's authority to operate the equipment.
Failure to follow the SAFETY PRECAUTIONS may result in radio equipment failure and serious personal injury
Installation
PROVIDE A SAFETY CUTOFF SWITCH. If maintenance is required, the radio must be disconnected from power
USE PROPER WIRING. Loose or frayed wires can cause system failure, intermittent operation, machine damage, etc.
DO NOT INSTALL IN HOT AREAS. This apparatus can be damaged by heat in excess of 158° F (70° C)
Personal Safety
MAKE SURE MACHINERY AND SURROUNDING AREA IS CLEAR BEFORE OPERATING. Do not activate the remote
system unless it is safe to do so.
TURN OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY. Always disconnect the remote system
before doing any maintenance to prevent accidental operation of the machine
Care
KEEP DRY. Do not clean the transmitter / receiver under high pressure. If water or other liquids get inside the transmit-
ter battery or receiver compartment, immediately dry the unit. Remove the case and let the unit air dry
CLEAN THE UNIT AFTER OPERATION. Remove any mud, dirt, concrete, etc. from the unit to prevent clogging of but-
tons, switches, etc. by using a damp cloth.
Maintenance / Welding
DISCONNECT THE RADIO RECEIVER BEFORE WELDING on the machine the receiver is connected to. Failure to
disconnect will result in the destruction of the radio receiver.
The ORIGA T110 / R160 system uses Frequency Hopping Spread Spectrum (FHSS) technology. FHSS devices concen-
trate their full power into a very narrow signal that randomly hops from frequency to frequency within a designated band.
This transmission pattern, along with CRC-16 error-checking techniques, enables signals to overcome interference that
commonly affects licensed radios.
The R160 receiver is designed to be powered from a 12VDC or 24VDC system. It features 19 solid state, high-side driver
input / output controls and a reliable E-Stop control.
The ORIGA T110 comes with 4 to 10 buttons to provide the user flexibility to control the functions they need. It uses stan-
dard, long lasting AA batteries. Each T110 transmitter uses a unique ID code to ensure that no two systems will conflict at
a job site.
Features
Power ON Button
SHIFT Button when unit is on
1 2
5.8” 3 4
5 6
7 8
9 10 Function Buttons
Power OFF
Button
3.4” 1.2”
Wiring Diagram
Pin-Output Wire Colors Functions Notes
B7 Factory Configurable Only ________________
B8 Factory Configurable Only ________________
B12 - 19 Black/Red Input / Output ________________
B11 - 18 White/Black Input / Output ________________
B10 - 17 Blue/White Input / Output ________________
A1 - 16 Blue/Black Input / Output ________________
A2 - 15 Black/White Input / Output ________________
A4 - 14 Green/Black Input / Output ________________
B9 - 13 Red/White Input / Output ________________
B6 - 12 Orange Input / Output ________________
B5 - 11 White Input / Output ________________
B4 - 10 Green/Black/White Input / Output ________________
B3 - 9 Green Input / Output ________________
B2 - 8 Red/Black/White Input / Output ________________
B1 - 7 White/Red/Black Input / Output ________________
A12 - 6 Orange/Red Input / Output ________________
A10 - 5 Orange/Black Input / Output ________________
A11 - 4 Blue/Red Input / Output ________________
A9 - 3 White/Red Input / Output ________________
A8 - 2 Red/Green Input / Output ________________
A7 - 1 Orange/Green Input / Output ________________
Outputs: 19 solid state, high-side driver outputs, 5A max. per pin and 7A max per bank, total combined current 15A
Inputs: All output pins can be factory configured as inputs. Input pins should be connected to a current limiting (fused) source
5.13”
A B
4.00”
Installation Considerations
NOTE: The FCC and ISC require that the antenna be restricted to that supplied by the manufacturer and approved for use with this product. An op-
tional 0dB coax wire antenna may be supplied. For other antenna options, please contact OMNEX Control Systems ULC
When selecting a mounting point for the receiver, it is recommended that the location require only a minimal length of wir-
ing to connect it to the control panel, that it will be in a visible area where it has good exposure to the operator and that it
is mounted on a surface that is protected from the weather and sustains minimal vibration. It is also recommended that
the receiver have the best possible line of sight with the transmitter for maximum operating range.
Make sure that wire of sufficient gauge and insulator type is used when connecting the outputs of the receiver to the con-
trol panel. Observe any component manufacturer's instructions and recommendations for proper integration of their prod-
uct. This includes the power ratings and requirements of such components as relays, valves, solenoids, etc.
Be sure to test each of the outputs with a multi-meter prior to connecting the outputs to your end devices. This will ensure
that each output has been programmed to operate in the manner required by each end device.
WARNING: do not install batteries backwards, charge, put in fire, or mix with
other battery types. May explode or leak causing injury. Replace all batter-
ies at the same time as a complete set and do not mix and match battery
types.
NOTE: For operation at temperatures below –10° C lithium batteries are recom-
mended. Low temperatures reduce battery performance for both alkaline and lithium
types. Refer to the battery manufacturerʼs specifications for detailed information on
low temperature performance.
If the transmitter's (Active) light does not flash, check the battery orientation.
To turn off the transmitter, press the Power [OFF] button.
1. Power R160
2. Power T110
NOTE: The transmitter will shut itself off (and the receiver will then shut off all outputs) after 10 minutes of inactivity as a battery saving feature.
Momentarily operating any button on the transmitter, including the [Power] button will restart the 10 minute timer.
2. Power R160
A. Supply power to the receiver. The (E- A.
C.
D.
NOTE: If left idle in Setup Mode for over 30 seconds, the receiver will time out. The (Link) light and (Status) light will flash RED rapidly. To return to
Setup Mode, repeat step 4.
5. Send Code
NOTE: When downloading a new ID to a receiver, a safety feature requires that the transmitter be in close proximity to the receiver. This will pre-
vent a transmitter from accidentally reprogramming a different receiver in the area.
Once the ID Code has been downloaded, the RED (Battery) light and the YELLOW (Active) light on the transmitter will
go out. The (Link) light on the receiver will change from GREEN to RED.
NOTE: When replacing the receiver cover, ensure the cover snaps completely into place to create a weather proof seal around the base of the receiver.
A. The cap is held on by two plastic tabs at A. B.
A. B. C.
A. Power T110 into configuration
mode by following Step #3 from 1 2
3 4
Download ID Code
B. Press function buttons in order 3,
1, 4, 2
C. Press Power [ON] button
Enter the 10-digit Configuration Code associated with one of the following startup and shutdown modes:
ON / OFF Mode 1188888888 ON normal. OFF when T110 / R160 link is lost.
Secure Mode 4188888888 ON by entering the “3, 1, 4, 2” password on the T110 and pressing the
GREEN [Power] button. OFF when T110 / R160 link is lost.
Auto Power Down Mode 5188888888 ON normal. OFF when T110 / R160 link is lost or after 10 minutes of
being idle.
NOTE: If left idle in Setup Mode for over 30 seconds, the receiver will time out. The (Link) light and (Status) light will flash RED rapidly. To return to
Setup Mode, repeat step 4.
5. Send Code
Once the ID Code has been
A.
downloaded, the RED
A. Press Power [ON]
button to send code (Battery) light and the YEL-
LOW (Active) light on the
transmitter will go out. The
(Link) light on the receiver
will change from GREEN to
RED.
Change Batteries
Low Battery. Note: Low batteries will last approximately 8
hours once the Low Battery light begins to flash.
Replace batteries during next break.
Trouble Indicators
Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. Please note the transmitter status in the
“Description” column for each case.
Most likely cause of this condition is that an output wire or the E-Stop
Transmitter is OFF
wire has been connected to the power supply while the power wire is
The receiver is powered incorrectly.
disconnected from the power supply.
Start OK state:
Initial Condition: Status—GREEN
Turn transmitter off (all lights are off—press the Link—RED
What is the state
E-Stop button) E-Stop—RED
of the lights on
Cycle power to receiver (turn off and back on) Fault—OFF
the receiver?
Note: If there is a short to ground on
an output, it is not indicated at this
stage. To test for short to ground,
Problem state: refer to the “*Fault Light is RED*”
Status—RED procedure at the bottom of this page
and follow the instructions.
OK state:
E-Stop—RED
Fault Light is Call for service.
OFF
YES YES NO
Go to Chart 3
Reconfigure the transmitter to
ensure it is out of secure
mode
Refer to the Installation / Con-
Complete the following steps in order: figuration manual for
1. Check battery orientation directions.
Neither light comes 2. Clean battery contacts
on at any time 3. Check or Replace batteries
4. Send in for service
Transmitter: Transmitter:
Active light is flashing Active light is flashing
NO
If by accident, the transmitters have been switched with another unit, by downloading the
ID code to a new receiver, it is possible for the transmitter to operate 2 units at the same
time (if the original receiver unit is still on the job site). Therefore it must be
certain that the transmitter / receiver pair are the correct set.
Secondly, once the download procedure is completed, ensure all other units on the job site
are stopped. Test the operation of the newly configured set to ensure no other
machines on the site work with the same transmitter.
Once you are certain that the transmitter / receiver pair are a unique set, continue
normal operations.
If testing of the receiver and transmitter both show the system as working (Chart 1 & 2), then the transmitter and receiver
will both go into Download/Configuration mode.
Possible issues could arise during Step 4, the download phase of reprogramming. In this case there are 2 symptoms to
look for:
1. The Link light on the receiver will not turn GREEN when the power switch is toggled on the transmitter to download
2. The receiver will “time out” indicating that it didnʼt receive a signal from the transmitter within the 30 seconds from
the time the receiver was put into Setup Mode.
If all indications appear normal during the download phase, test the link by turning on the transmitter (note: the transmit-
ter shuts off after transmitting the ID code in Step 4)
1. If the Link light on the receiver doesnʼt turn GREEN, the receiver didnʼt receive all of the information that was sent
from the transmitter.
Possible Solutions
Note: you could try to determine whether the fault lies with the transmitter or receiver by completing the Reprogram-
ming procedure with a different transmitter. If this step works, then the fault lies with the original transmitter. If not,
the fault may lie with the receiver.
!!Caution!!
Reprogramming Tips:
1. Be patient and deliberate when pressing the Power and E-Stop buttons in the correct order during power up in Con-
figuration mode
2. Use a pointy instrument to depress the Setup button on the receiver (i.e. a pen) as the button is relatively small
3. Follow each step as laid out in the procedure
4. Never lay the receiver circuit board down on anything metallic (there are contact points on the back which could con-
tact the metal and damage the receiver)
Specifications
31NT91-1
manufacturers
Description
MICRO SWITCH™ NT Series toggle switches meet the need for a rugged, cost-
effective toggle switch. Quality construction features include a seal between the
toggle lever and bushing, and between the cover and case. These switches can
be used where panels are subject to splashes, hosedowns, or outdoor
environments. The "Easy-Start" threaded bushing enables quick alignment of
mounting nut to decrease the chance of cross threading. The panel stand-off with
O-ring feature available on some listings, eliminates the need for behind-the-panel
hardware, provides uniform panel height, and provides a panel to cover seal.
Product Specifications
Circuitry/
Operating
action
MAC Valves
Coalescing Filter
Chute Lock
www.ctmmixers.com
MAC Air Valve Manifold System
The MAC air valve manifold system that is responsible for auxiliary air functions such
as chute lock, tip up hopper and air operated suspensions. Proper maintenance of the
coalescing (water) filter is IMPERATIVE to the proper operation of the air solenoids.
The filter MUST be drained daily and even more so in high humidity conditions. Any
“milky” build up found in the filter must be removed to prevent damage to the valves.
You should also report this to your maintenance department as this may be a symptom
of a faulty air compressor.
In the event that the truck is to be stored for a long period of time (or being brought
back into service after sitting for some time), it is recommended that the supply line
to the manifold (after the filter) be removed and a table spoon of ATF or Polar-Lube®
Blue air system treatment poured into the air line. Re-install air line and cycle all valves
(manually).
If you replace the fittings, make sure only DOT approved air fittings are installed.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 55 www.ctmmixers.com
MAC Air Valve Manifold System
Manual Override
Buttons
Page 56 www.ctmmixers.com
MAC Air Valve Manifold System
Manifold - Chute Lock
Air
Supply
(Black)
Chute
Lock
(Red)
Part # 760075
Chute Pusher
Lock Up
(Red) (Blue)
Air
In
(Black)
Hopper Part # 760080
Up
(Orange)
Page 57 www.ctmmixers.com
MAC Air Valve Manifold System
Manifold - Chute Lock, Hopper
Air Hopper
Supply Down
(Black) (Yellow)
Chute
Lock Hopper
(Red) Up
(Orange)
Exhaust
(Black)
Part # 760085
Tag
Down Pusher
(Green) Down
(Green)
Pusher
Tag Up
Up (Blue)
(Blue)
Page 59 www.ctmmixers.com
Mac Valve-Chute, Hopper, Axle Valves
SPOOL CONFIGURATIONS
CHUTE LOCK
HOPPER
LIFT AXLE
Page 60 www.ctmmixers.com
Coalescing Filter System
The coalescing filter should be drained daily. If your coalescing bowl shows any kind of discoloration
or oil in the bowl the element needs to be replaced. Also check the chassis air drier for proper
performance.
The coalescing filter should be inspected daily.
When replacing the coalescing filter unit, always make sure it is installed in the correct direction for
proper air flow.
If you replace the fittings, make sure only DOT approved air fittings are installed.
For parts, refer to page 16 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
Coalescing Filter
Element Only
# 735006
Quarter Turn
Drain
Part # 735004
Page 61 www.ctmmixers.com
Water Tank System / Controls
The water tank is connected to the truck air system by a pressure hold back valve on the
truck air tank, or auxiliary air tank. This valve is set at 75 PSI and should not be altered.
It is recommended that the vehicle operator check the air brake pressure gauge in the
truck cab to assure safe vehicle operation.
Water tanks include three safety controls preset at the factory. To fill water tank, the air
line must be shut off and tank brought to zero pressure by releasing the air through the
two way or ball valve. A decal is provided showing proper direction.
The following safety controls should NEVER altered. PERSONAL INJURY OR DEATH
MAY RESULT FROM MODIFYING THE PRESET AIR TANK PRESSURE VALVES.
1. Hold-back valve on truck air tank-set at 75 PSI
2. Pressure relief valve on water tank-set at 60 PSI
3. Water tank operating pressure 55 lb. maximum.
If you replace the fittings, make sure only DOT approved air fittings are installed.
For parts, refer to page 34 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 62 www.ctmmixers.com
Water Tank System / Controls
Front
Water Tank
Block
# 760031
Water Tank
Site Glass
# 730027 - 28”
# 730032 - 30”
Water Tank
Pressure Gauge
0-100 PSI
# 760022
Back
From Pressure
Regulator Line to the Pop Off
Valve / Water Tank
Water Tank
Block
# 760031
Page 63 www.ctmmixers.com
Auxiliary Air Tank Controls
The auxiliary air tank is fitted with a 75 psi holdback valve, and a 0-60 psi pressure regulator for the water
tank system. NEVER OVER PRESSURIZE THE WATER TANK SYSTEM. This air system can be drained
using the drain valve with cable.
If you replace the fittings, make sure only DOT approved air fittings are installed.
For parts, refer to page 15 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
0-60 psi
Pressure
Regulator
# 760020 Holdback Valve
(75 psi)
D.O.T. Rated
# 760023
Supply Line
Supply Line
to the Mac
to the Water
Valves
Tank
Part # 785100
NEVER INSTALL
A HIGH
Drain Valve PRESSURE
with 48” REGULATOR ON
Cable YOUR WATER
# 760040 TANK SYSTEM
Page 64 www.ctmmixers.com
Chute Lock
The air chute lock brake can is a spring return air actuator. When activated it will lock
the main chute into position. When the released, the quick dump valve will speed up
the release of the air, releasing the lock faster.
If you replace the fittings, make sure only DOT approved air fittings are installed.
For parts, refer to page 10 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 65 www.ctmmixers.com
Hopper Lift Cylinder
The hopper lift cylinder down airline is pressurized when the air tank is at 75 psi
and over. Yellow airline is down, and the orange airline is up. NOTE: The fittings on
the cylinder are not standard fittings. They have an orifice in them to ensure smooth
operation. If a fitting needs replacement, contact the Con-Tech parts and a service
department.
If you replace the fittings, make sure only DOT approved air fittings are installed.
For parts, refer to page 7 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 66 www.ctmmixers.com
Pusher / Tag Axle Quick Release Valves
(Con-Tech Installed Suspensions)
The operation of your pusher and or tag axle is done through the pusher up/down valve. When
the pusher or tag axle switch is activated on the in cab control box, the MAC valve will allow
air to the up bags, raising the axle “Up”. When the switch is activated “down”, the Mac valve will
release air from the up bags, and supply air to the down bags lowering the suspension.
The quick dump valves on the front pedestal are for the pusher axle. If you have a tag axle, those
valves will be located in the rear pedestal.
If you replace the fittings, make sure only DOT approved air fittings are installed.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
NOTE: For factory mounted auxiliary suspensions, refer to the factory service manual.
Main Air In
(Blue)
Down to
Air Bag
(Green)
Up to
Air Bag
(Blue)
Page 67 www.ctmmixers.com
BridgeKing Trailer Brakes
The brakes on the BridgeKing trailer are controlled by the LQ-5 and the RP-12 valves. These are
located in the rear pedestal. The LQ-5 is a ratio valve that proportions the air to the RP-12 to
prevent the brakes from locking up. The RP-12 sends the air to the BridgeKing axle.
If you replace the fittings, make sure only DOT approved air fittings are installed.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
Signal From
Main Brake
Main Air In
(Black)
Page 68 www.ctmmixers.com
c h e c k & Q U Ic k e x h aUs T v al v e s
PNEUMATIC DATA
*Qn flowrate [scFM] determined with a supply pressure of 6 bar, [87 psi], and with a pressure drop of 1 bar, [14.5 psi].
** soft-seal repair kits are available for series vsc Quick-exhaust valves.
***Dimensions are in millimeters.
The company reserves the right to vary models and dimensions without notice.
96 These products are designed for industrial applications and are not suitable for sale to the general public.
c he c k & QU I ck e x h a U s T val ves
The check valves in the VNR Series are available with M5 Quick exhaust valves are commonly used to increase the speed
(10-32 UNF), 1/8” and 1/4” ports. They must be used when it is of cylinders or for rapid depressurisation of tanks containing
required to intercept a flow in one direction only. The design of compressed air. The models VSO 425-M5 and VSO 426-04
these valves is of the poppet type and this feature allows opera- are specially designed for mounting on solenoid valves and
tion at low pressures both when there is a free flow and during valves incorporating a 5/32” O.D. port. We recommend that a
retention. silencer be mounted on the outlet (2931-M5).
Materials used: Materials used:
- OT58 (brass) body, Nickel Plated (1/4") - OT58 (brass) body, Nickel Plated
- Buna-N seals - Buna-N seals
- stainless steel spring
VSO 425-M5
VSO 426-04
nominal flowrate
from P → a Qn* 50 nl/min. [1.76 scFM]
from a → r Qn* 100 nl/min. [3.53 scFM]
VNR-205-M5 Qn* = determinated with 6 bar [87 psi] and DP = 1 bar (14.5 psi)
Qn** = 150 nl/min Minimum operating pressure = 1 bar (14.5 psi) Minimum operating pressure = 1 bar (14.5 psi)
VNR-210-02
Qn* = 600 nl/min Minimum operating pressure = 0.3 bar (4.3 psi) cv rating
VNR-843-07TF from P → a: cv = 0.04
Qn* = 1400 nl/min Minimum operating pressure = 0.2 bar (2.9 psi) from a → r: cv = 0.09
* Qn = determinated with 6 bar and Dp = 1 bar
** Qn = determinated with 6 bar and Dp = 2 bar
DIMensIons Mod.
The company reserves the right to vary models and dimensions without notice.
These products are designed for industrial applications and are not suitable for sale to the general public. 97
c h e c k & Q U Ic k e x h aUs T v al v e s
3
Flow conTrol valves
VSC 544-04 1/4” 1.299 1.653 1.122 .669 38.8 1.16 67.1 2.00
VSC 538-06 3/8” 1.692 2.263 1.555 .944 158.9 4.73 222.5 6.62
VSC 522-08 1/2” 1.692 2.302 1.555 .944 158.9 4.73 222.5 6.62
The company reserves the right to vary models and dimensions without notice.
98 These products are designed for industrial applications and are not suitable for sale to the general public.
NORTH AMERICAN FRL CATALOG > Release 8.2
2
Coalescing Filters Series MC
Port 1/4", 3/8" & 1/2" NPTF
Modular with metal bowl guard and bayonet-type mounting
The Series MC coalescing filters are available with 1/4", 3/8", 1/2"
NPTF port.
TECHNICAL SPECIFICATIONS
PNEUMATIC DATA
Operating pressure 0.3 - 16 bar, (with depressurizing drain P Max. of 10 bar) : 4.35 - 232 psi, (P Max 145 psi w/ depressurizing drain) -
“Spitter-Type”
1.5 - 15 bar for Full Automatic float drain, (22 - 220 psi), 3/8" & 1/2" models only
Nominal flow see graph
The company reserves the right to vary models and dimensions without notice.
32 These products are designed for industrial applications and are not suitable for sale to the general public.
NORTH AMERICAN FRL CATALOG > Release 8.2
CODING EXAMPLE 2
MC 1 04 - F B 0 TF
MC SERIES
1 SIzE
1 = 1/4"
2 = 3/8" or 1/2"
04 PORTS:
04 = 1/4" NPTF
38 = 3/8" NPTF
02 = 1/2" NPTF
F FILTER
B FILTERING ELEMENT
B = 0,01 μm coalescing
0 DRAINING OF CONDENSATE
0 = normal - semiautomatic
3 = Fully automatic, Float-Drain, 3/8" & 1/2"
4 = depressurization, “Spitter-Type”, 1/4" ONLY
5 = depressurization, protected, “Spitter-Type” w/ filter
8 = port 1/8" female, free-flow
TF PORT
TF = NPTF
Blank = BSPP thread ports
FLOW DIAGRAMS
0 0
0 400 800 1200 1600 Q (Nl/min) 0 500 1000 1500 2000 2500 Qn (Nl/min)
14 28 42 56 Air Flow (SCFM) 18 35 53 71 88 Air Flow (SCFM)
6 0.4
4.5 0.3
3.0 0.2
1.5 0.1
0
0 500 1000 1500 2000 2500 Qn (Nl/min)
18 35 53 71 88 Air Flow (SCFM)
Pa = Inlet pressure
DP = Pressure Drop
Qn = Flow
The company reserves the right to vary models and dimensions without notice.
These products are designed for industrial applications and are not suitable for sale to the general public. 33
NORTH AMERICAN FRL CATALOG > Release 8.2
2
Coalescing filters Series MC
MODULAR FRL SERIES MC
The company reserves the right to vary models and dimensions without notice.
34 These products are designed for industrial applications and are not suitable for sale to the general public.
PRECAUTIONS AND WARNINGS
CONCERNING THE APPLICATION, INSTALLATION AND SERVICE OF MAC VALVES AND OTHER MAC VALVES PRODUCTS
The warnings and precautions below are important to be read and understood before OPERATING SPECIFICATIONS -
designing into a system any MAC Valves products, and before installing or servicing any MAC Valves MAC Valves products are to be installed only on applications that meet all operating specifications
product. Improper use, installation or servicing of any MAC Valves product in some systems could described in the MAC catalog for the MAC Valves product.
create a hazard to personnel or equipment. No distinction in importance should be made between
the terms warnings and precautions. MANUAL OPERATORS-
Most MAC valves can be ordered with manual operators. Manual operators when depressed, are
WARNING : . designed to shift the valve to the same position as would the corresponding solenoid or remote air
Under no circumstances are MAC Valves products to be used in any application or in any manner pilot operator if it were activated. Care must be taken to order a type, if any, that will be safe for the
where failure of the MAC Valves product to operate as intended could in any way jeopardize the physical location of the manual operator in the system. If intentional or accidental operation of a
safety of the operator or any other person or property. valve by a manual operator could cause personal injury or property damage, a manual operator
• Do not operate outside of pressure range listed on a valve label or outside of the designated should not be used.
temperature range.
• Air supply must be clean and dry. Moisture or contamination can affect proper operation of the REMOTE AIR OPERATED VALVES
valve. Pilot valves supplying signal pressure to remote air operated valves should be 3-way valves with
• Before attempting to repair, adjust or clean a MAC Valves product, consult catalog, parts & operation adequate supply and exhaust capacity to provide positive pressurizing and exhausting of the pilot
sheet, or factory for proper maintenance procedures, lubrication and cleaning agents. Never supply line. Pilot lines should be open to exhaust when valves are deenergized.
attempt to repair or perform other maintenance with air pressure to the valve.
• If air line lubrication is used do not use any lubrication other than those recommended in the INSTALLATION PRECAUTIONS : .
catalog, parts & operation sheet or by the factory. A. Do not install any MAC Valves product without first turning off air (bleed system completely) and
electricity to the machine.
APPLICATION PRECAUTIONS : . B. MAC Valves products should only be installed by qualified, knowledgeable personnel who
INDUSTRIAL USE - understand how the specific valve is to be pneumatically piped and electrically connected (where
• MAC Valve products are intended for general use in industrial pneumatic and/or vacuum systems. applicable). Flow paths through the valve are shown in the catalog and on the valve by use of ANSI
They are general purpose industrial products with literally thousands of different applications in or ISO type standard graphic symbols. Do not install unless these symbols and the valve functions
industrial systems. These products are not inherently dangerous, but they are only a component of and operations are thoroughly understood.
an overall system. The system in which they are used must provide adequate safeguards to prevent C. If air line lubrication is used do not use any lubrication other than those recommended in the
injury or damage in the event failure occurs, whether it be failure of switches, regulators, cylinders, catalog, parts & operation sheet or by the factory.
valves or any other component.
SERVICE PRECAUTIONS :
POWER PRESSES - A. Do not service or remove from service any MAC Valves product without first shutting off both the
MAC Valve products are not designed nor intended to be used to operate and/or control the air and electricity to the valve and making certain no pressurized air which could present a hazard
operation of clutch and/or brake systems on power presses. There are special products on the market is retained in the system.
for such use. B. MAC Valves products should only be serviced or removed from service by qualified, knowledgeable
personnel who understand how the specific product is used and/or how the specific valve is piped
2-POSITION VALVES - and used and whether there is air retained in the connecting lines to the valve or electric power still
Some MAC valves are 2-position, 4-way valves. When air is supplied to the inlet port(s) of these valves, connected to the valve.
there will always be a flow path from the inlet to one of the outlets regardless of which of the two C. Before attempting to repair, adjust or clean a MAC Valves product, consult catalog, parts &
positions the valve is situated. Therefore, if pressurized air retained in the system would present a operation sheet, or factory for proper maintenance procedures, lubrication and cleaning agents.
hazard in the application or servicing of the valve or system, a separate method in the system must Never attempt to repair or perform other maintenance with air pressure to the valve.
be provided to remove the trapped air. D. MAC Valves products are never to be stepped on while working on a machine. Damage to a MAC
valve, or other product or lines to the product (either air or electrical lines) or accidental activation
3- POSITION VALVES- of a manual operator on the valve could result in personal injury or property damage.
Some MAC valves are 3-position, 4-way valves. These valves are either double solenoid or double
remote air operated. LIMITATION OF GUARANTEE .
If either of the two operators is in control, air supplied to the inlet port(s) will pass through the valve This Guarantee is limited to the replacement or rebuilding of any valve or other product which should
to one of the outlets as on 2-position, 4-way valves. However, if neither operator is in control, the fail to operate properly. Valves or other products, under the MAC Guarantee, must be returned (with
valve moves to a center position. Listed below are the various center position functions : or without bases) transportation prepaid and received at our factory within the Guarantee period.
They will be returned to the customer at the expense of MAC Valves, Inc., and will carry the same
A. CLOSED CENTER- guarantee as provided under the Flat Rate Rebuild Program.
With this type valve, when in the center position all ports are blocked (inlets and exhausts) meaning
the air at both outlet ports is trapped. If trapping the air in both outlet ports would present a hazard DISCLAIMER OF GUARANTEE .
in the application or servicing, a separate method in the system must be provided to remove the No claims for labor, material, time, damage, or transportation are allowable nor will any valve or other
trapped air or this type valve should not be used. product be replaced or rebuilt under this guarantee which has been damaged by the purchaser not
in the normal course of its use and maintenance during the warranty period. The guarantee does not
B. OPEN CENTER- apply to loss or damage caused by fire, theft, riot, explosion, labor dispute, act of God, or other causes
With this type valve, when in the center position, the inlet port(s) is blocked and the two outlet ports beyond the control of MAC Valves,Inc. MAC Valves, Inc. shall in no event be liable for remote, special
are open to the exhaust port(s) of the valve. If having no air in either outlet port would present a or consequential damages under the MAC Guarantee, nor under any implied warranties, including
hazard in the application or servicing, this type valve should not be used. the implied warranty of merchantability.
C. PRESSURE CENTER- The above Guarantee is our manner of extending the engineering and service resources of the MAC
With this type valve, when in the center position, the inlet port(s) is connected to both outlet ports of Valves, Inc. organization to assure our customer long, and continued satisfaction.
the valve. If having pressurized air to either or both outlet ports would present a hazard in the
application or servicing of the valve or system, a separate method in the system must be
provided to remove the retained air or this type valve should not be used.
327
Chute Pivot
Part List:
Page 78 www.ctmmixers.com
Chute Pivot Maintenance
Main Pivot
Grease Zerk
Roller
Grease
Zerks
(See Drum
Roller Maintenance)
Manual Chute
Lock
# 770003
Rear Pedestal
A-Frame
Main Chute
Cylinder
Clevis
# 770004
Page 79 www.ctmmixers.com
Hydrostatic Pump and Motor Maintenance
Hydraulic Fluid b. Typically not shear stable in
high pressure piston pumps.
1. ISO 68 - Ambient Less than 80° F B. High viscosity index
A. Specifications 1. 130-150
1. SUS @ 210° F = 55-60
2. Viscosity Index = 100-120 6. Automatic Transmission Fluid (ATF)
3. Pour Point = 25° F Average A. Should not be substituted in hydrostatic
mixers
2. ISO 100 - Ambient More than 80° F B. Is not shear stable in high pressure piston
A. Specifications 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
3. Looses hydrodynamic film
3. Recommended Additives 4. Not always compatible with hydraulic
A. Anti-Corrosion fluid
B. Anti-Rust 5. Normally higher priced than hydraulic
C. Antioxidant fluid
D. Anti-Foam
E. Anti-Wear 7. Water Base Oil
F. Emulsifier A. DO NOT USE in hydrostatic systems
G. Detergent B. Shortens lifetime of hydrostatics
Page 81 www.ctmmixers.com
Hydrostatic Pump and Motor Maintenance
B. Filter must withstand 20 inches of mercury
2. Suction Hose Applications
A. SAE100R4 or equivalent 6. Many Filters Do Not Qualify
1. 28” Vacuum A. Incorrect beta ratings
2. 200 PSI maximum 1. B10 = 2 minimum
3. Aeroquip FC310, 2661 or equivalent
Hydraulic Fluid Fan Cooler
3. Chute Hose Applications
A. SAE100R2 or DIN 20 022 1. Flow Capacity is Determined by Charge Pump
1. Minimum operating pressure of 3,000 Flow
PSI required A. 1.28 charge pump @ 2,000 RPM = 10.5 GPM
2. Aeroquip GH781 or equivalent @ 95% efficiency
B. 12 Volt fan cooler
4. Closed Loop System (Hydrostatic Pump & 1. 19,000 BTU w/ ram air
Motor) A. SAE100R12 2. 15,000 BTU w/ fan air
1. Minimum operating pressure of 4,000 3. Fan temperature switch to activate
PSI fan @ 157°F
2. GH493 or equivalent 4. ZF mount is Standard
Page 83 www.ctmmixers.com
Hydraulic Pump
Hydraulic Pump
Hydraulic Motor
Hydraulic Reservoir
www.ctmmixers.com
Hydraulic Test Kit
When servicing your Con-Tech mixer, it is best to have the proper tools and equipment
to do the job. Con-Tech offers a hydraulic test kit to properly check and diagnose your
mixer’s hydraulic system. To purchase, call our Parts Sales Department.
For use, troubleshooting, and how to, please review the “Troubleshooting” section.
For Instructions on hooking up your hydraulic test kit, please refer to pages 4 & 5 in the
Eaton Troubleshooting Guide For Eaton Hydrostatic Transmissions used on Concrete
Mixers No. 3-406.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Part # 799600
Page 85 www.ctmmixers.com
Troubleshooting Pumps and Motors
#1 #2 Call
Inspect Inspect Con-Tech
Control Control Service
507-374-2239
Linkage Valve
Repair or Repair or
Replace Replace
if Defective if Defective
#1 #2 #3
Inspect Inspect Inspect
Control Control Relief
Linkage Valve Valve
#5
#4 Inspect Call
Inspect Charge/ Con-Tech
Shuttle Service
Check
507-374-2239
Valve Valve
Repair or Repair or
Replace Replace
if Defective if Defective
See Pumps and Motors Steps and Actions for Additional Information
Page 86 www.ctmmixers.com
Troubleshooting Pumps and Motors
#12 Call
#2
Check Con-Tech
Inspect Service
Charge Control 507-374-2239
Pressure Valve
Repair or
Replace
if Defective
Low
Low Low In In
In Charge Or Neutral,
Charge Or
Neutral Discharge
Discharge
Call
Con-Tech
Service
507-374-2239
See Pumps and Motors Steps and Actions for Additional Information
Page 87 www.ctmmixers.com
Troubleshooting Pumps and Motors
#8
#6 #12
#7 Inspect
Check Oil Check
Inspect Oil External Oil
Level In Charge
Cooler Cooler (If
Reservoir Pressure
Used)
Repair or
Low Replace
Replace
if Defective
if Defective Low High In
In Charge or
Fill To Neutral Discharge
Correct Level
#13 #14
#15 Inspect Inspect
#9, 10
Inspect Charge Charge
Inspect Inlet
Charge Relief Valve Relief Valve
Filter
Pump @ Pump @ Motor
Call #11
Con-Tech Check
Service System High
507-374-2239 Pressure
Low
#3
Replace Inspect
if Defective Relief Valves
See Pumps and Motors Steps and Actions for Additional Information
Page 88 www.ctmmixers.com
Troubleshooting Pumps and Motors
Mixer Drum Does Not Operate In Either Direction...
#8
#6 #1 #2
Inspect Check
Check Oil Inspect Inspect
External Oil Charge
Level In Control Control
Cooler (If Pressure
Reservoir Linkage Valve
Used)
Repair or Repair or
Low Replace
Replace Replace
if Defective
if Defective if Defective
Fill To
Correct Level
Low
In High In
Neutral, Charge or
Charge Or
Discharge
Discharge
#13 #14
#15 Inspect Inspect
#9, 10
Inspect Charge Charge
Inspect Inlet
Charge Relief Valve Relief Valve
Filter
Pump @ Pump @ Motor
Call #11
Con-Tech Check
Service System High
507-374-2239 Pressure
#3
Replace Inspect Low
if Defective Relief Valves
See Pumps and Motors Steps and Actions for Additional Information
Page 89 www.ctmmixers.com
Pump and Motor Steps And Actions
1. Inspect control linkage for: charge pump) for:
a. Cables out of adjustment, binding, broken, etc. a. Damaged or missing O-ring
b. Cables not coordinated with control valve b. Damaged check ball seat
neutral c. Stuck check ball
c. Arm on control valve slipping on control valve
shaft splines. Cable bracket loose or installed 6. Check Oil Level In Reservoir:
incorrectly a. Follow the manufacturer’s recommendations
b. Normally oil should be to the sight glass with all
2. Inspect control valve for: cylinders retracted
a. Plugged control orifice c. Do not overfill reservoir
b. Damaged mounting gasket
c. Mis-adjusted, damaged or broken neutral return 7. Inspect Oil Cooler for:
spring a. Obstructed air flow from dirt, grease, etc. on the
d. Broken control connector pin outside of the cooler
e. Broken or missing control linkage pins b. Improper plumbing
f. Galled, stuck, or contaminated control spool c. Obstructed oil flow through the cooler; may
g. Exchange control valves with a units which require flushing the cooler or a new cooler
works properly to verify the control valve is at
fault 8. Inspect External Oil Cooler Bypass(if used):
a. Broken, clogged, or defective bypass valve
3. *Inspect relief valves for: b. The Con-Tech cooler has an internal bypass
a. Improper pressure relief setting rather than an external bypass
b. Damaged or missing O-ring and backing ring
c. Plugged orifices 9. Vacuum Hose Should Be Inspected for:
d. Center spool galled, stuck, or contaminated a. SAE 100R4 rating - This hose must be corrector
e. Poppet style relief valve may be stuck open or the internal liner may collapse under vacuum
contaminated applications. Pressure hose will not work.
f. Older style motors have the high pressure relief
valves installed in a manifold on the rear of the 10. Inspect Inlet Filter for:
motor. a. Plugged or clogged filter element
g. Newer Eaton systems have poppet style high b. Obstructed inlet or outlet
pressure relief valves (called power limiters) c. Incorrect rating filter (should be 10 micron filter
installed in the pump. These power limiters can be designed for vacuum applications)
exchanged from port to port for test purposes. d. High vacuum (10” maximum vacuum when oil
is warm)
4. Inspect shuttle valve (located on the end of the
motor) for: 11. Check System High Pressure:
a. Bent or broken return centering spring a. See the test pages showing gauge installation
b. Galled, stuck, or contaminated spool and test procedures.
c. Bent or broken shuttle spools. Excess wear b. An empty drum will normally register
approximately 500 PSI on the test gauge
5. Inspect Charge Check Valves (located behind c. A loaded drum will normally register from 2,500
Page 90 www.ctmmixers.com
Pump and Motor Steps And Actions
-3,500 PSI on the gauge depending on the load and b. Damaged or missing O-ring
slump of the concrete in the drum c. Broken drive key
d. WARNING: Do not attempt to “lock up” the d. Excessive gerotor clearance
system or prevent the drum from turning to test e. Galled or broken gerotor set
high pressure. The result may be serious damage to
the system and serious personal injury. *Charge Relief Valve and High Pressure Relief
Valve Identification: The relief valves are factory
12. *Check charge pressure: preset. The pressure code is stamped on the hex
a. Charge pressure is checked by installing a plug located on the end of the valve cartridge.
0-600 PSI gauge in the O-ring port on the top To determine the pressure setting on the motor
of the pump. See the test pages showing gauge manifold high pressure relief valves, add a zero
installation and test procedures. to the right of the stamped number (Eaton up to
b. Charge pressure on the Eaton hydrostatic 1987).1988 and newer high pressure relief valves
systems normally reads 240 - 260 PSI on the gauge (power limiter) located in the Eaton pump are
when the pump is in neutral. The reading should marked internally. They must be removed to see
drop 60 PSI when the pump is put in charge or the number.
discharge.
c. A minimum reading of approximately 150 PSI Charge Pressure High Pressure
on the gauge is required to turn the drum Relief Valves Relief Valves
13. *Inspect Charge Relief Valve at Pump for: 016 = 160 PSI 500 = 5,000 PSI
a. Improper charge relief pressure setting 022 = 220 PSI 550 = 5,500 PSI
b. Plugged orifice
c. Spool galled, contaminated, or stuck open or
closed
d. Damaged or missing O-ring
e. Poppet valve held off seat
f. Exchange a known good charge relief valve from
another pump to verify the relief is the problem
Page 91 www.ctmmixers.com
Hydraulic Pump
Your Con-Tech Mixer comes equipped with an Eaton 54 Series Variable displacement
hydraulic pump. This pump is responsible for turning the drum (both direction and
speed). Power is supplied to the pump via the rear engine pto and drive shaft.
The pump (and drum speed/direction) can be controlled via two different methods:
1: Cable Control: The drum direction and speed is controlled by moving the cable
control arms (located on cab console and on rear control box). In order to place the
drum in neutral, you place the cable control arm in the “middle” of it’s travel range.
For emergency drum operation on trucks equipped with RE controls, please see the
following instructions: See Page’s 78-79
Regular hydraulic fluid and filter changes are a requirement for warranty coverage as
well as maintaining the performance of your Con-Tech mixer. Eaton and Con-Tech
require a fluid and filter change after the first 100 hours of operation. This will ensure
the removal of break in contamination as well any other debris in the hydraulic system.
The most contamination your hydraulic system will see will be in this first 100 hours.
After this break in, Eaton and Con-Tech suggest fluid and filter replacement every 6
months or 1000-1200 hours (whichever comes first).
Con-Tech trucks come factory filled with Chevron Rando HD ISO 68 oil
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 92 www.ctmmixers.com
Hydraulic Pump
Parker Pump
Case Drain
RE Pump
to Reservoir
High Pressure
To Filter
Case Drain
to Reservoir
Parker Pump
Suction From
Filter
Page 93 www.ctmmixers.com
Hydraulic Motor
Your Con-Tech mixer is equipped with an Eaton fixed displacement motor (located
on the front of the ZF drive transmission). This motor is responsible for taking the
hydraulic flow (and fluid direction) from the pump and driving the drum.
This motor requires VERY little maintenance. The biggest maintenance item that you
could see from the motor is the output shaft seal leaking. If you find the ZF gearbox
leaking gear lube from the output seal (and running down the head of the drum),
immediately check the fluid level in the ZF drum drive. Take precaution in removing
the dip stick from the ZF gearbox, as a leaking output seal from the hydraulic motor
will create a small amount of pressure inside the ZF unit. Removing the dipstick quickly
will result in a spray of gear lube from the gearbox.
If you find the gearbox to be overfilled, a failed output seal on the hydraulic
motor is likely the cause. The motor output shaft is leaking hydraulic fluid and the case
pressure of the hydraulic system is pushing hydraulic fluid into the gearbox. Prior to
performing ANY repairs, allow system to cool.
Seal Replacement:
1. Remove the four bolts holding the motor to the gearbox
2. Slide the motor back out of ZF input housing and rotate upward
3. Remove snap ring that is located on output shaft (of the motor) and remove
4. Remove lip seal located behind snap ring
5. Drive in new lip seal and install new snap ring (included in seal kit)
6. Re-Install motor on gearbox input housing and verify operation
7. Change gear lube in gearbox to remove hydraulic fluid
8. Run drum in charge for 20-30 minutes, inspect for leaks and re-check gearbox fluid
level
Con-Tech trucks come factory filled with Chevron Rando HD ISO 68 oil
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Page 94 www.ctmmixers.com
Hydraulic Motor
Motor
Rear
Slump Gauge Gear Box
#4 hose size
Case Drain
To Pump
#12 hose size
Case Drain
To Pump
#12 hose size
Pump To
Fan Cooler
#12 hose size
High Pressure
High Pressure
From Pump #16 hose size
From Pump #16
hose size
Page 95 www.ctmmixers.com
“RE” Pump Controls
In the event of an ELECTRICAL failure in the pump control
system, please see below for the override procedure to control the
direction and speed of the drum.
3. Now the electric portion of the controls has been “locked out”
and the pump direction/speed is being controlled by the manual
lever arm (#3 shown below). By rotating the lever arm in/out,
you will now control the drum speed and direction. The neutral
position of the lever arm will cause the drum to come to a stop.
(Image C)
B.
4. After the situation has been resolved, to return the pump
control to the electric controller, you must return the manual
lever (#3) to the middle neutral position.
5. Next screw the outer handle (#2) clockwise and snug it down
with a pliers or channel locks.
6. You must then turn the set nut (#1) clockwise and snug that
down also with pliers or channel locks. C.
Page 96 www.ctmmixers.com
“RE” Pump Controls
RE Pump
Charge /
Discharge
Coils
Start / Stop
Coil
Arm
(Manual Override)
Ref #3
RE Pump
Arm
(Manual Override)
Ref #3
Page 97 www.ctmmixers.com
Hydraulic Reservoir
Your Con-Tech mixer has either a 13 gallon oil reservoir(Extreme Duty), or a 18 gallon reservoir
(BridgeKing). Because BridgeKing trucks have the additional BridgeKing cylinder and high flow, a
larger, vented oil reservoir is required. A 10 micron breather cap must be installed on all BridgeKing
oil reservoirs.
Check the reservoirs oil level using the site glass on the end of the reservoir. If oil is not visible in the
site glass, oil must be added. (Always Check with the BridgeKing Cylinder/Arm in the Up Position!)
Always establish a routine, and use care when filling your oil reservoir. Clean off the fill tube and cap
before removing the cap or breather to fill your reservoir. This reduces the risk of contamination.
Use only approved Hydraulic Fluid – Do Not Use ATF OR ENGINE OIL
Con-Tech trucks come factory filled with Chevron Rando HD ISO 68
For parts, refer to page 32 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
Site Glass
Page 98 www.ctmmixers.com
CHEVRON RANDO® HD
ISO 10, 22, 32, 46, 68, 100, 150, 220, 320
CUSTOMER BENEFITS APPLICATIONS
Chevron Rando HD oils deliver value through: Chevron Rando HD ISO 10 and 22 can be
used as spindle lubricants or as telemotor
• Longer equipment life — Special antiwear
oils aboard ships.
additive package reduces wear by protecting
surfaces when load causes breakdown of the Chevron Rando HD ISO 32, 46, or 68 are
lubricant film. recommended for:
• Reduced downtime — Effective rust and • vane-, piston-, or gear-type pumps, especially
oxidation inhibitor system prevents the production where pressures exceed 1000 psi
of abrasive particles from rust formation, and • lightly loaded reciprocating compressors
deposits, varnishes and sludges from oil breakdown, • motors and bearings
which can damage equipment surfaces and seals,
and block filters prematurely. Chevron Rando HD ISO 100, 150, or 220 are
recommended for:
• Trouble-free operation — Good hydrolytic
• hydraulic equipment reduction gears
stability and water separation characteristics provide
excellent filterability in the presence of water • reciprocating air compressors
contamination. Good anti-foam and air release • plain and antifriction bearings
properties ensure smooth operation and system • circulating oil systems
efficiency.
• Extended oil service life — High oxidation Chevron Rando HD oils are approved for:
stability resists oil thickening and deposit formation • Eaton-Vickers 35VQ25A pump, M-2950-S
in service, eliminating the need for unscheduled (Mobile) and I-286-S (Stationary) (ISO 32, 46, 68)
change of hydraulic fluid. • Denison HF-0/T6C, HF-2 (ISO 32, 46, 68)
• Bosch Rexroth (ISO 32,46, 68)
FEATURES Chevron Rando HD oils meet the requirements of:
Chevron Rando HD ISO 32, 46, and 68 are designed • MAG Cincinnati, Cincinnati Machine P-68 (ISO
to give maximum hydraulic pump protection in mobile 32), P-70 (ISO 46), P-69 (ISO-68)
and stationary systems. They are formulated with • General Motors LS2 Specification, LH for anti-wear
ISO SYN® base stocks. hydraulic fluids (ISO 32, 46, 68)
Chevron Rando HD ISO 100, 150, and 200 are • ANSI/AGMA 9005-D94, Industrial Gear
designed for all types of lubricant applications where a Lubrication, for gear lubrication as rust and
premium antiwear lubricant in their ISO viscosity grade oxidation inhibited gear oils (ISO 46, 68, 100, 150,
is required, such as an AGMA Gear Lubricant or general 220)
machinery lubrication. • DIN 51524-2
Chevron Rando HD oils provide excellent: Chevron Rando HD ISO 32, 46, 68, 100, 150, 220,
and 320 are certified by NSF and are acceptable as
• antiwear protection lubricants where there is no possibility of food contact
• oxidation and corrosion inhibition (H2) in and around food processing areas. The NSF
• foam and aeration suppression Nonfood Compounds Registration Program is a
continuation of the USDA product approval and listing
Under moderate loads and temperatures, the high program, which is based on meeting regulatory
viscosity index of Chevron Rando HD oils assures good requirements of appropriate use, ingredient review and
film strength between metal surfaces and is further labeling verification.
enhanced by antiwear additive protection.
Do not use in high pressure systems in the vicinity of
flames, sparks and hot surfaces. Use only in well
ventilated areas. Keep container closed.
©2009 Chevron Products Company, San Ramon, CA. All rights reserved. 12 March 2009
All trademarks are the property of Chevron Intellectual Property LLC. IO-170
www.ctmmixers.com
TYPICAL TEST DATA
©2009 Chevron Products Company, San Ramon, CA. All rights reserved.
www.ctmmixers.com
Typical test data are average values only. Minor variations which do not affect product performance are to be expected in normal manufacturing.
IO-170
12 March 2009
Hydraulic Suction Filter
Every Con-Tech mixer uses a 10 micron hydraulic suction filter to protect the hydraulic
system from contaminates. This filter is placed in the suction line to the pump.
You should change your filter every time you replace your hydraulic fluid. When a
mixer is new, the filter and fluid must be changed at 100 hours. After the initial
service, change after 1000 hours, or every six months(ONLY USE APPROVED OEM
FLUIDS). Always check your suction filter vacuum gauge when the oil is at operating
temperature. At operating temperature you should read between 0 to 5 inches of
vacuum. If your reading over 10-15 inches of vacuum you should check your gate valve
to make sure it is open, or replace your fluids and filter.
Use only approved Hydraulic Fluid – Do Not Use ATF OR ENGINE OIL
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Suction Line
To Chute Pump
Pump #12 hose size
1 1/4”
Gate
Valve
# 760005
Suction
Line to
Charge
Pump
#16 hose size
Oil Filter
Housing
# 735001 Vacuum
Gauge
# 760001
1 1/4”
Gate
Valve
# 760005
Hydraulic Filter
# 735000
The cooler is designed to come on at 158°F. As a general rule of thumb, your hydraulic
system will run approximately 100°F above ambient (outside) temperature. This gives
you an idea of when you should expect (or not to expect) to see the cooler running.
During times of heavy use or extreme heat, it is not uncommon to see the cooler
running continuously.
The LED indicator in the cab console will light yellow when the cooler is running. If the
light/fan come on immediately when ignition key is turned on (when system is cold)
OR you do not see the light on (in times of extreme use or heat), please contact your
maintenance manager OR Con-Tech Service at 507-374-2239 immediately. Prolonged
use with an inoperative fan cooler (or a continuously operating fan cooler) can cause
damage to the electrical system and/or hydraulic system.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Hydraulic
Fan Cooler Assy
# 740010
Slump Gauge
0-3000# - 760007
Hydraulic
0-5000# - 760002
Fan Cooler Assy
# 740010
Fan
Controller
# 740011
Temp Switch
# 740013 - 3/4”
# 740012 - 3/8”
(Old Style)
Gear Box
Slump Gauge
0-3000# - 760007 Part # 740010
0-5000# - 760002
Hydraulic
Fan Cooler
# 740010
Pump To
Cooler To
Fan Cooler
Part # 740010 Reservoir
#12 hose size
#12 hose size
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Identification Tag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Valve Block Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Motor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Dis-assembly Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Dis-assembly/Assembly Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Dis-assembly End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dis-assembly Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Assembly Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Assembly End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Assembly Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Assembly Valve Block/Integral Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29
Hydraulic Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
2 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Introduction
This manual will provide you with service information and procedures for disassembly and reassembly of Eaton® Series 1 Heavy Duty Hydrostatic Fixed
Displacement Motors – Models 33, 39, 46, 54, and 64. Procedures outlined in this manual will allow you to better service your motors and obtain the best
results possible. To ensure accuracy of repair and prevent part loss or damage, certain components or subassemblies are disassembled, inspected, and
reassembled when removed from the motor.
Note: All requests or inquiries must be accompanied by the complete model and serial number.
Important: Cleanliness is extremely important when repairing a hydrostatic pump or motor. Before disconnecting the lines, clean foreign material
from exterior of unit. Work in a clean area. Clean all metal parts in clean solvent. Blow parts dry with air. Don’t wipe parts with cloth or paper towel,
because lint or other matter could cause damage. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage.
Don’t use coarse grit paper, files or grinders on parts.
Note: All torque specifications are for lubricated threads. Bolts for gasketed surfaces should be checked for proper torque.
A good service policy is to replace all old seals with new seals whenever unit is disassembled. Lubricate seals (except metal sealing surfaces of shaft
seal assembly) with petroleum jelly. Use only clean, recommended oil when assembling unit. See Hydrostatic Fluid Recommendations on page 28-29 or
publication 03-401 and 03-405.
ID Tag
A B C
Eaton
Refer to specific motor assembly A - Displacement (cu.in./rev.) Model No. 0000 00 - 000
part listings for your Eaton motor 0033 = 3.3 Serial No. 00 00 000000
when ordering replacement parts. 0039 = 3.9 Rotation
Parts Lists are available from Eaton. Eaton Corporation
0046 = 4.6 D Hydraulics Division
Sample tag shows motor 0054 = 5.4 Spencer, Iowa 51301
identification. 0064 = 6.4
When ordering replacement parts, B - Identifies Type of Product E F
you must include the
31 = Fixed Displacement Motor with Face Seal
following information:
33 = Fixed Displacement Motor with Lip Seal
C - Identifies Specific Unit Configuration
D - Month of Manufacture
E - Year of Manufacture
F - Specific Serial Number of Unit
Tools Required
• Stationary Seal Puller (1/4 • 1/4 in. Hex Key • Clean Lint Free Rags
in. x 20 UNC capscrew,
3 to 4 in. long) • Loctite® No. 271 Special Tools needed
(shown on pages 26 and 27).
• Retaining Ring Pliers, • Pliers
No. 5 or 7 • Bearing Cone Driver
• Punch
• Breaker Bar or Ratchet • Rotating Seal Puller
• Magnetic Base Indicator
Wrench • Limit Stop for Bearing
• Hammer Cone Installation
• 1-3/8 in. Hex Wrench
• Bearing Press or Driver • Headless 5/16 in. Cap
• 1 in. Hex Wrench Screws, 5 to 6 in. Long (2)
• Light Petroleum Jelly
• 9/16 in. Socket • Low Clearance Bearing
• Cleaning Solvent Puller
• 5/8 in. Socket
• Micrometer or Vernier
• Torque Wrench Calipers
(200 lb-ft capacity)
• Small Screwdriver
• 1/4 in. Hex Bit Socket (1/8 in. blade)
EATON Series 1 heavy Duty Hydrostatic Fixed Displacement Motors Repair E-MOPI-TS002-E September 2004 3
Parts
Assembly Drawing
Motors with Valve Blocks Motors with Integral Shuttle and Low
Pressure Relief Valves
A
B
E C
D
F
End Cover
with Integral K
Shuttle and C 31
Low Pressure B
Relief Valve K
A
6
or
End Cover 2 I
with Valve 5 J
Block 6
24 5 G
6
6
35
25 2
4
24
5
8 10
1
9
3
24 5
6 6
7
7 7
23
990709-000
21 Lip Seal
Motors P/N XX33-XXX 15
(Current version)
16
or 19 14
990231-000
Face Seal
Motors P/N XX31-XXX
17
18
13
4 EATON Series 1 Hydrostatic Fixed Motors Repair E-MOPI-TS002-E September 2004
Parts
Table 1.0 Parts List
ITEM REFERENCE
NO. PART NO. QTY. DESCRIPTION PAGES
1 See Table 2.0 1 Output Drive Shaft Subassembly for Motors with Lip Seal XX33-XXX (Current Production) 6
1 See Table 2.1 1 Output Drive Shaft Subassembly for Motors with Face Seal XX31-XXX 6-8
2 See Table 3.1 1 End Cover Subassembly for Motors with Integral Shuttle and Low Pressure Relief Valve 9
3 See Table 4.0, 4.1 1 End Cover for Motors with Valve Block Subassembly 10
3 See Table 4.2 1 Valve Block Subassembly 10
4 See Table 6.0 1 Fixed Motor Housing Subassembly 13
5 See Table 4.0 2 Hex Head Bolt 3/8-16 GR 8 9
6 See Table 4.0 4 Hex Head Bolt 3/8-16 GR 8 9
6 See Table 4.0 6 Hex Head Bolt 3/8-16 GR 8 9
7 See Table 4.0 4 Hex Head Bolt 3/8-16 GR 5 9
8 8775-021 1 Square Cut Seal Ring
9 8765-118 2 O-ring
10 101129-000 2 Back-up Ring
13 103224-000 1 End Cover Gasket (model 33/39/46)
13 103877-000 1 End Cover Gasket (model 54/64)
14 98202-000 3 Dowel Pin (5/16 x 5/8 long)
15 103230-000 1 33/39 Motor Valve Plate
15 104189-000 1 46 Motor Valve Plate
15 105104-000 1 54 Motor Valve Plate
15 105099-000 1 64 Motor Valve Plate
16 See Table 7.0 End Cover Bearing Shims 13
17 See Table 6.0 1 Bearing Cup* 13
18 See Table 6.0 1 Bearing Cone* 13
19 See Table 5.0-5.2 1 Rotating Group Subassembly 12
21 See Table 7.0 1 Seal Kit for Motors with Lip Seal only XX33-XXX (Current Production) 13
21 See Table 7.0 1 Seal Kit for Motors with Face Seal only XX31-XXX 13
23 See Table 7.0 1 Retaining Ring for Lip Seal 13
24 96558-000 2 Lifting Strap (models 33/39/46)
24 96559-000 2 Lifting Strap (models 54/64)
25 103223-000 2 Sealing Washer
31 104511-300 2 Cap Screw, Socket Hd 3/8-16
35 95912-300 2 Cap Screw, Socket Hd 5/16-18
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 5
Parts
Drive Shaft
Shaft Retaining Ring Bearing Cone
(Item 1)
Table 2.0 Output Drive Shaft Assembly For Motors XX33-XXX (Lip Seal Design)
Models 3333-3933-4633
MODELS 5433-6433
6 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Parts
Drive Shaft Shaft Retaining Ring Bearing Cone
(item 1)
Table 2.1 Output Drive Shaft Assembly For Motors XX31-XXX (Face Seal Design)
MODEL 3331-3931
Model 4631
SHAFT BEARING RETAINING
ASSEMBLY SHAFT CONE RING DESCRIPTION
103579-000 103577-000 103227-000 103222-188 23 Tooth, 16/32, Pitch Spline
104190-000 104192-000 103227-000 103222-188 14 Tooth 12/24, Pitch Spline
105123-000 105121-000 103227-000 103222-188 21 Tooth, 16/32, Pitch Spline, Speed Sensor
105364-000 105365-000 103227-000 103222-188 20 Tooth, 16/32, Pitch Spline, 3/8-24 UNF x [.75] DP
105449-000 105448-000 103227-000 103222-188 19 Tooth, 16/32, Pitch Spline
106910-000 106909-000 103227-000 103222-188 20 Tooth, 16/32, Pitch Spline, Speed Sensor
107315-000 107314-000 103227-000 103222-188 [1.500] Diameter Straight W/ [.3750] X [2.5] Square key, 3/8-24 UNF x [.75] DP
109261-000 109260-000 103227-000 103222-188 14 Tooth 12/24, Pitch Spline, Speed Sensor
110107-000 110099-000 103227-000 103222-188 23 Tooth, 16/32, Pitch Spline, 3/8-24
111052-000 111051-000 103227-000 103222-188 [1.500] Diameter Taper W/ [.375] X [1.00] Square Key
111780-000 111779-000 103227-000 103222-188 19 Tooth, 16/32, Pitch Spline, Speed Sensor
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 7
Parts
Drive Shaft
(item 1) Shaft Retaining Ring Bearing Cone
Output Drive Shaft Assembly For Motors XX31-XXX (Face Seal Design)
Model 5431
MODEL 6431
8 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Parts
End Cover
(Item 2)
24 5
Table 3.1 End Cover with Integral Shuttle and 5
Low Pressure Relief Valve 6
7
ITEM PART
NO. NO. QTY. DESCRIPTION
7 7
A 104635-000 2 Shuttle Valve Plug/O-ring
B 101730-00 2 Shuttle Spring (Low–Rate)
B 102530-000 2 Shuttle Spring (High–Rate)
C 101727-000 2 Shuttle Valve
D 102418-000 1 Shuttle Spool
E 25090-008 1 Gauge Port Plug/O-ring
F 25090-006 2 Gauge Port Plug/O-ring
G 104634-000 1 Plunger
A
H See table 3.3 1 Low Pressure Relief Valve Spring B
I 104659-XXX A/R Low Pressure Relief Valve Shims E C
J 104657-000 1 Low Pressure Relief Valve Plug/O-ring D
K 8785-010 2 O-ring F
A/R – As Required
K
C 31
Table 3.2 Low Rate Shuttle Valve Service Kit B
K
Motors with Integral Shuttle A
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 9
Parts
Valve Block
(Item 3)
I
F H
G
Table 4.0 Valve Block Subassembly
D
ITEM
NO. P/N QTY. DESCRIPTION C
A 25090-004 3 Gauge Port Plug/O-ring
J
B 96083-062 4 Back-up Ring I 3
C 8765-017 3 O-ring H
D 8785-010 3 O-ring
G
E
E (See Table 4.2) 2 High Pressure Relief Cartridge 101047-XXX D
F (See Table 4.2) 1 Low Pressure Relief Cartridge 101048-XXX B
A C
G 101727-000 2 Shuttle Valve B
H (See Table 4.2) 2 Shuttle Spring
L 101729-000 2 Shuttle Valve Plug/O-ring B A
J 102418-000 1 Shuttle Spool C A
E B
D
10 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Parts
Valve Block Kits
VALVE
BLOCK *HPRV *HPRV SHUTTLE
S/A BLOCK A-PORT B-PORT LPRV SPRING DESCRIPTION
101732-XXX 107131-000 101047-XXX 101047-XXX 101048-016 101730-000 160 psi, LPRV, High Rate
102687-XXX 107131-000 101047-XXX 101047-XXX 101048-022 101730-000 220 psi, LPRV, High Rate
102769-XXX 107131-000 101047-XXX 101047-XXX 101048-020 101730-000 200 psi, LPRV, High Rate
103062-XXX 107131-000 101047-XXX 101047-XXX 103355-016 101730-000 160 psi, Orifice LPRV, Low Rate
103071-XXX 107131-000 101047-XXX 101047-XXX 101048-028 101730-000 280 psi, LPRV, High Rate
103533-XXX 107131-000 103114-XXX 103114-XXX 101048-028 101730-000 280 psi, LPRV, High Rate, HPRV w/THD. Retainer
104923-XXX 107131-000 103114-XXX 103114-XXX 103355-016 101730-000 160 psi, Orifice LPRV, Low Rate, HPRV w/THD. Retainer
104955-XXX 107131-000 103114-XXX 103114-XXX 101048-016 101730-000 160 psi, LPRV, High Rate, HPRV w/THD. Retainer
105941-XXX 107131-000 101047-XXX 101047-XXX 101048-028 102530-000 280 psi, LPRV, High Rate
105963-XXX 107131-000 103114-XXX 103114-XXX 103355-022 102530-000 220 psi, Orifice, LPRV, Low Rate HPRV w/THD. Retainer
105964-XXX 107131-000 103114-XXX 103114-XXX 101048-028 102530-000 280 psi, LPRV, High Rate, HPRV w/THD. Retainer
106707-XXX 101731-000 101047-XXX 101047-XXX 101048-018 101730-000 180 psi, LPRV, High Rate
107134-000 – – – – – End Cover Sealing Plate
107149-XXX 107131-000 103114-XXX 103114-XXX 103355-016 102530-000 160 psi, Orifice LPRV, Low Rate, HPRV w/THD. Retainer
107196-XXX 107131-000 101047-XXX 101047-XXX 103072-030 101730-000 300 psi, LPRV, High Rate
110618-XXX 107131-000 101047-XXX 101047-XXX 101048-024 101730-000 240 psi, LPRV, High Rate
*Note: High pressure relief setting XXX=lbf/in2
Table 4.4 Low Rate Shuttle Valve Service Kit Table 4.7 High Pressure Relief Valve Seal Kit
Table 4.6 Valve Block Sealing Kit Table 4.9 End Cover Sealing Plate Kit
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 11
Parts
Rotating Group
A
(Item 19)
10
9
Table 5.0 Rotating Group Subassembly B
8 5
Models 3331/3333
Subassembly 103247-000 7
ITEM PART NO. QTY. DESCRIPTION 4
A 103239-000 Rotating Group Subassembly 6
Include all except item 9, 10
B 990412-000 1 Barrel Kit (includes items 1 through 5)
1 103278-200 1 Retaining Ring 12 3
2 103242-000 1 Spacer Cyl Barrel Spring 2
3 103240-000 1 Cylinder Barrel Spring 1
4 103243-000 1 Spacer Shaft Spring
5 103245-000 1 Barrel and Sleeve S/A 11
6 990416-000 1 Hold-down Kit (See Table 6.2)
7 103244-000 1 Shoe Retainer Plate
8 101073-000 9 Shoe Piston Subassembly
9 103236-000 1 Fixed Clr Thrust Plate
10 103248-000 1 Swashplate Subassembly
11 103241-000 1 Bearing Plate
12 98202-000 2 Dowel Pin(5/16 x 5/8 long)
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 13
Parts
Kits
(Item 4)
MODEL PART NO. DESCRIPTION 990709-000 Shaft Seal Kit (Lip Design)
33-46 990014-000 End Cover Bearing Kit For Models 3333/3933/4633/5433/6433
54-64 990016-000 End Cover Bearing Kit PART NO. QTY. DESCRIPTION
33-46 990089-000 Mounting Flange Bearing Kit
108395-000 1 Drive Shaft Seal
54-64 990387-000 Mounting Flange Bearing Kit
101680-250 1 Retaining Ring
107836-000 1 Spacer
End Cover Shim Kits
14 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Disassembly
Shaft Seal
1. Remove the shaft seal following the procedure for your type of seal.
There are two types of shaft seals. Depending on the part number of your motor, either type of seal may have
been used. A unit MUST be serviced with the same type of seal as was originally installed. The seals are not
Note: Thoroughly clean the interchangeable.
exterior of the unit before dis
assembly. Make sure all open Important: Clean surface area around stationary seal assembly.
ports are sealed.
STEP C STEP D
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 15
Disassembly
Seal all open ports. Thoroughly clean exterior of motor before disassembly.
Cleanliness is extremely important when repairing a hydrostatic pump or motor. Work in a clean area, as the level of cleanliness maintained when
repairing the unit may affect performance. After washing the parts with clean solvent, blow dry the parts with filtered, moisture free air. Inspect all mating
surfaces. Replace all damaged parts. Do not use grit paper, files or grinders on finished parts.
Whenever a unit is disassembled, it is a good service policy to replace all seals. Lubricate the seals with petroleum jelly. Use only clean, recommended oil
when assembling the unit. See Hydrostatic Fluid Recommendations on page 28-29 or
publication No. 03-401 & 03-405 for recommended fluids.
Valve Block/
Integral Shuttle End
Cover
1. There are two types of Series 4. Using a 1-3/8 in. hex wrench,
1 hydrostatic motors. If your remove the low pressure relief
High Pressure
motor has an integral shuttle valve cartridge. Relief Valves
and low pressure relief valve,
go to step 14 on page 16. If Note: The low pressure relief
you have a motor with a valve valve doesn’t have back-up
block, continue with step 2. rings. There is only one O-ring
in the lower groove.
Motor with 5. Using a 1-3/8 in. hex wrench,
Integral Shuttle remove the two high pressure
and Low relief valves from valve block.
Pressure Low Pressure
Relief Valve Note: The high pressure Relief Valve
relief valves have two white
back-up rings and one O-ring in
the lower groove.
High and low pressure relief
settings are preset at the
factory. Stamping on cartridge
Motors with Valve Block identifies setting.
Disassembly See examples.
16 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Disassembly
6. Using a 1 in. hex wrench, 13. Install low pressure relief valve.
remove the two shuttle valve Torque valve to 75 lb-ft [100 Nm].
plugs. Then remove shuttle Shuttle
Valve Continue with step 19, page 15.
valve springs.
Plugs
Low
Pressure
Relief Valve
Shuttle Valve Spring
Shuttle Spool
Shuttle
Valve Shuttle
Spring Valve Table 8.0 Torque Specifications – lb-ft [Nm]
Plug
MODEL MODEL
8. Remove the three gauge port WHERE USED 33-39-46 54-64
plug assemblies. Gauge Port Plug Assembly 16 [22] 16 [22]
Gauge
Port Gauge Shuttle Cap 68 [92] 68 [92]
Plug Port High Pressure Relief Valve 25 [34] 25 [34]
Plug
Low Pressure Relief Valve 75 [100] 75 [100]
End Cover Bolts – Grade 8 39 [53] 63 [85]
Relief Valve (Feathering) 25 [34] 25 [34]
Socket Pipe Plug 16 [22] 16 [22]
Valve Block Mounting Bolts 28 [38] 28 [38]
Assembly
Assembly of
Valve Block
9. Install the three gauge port plug
assemblies. Torque to 16 lb-ft [22Nm]. Shuttle
Valve
10. Install shuttle spool and
Plugs
shuttle valves in valve block.
11. Install shuttle valve springs and shuttle
valve plugs. Torque plugs to 68 lb-ft
[92Nm].
Shuttle Valve Spring
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 17
Disassembly
Motor with Integral 14. Position the motor on its Low Pressure
Shuttle and Low Pressure mounting flange as shown. Relief Valve Shims
Relief Valve 15. Using a 1-3/8 in hex wrench,
remove the low pressure relief
valve.
Note: Retain the shims, they Shuttle
are used to adjust the relief Valve
setting.
16. Using a 1 in. hex wrench,
remove the shuttle valve
plugs.
Gauge Port
17. Remove shuttle valves and Plugs
shuttle spool.
18. Remove the gauge port plugs.
18 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Disassembly
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 19
Disassembly
Drift
Punch
20 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Assembly
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 21
Assembly
22 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Assembly
Guide –
Headless
End Cover Cap Screws (2)
Figure 23
16. After adjusting end play,
reposition motor on mounting
flange and remove end cover.
17. Install two dowel pins in face
Check Output Shaft of cylinder barrel subassembly.
End Play Freely lubricate bearing plate
with dowel pins and install it
15. You must check the end play on cylinder barrel
of the output drive shaft subassembly.
subassembly.
Install the end cover without
installing either valve or
bearing plates. This eliminates
spring tension against the
output shaft.
Install cap screws in end cover
and slowly and evenly tighten
them. On models 33/39/46
torque cap screws to 39 lb-ft
[53 Nm]. On models 54/64,
torque to 63 lb-ft [85 Nm].
Place and support motor
Temporary
assembly on end cover. Gently Assembly
tap output shaft inward with
hammer.
Install magnetic base indicator
on mounting flange with
gauge on output shaft end. .002 in. - .007 in.
Use pliers to grip output shaft
as low as possible. Pry
upward to determine shaft end
play. Indicator must read .002
to .007 inches [,05 to ,17 mm]
shaft end play. Magnetic
Base
If end play is incorrect, adjust Indicator
by adding or removing shims
under bearing cup located in
end cover.
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 23
Assembly
Shaft Seal
Installation
For best sealing results, Units Having Face Seal Retaining Ring
clean the metal-to-metal (xx31-xxx Part Number
seal surfaces. The cleaner Configuration) Stationary Seal Assembly
must evaporate and not
leave any residue, and 22. Reinstall the shaft seal Rotating Seal
must be compatible following the procedure for
with Viton. your type of seal. Retaining O-ring
a. Lubricate O-ring seal of Ring Pliers Puller
Do not touch these
surfaces. Coat with rotating seal. Then install (Bolt 1/4-20)
clean, filtered oil rotating seal with seal puller. Seal Puller
Ensure rotating seal O-ring is (refer to
before reassembly. Special Tools)
placed inside the rotating seal
before assembly onto the
output drive shaft.
Note: There are two types b. Lubricate O-ring seal of
of shaft seals. stationary seal subassembly.
Depending on the date Then install stationary seal
of manufacture, either subassembly.
type of seal may have c. Using a No. 5 or No. 7
been used. A unit retaining ring pliers, install
MUST be serviced with retaining ring (beveled side
the same type of seal of ring out).
as was originally
installed. The seals are
not interchangeable.
24 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Assembly
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 25
Assembly
Ensure the shaft sealing surface and housing seal bore 4. With the shaft seal on the bullet, insert bullet over drive
are clean and free of all dirt and debris to avoid shaft and into the seal pocket. Take care to ensure seal is
introducing any contaminants into unit. properly aligned with housing bore as seal is pressed in to
1. Grease the inside surface of seal that contacts shaft. minimize chance of damaging seal.
2. Select correct bullet and driver. Bullet and drive 5. Using the driver and a mallet, push the seal until the tool
shaft chamfer must align with each other leaving bottoms on the pilot of flange.
no gap between the bullet and shaft. Bullet should 6. Remove the tool and insert the retaining ring into the seal
pilot on shaft diameter so bullet cannot shift side to pocket. A spacer is required, whenever there is a
side, allowing step between bullet and shaft seal significant groove in the shaft from the seal. (A maximum
diameter. of two spacers may be used before the shaft must be
3. Press the new, greased shaft seal over a shaft bullet. replaced), place it between the shaft seal and the
Closed face of the shaft seal faces the closed end of retaining ring.
the bullet. 7. Using the tool and mallet, drive the seal, spacer(as
required if using, and retaining ring in until the retaining
ring snaps into place in the groove.
26 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Assembly
Motor with Integral 25. Install two outer gauge port plug
Shuttle and Low assemblies.
Pressure Relief Valve Torque to 25 - 31 lb-ft [18 - 23 Nm].
Install center gauge port plug assem- Low Pressure
bly. Relief Valve Shims
Torque to 40 - 48 lb-ft [30 - 35 Nm].
26. Lubricate and install shuttle spool and
shuttle valves. The smaller ends face
the center of the spool. Shuttle
Valve
27. Install the shuttle valve springs and
plugs.
Torque to 68 - 82 lb-ft [50 - 60 Nm].
28. Install the low pressure relief valve
plunger and spring. Lubricate and Gauge Port
insert the shims in the relief valve Plugs
plug. Install the plug over the spring,
making sure the shims are not dis-
lodged. Screw the plug in and torque
to 68 - 82 lb-ft [50 - 60 Nm].
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 27
Special Tools
Dimensions
MODEL A B C D Dim. C
33/39/46 4.0 1.5* 1.01 1.25
54/64 4.0 1.5* 1.30 1.48 Dim. B Caption??
*1.5 in. from shaft with splined drive for Dim. A
B pad Charge Pump
Model Number(s) Stamp
Material: C.R.S., Hardern to Rc 50-55
5 in.
Reinforcement Optional .19/.21
Available from
Owatonna Tool Co.
.87 R. (Typ.)
1.12 R. No. CAS - 1844
(Typ.)
Material: SAE 1074
Spring Steel
16 Ga. x .75 Wide
.75
Dimensions
Drive Shaft
MODEL A B C D
Bearing Cone
33/39/46 5.803 1.00/1.20 2.20/2.30 3.00 Min.
54/64 6.682 1.30/1.32 2.20/2.30 3.00 Min.
A
Headless Cap Screw
28 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Special Tools
Shaft Seal
Installation Tools
Model Number...........
Etched on this Face
in 1/8 in. High Letters
Dimensions
MODEL PART NO. B C Ø Ref D E FØ GØ
33/39/46 990469-001 1.060 .010
+
1.565 .132 .003+
13º 0’ 0°-15’
+ +
1.910 .003+
2.023 +.003
54/64 990469-002 1.25 +.010 2.071 .128 +.003 10º +0’+0°-15’ 2.313 +.003 2.435 +.003
54/64 990469-003 1.25 +.010 1.603 .138 +.003 20º +0’+0°-15’ 2.226 +.003 2.321 +.003
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 29
Hydraulic Fluid
Recommendations
Introduction The ability of Eaton hydrostatic components to provide the desired performance and life expectancy depends large-
ly on the fluid used. One of the most important characteristics to consider when choosing a fluid to be used in a
hydraulic system is viscosity. Viscosity choice is always a compromise; the fluid must be thin enough to flow easily
but thick enough to seal and maintain a lubricating film between bearing and sealing surfaces. Viscosity
requirements are specified later in this document.
Viscosity and Fluid temperature affects viscosity. In general, as the fluid warms it gets thinner and viscosity decreases. The
Temperature opposite is true when fluid cools.
When choosing a fluid, consider the start-up and operating temperatures of the hydrostatic system. Generally, the
fluid is thick when the hydraulic system is started. With movement, the fluid warms to a point where the cooling
system begins to operate. From then on, the fluid is maintained at the temperature for which the hydrostatic
system was designed.
In actual applications this sequence varies; hydrostatic systems are used in many environments from very cold
to very hot. Cooling systems also vary from very elaborate to very simple, so ambient temperature may affect
operating temperature
Cleanliness Cleanliness of the fluid is extremely important. Eaton recommends that the fluid used in its hydrostatic components
be maintained at ISO Cleanliness Code 18/13 per SAE J1165. The code allows a maximum of 2500 particles per
milliliter greater than 5µm and a maximum of 80 particles per milliliter greater than 15µm. When components with
different cleanliness requirements are used in the same system, the cleanest standard should be applied.
A reputable filter supplier can supply filter information.
Fluid Maintenance Maintaining correct fluid viscosity and cleanliness level is essential for all hydrostatic systems. Field testing and
monitoring are the only ways to get accurate measurements of system cleanliness. Test and establish fluid
maintenance schedules designed to meet the viscosity and cleanliness requirements.
Fluid Selection Premium grade petroleum based hydraulic fluids will provide the best performance. These fluids typically contain
additives that are beneficial. Eaton recommends fluids that contain anti-wear agents, rust inhibitors, anti-foaming
agents, and oxidation inhibitors. Premium grade petroleum-based hydraulic fluids carry an ISO VG rating.
SAE grade crankcase oils may be used, but it should be noted that these oils may not contain all of the
recommended additives. Using crankcase oils may increase fluid maintenance requirements.
Hydraulic fluids that contain V.I. (viscosity index) improvers, sometimes called multi-viscosity oils, may be used.
These V.I.-improved fluids are known to “shear-down” with use. Their actual viscosity drops below the rated value.
Fluid maintenance must be increased if V.I.-improved fluids are used. Automotive automatic transmission fluids
contain V.I. improvers.
Synthetic fluids may be used. A reputable fluid supplier can provide information on synthetic fluids.
Review applications that require the use of synthetic fluids with your Eaton representative.
30 EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004
Hydraulic Fluid
Recommendations
Viscosity/Cleanliness ISO
Guidelines OPTIMUM CLEANLINESS
MINIMUM RANGE MAXIMUM REQUIREMENTS
10cSt 16 - 39 cSt 2158 cSt 18/13
[60 SUS] [80 - 180 SUS] [10,000 SUS]
Biodegradable Oil Additional Notes: • Vegetable oil is miscible with mineral oil.
(Vegetable) Guidelines • Viscosity and ISO cleanliness requirements However, only the vegetable oil content is
must be maintained as outlined. biodegradable. Systems being converted
• Based on limited product testing to date, from mineral oil to vegetable oil should be
no reduction in unit life is expected when repeatedly flushed with vegetable oil to
operating at the pressure ratings indicated ensure 100% biodegradability.
above. • Specific vegetable oil products may provide
normal unit life when operating at pressure
ratings higher than those indicated above.
Note: A reputable supplier can help you make the • At normal operating temperatures,
best selection of hydraulic fluid for use in optimum viscosity ranges are from 80–180
Eaton hydrostatic products.For satisfactory SUS [16–39 cSt]. Viscosity should never
operation, the following recommendations fall below 60 SUS [10cSt] and, at the
apply: lowest expected startup temperature,
should not exceed 10,000 SUS [2158 cSt].
• The filter system used in the hydraulic cir-
cuit must be capable of maintaining the • The fluid should contain anti-wear agents,
fluid at ISO Cleanliness Code 18/13 per rust inhibitors, and anti-foaming agents.
SAE J1165. This code allows a maximum
of 2500 particles per milliliter greater than Note: If the fluid becomes black or milky, an
5µm and a maximum of 80 particles per overheating or water contamination
milliliter greater than 15µm. problem exists. Take fluid level
readings when the fluid is cold.
EATON Series 1 Heavy Duty Hydrostatic Fixed Displacement Motors Parts and Repair E-MOPI-TS002-E September 2004 31
Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road Dr. Reckeweg-Str. 1
Eden Prairie, MN 55344 Footscray D-76532 Baden-Baden
USA Victoria 3011 Germany
Telephone: 952 937-9800 Australia Tel: (49) 7221 682-0
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (49) 7221 682-788
www.hydraulics.eaton.com Fax: (61) 3 9318 5714
Ready
Mix
Concrete
2
Typical Hydrostatic System
Variable Pump-Fixed Motor
11
10
12 9
3
4 6
5
8
2
3
Gauge Requirements, Gauge Port Size and Locations
Variable Displacement Pumps
Inlet Vacuum Gauge
-1 to + 2 bar
Charge Pressure Gauge [- 30 to + 30 in. Hg (Mercury)]
0 - 37 bar [0 - 600 PSI ] ( Compound Gauge )
300 0
5
200 400 10
10
15
100 500 20 20
Compound
0
PSI 600 30 30
25
Vac Press
Charge Pressure
Relief Valve
A
7/16 - 20 UNF 2B 1-5/16 - 12 UN 2B
- 4 SAE O-Ring Port -16 SAE O-RIng Port
Optional
Power Limiter Valves
5000 5000
150 4000 6000 4000 6000
100 200
3000 7000 3000 7000
Customer must
supply Fitting
7/16 - 20 UNF 2B
1 - 1/16 - 12 UN 2B - 4 SAE O-Ring Ports
- 12 SAE O-Ring Port
Charge
Pressure
Relief
Valve
4
Gauge Requirements, Gauge Port Size and Locations
Fixed Displacement Motors
(with Integral Shuttle)
Case Pressure Gauge System Pressure Gauges ( 2 )
0 - 20 bar [0 - 300 PSI] 0 - 610 bar [0 - 10,000 PSI]
5000 5000
150 4000 6000 4000 6000
100 200
3000 7000 3000 7000
Customer must
supply Fitting 9/16 - 18 UNF 2B
- 6 SAE O-Ring Ports
1 - 1/16 - 12 UN 2B
- 12 SAE O-Ring Port
B A
Shuttle
Valve
5
Pressure Readings
Nominal Operating Pressures
The pressures given in this manual are gauge pressures or delta (At Normal Operating Temperature)
pressures. A pressure gauge reads zero when connected to
atmospheric pressure. Any reading above or below this zero Inlet Vacuum: Should not exceed 254 mm [10 in.]
point is referred to as gauge pressure (bar [PSI]). Delta mercury (Hg.) for an extended period of
pressure is the difference of two gauge pressures in a hydraulic time
circuit.
Case pressure: Should not exceed 2,8 bar [40 PSI]
Example: for an extended period of time
Charge pressure reading of 16,5 bar [240 PSI]
- Case pressure reading of 1,5 bar [20 PSI] Charge Pressure:* Neutral 15,2 ∆ bar [220 ∆PSI]
Differential pressure of 15,0 ∆ bar [220 ∆ PSI] Forward or Reverse 11,0 ∆ bar [160 ∆PSI]
Typical hydrostatic circuits usually include a inlet pressure, case *Charge Pressure Relief valves are factory preset to their
pressure, low or charge pressure and system or high pressure. nominal setting with a 7,6 l/min [2 GPM] flow rate. The original
These pressures will vary per each individual application and valve pressure will increase approximately ,45 bar per 3,8 l/min
operating conditions. [6.5 PSI per 1 GPM] additional flow over the valve. The charge
pressures given above are typical. Higher charge pressures may
be set at the factory for your particular application.
6
Fault-Logic Troubleshooting
This guide is designed as a diagnostic aid for the user to locate
possible transmission problems. Match the transmission
Symptom:
symptoms with the problem statements and follow the action Action
steps shown in the box diagrams. This will help in correcting Step
Inspect
minor problems, eliminating unnecessary mixer down time. Ok
Comment
Following the fault-logic diagrams are diagram action
Number 1 ?
comments to further help explain the action steps shown in the
diagrams. Where applicable, the action comment number of Decision Defective
the statement appears in the action block of the diagram.
Repair
Solution or
Replace
Defective Defective
Repair Repair
or or
Replace Replace
7
8
Drum Turns in One Direction Only
Inspect External Inspect Inspect
Pump Control OK Pump Control OK System Relief or
1 Linkage (if Used) 2 Valve 3 Power Limiter Valves
Defective Defective
Repair Repair
or or
Replace Replace
Hydraulic System Operating Hot
Check Oil Check Inspect Inspect Heat
Level in OK Engine OK Heat OK Exchanger By-Pass
6 Reservoir 9 R.P.M. 7 Exchanger 8 Valve (if Used)
Defective
9
10
Drum Response Sluggish
Check Inspect Replace
Charge OK Pump Control OK Transmission
13 Pressure 2 Valve (Pump & Motor)
Defective
Repair
or
Replace
OK
OK
Inspect Inspect Inspect Charge Inspect Charge
Charge OK Inlet OK Relief Valve Relief Valve
Pump 14 Filter 10 (At Pump) 12 (At Motor) 13
Defective Defective
Repair Repair
or or
Replace Replace
11
Diagram Action Step Comments
1. Inspect External Pump Control 4. Inspect Shuttle Valve for:
Linkage for: A. Bent or broken return centering spring
(Manual Operated Controls) B. Galled or stuck shuttle spool
A. Misadjusted or disconnected C. Bent or broken shuttle spool
B. Binding, bent or broken
5. Inspect Charge Check Valves for:
(Electrical Operated Controls) A. Damaged or missing O-ring
A. Disconnected electrical signal connection and/or back-up ring(s)
B. Damaged check ball seat
2. Inspect Pump Control Valve for: C. Stuck check ball
(Manual Operated Controls)
A. Plugged control orifice 6. Check Oil Level in Reservoir:
B. Damaged mounting gasket A. Consult owner/operators manual for
C. Misadjusted, damaged or broken neutral the proper type fluid and level.
return spring
D. Broken control connector pin 7. Inspect Heat Exchanger for:
E. Broken or missing control linkage pin(s) A. Obstructed air flow (air cooled)
F. Galled, stuck or bent control spool B. Obstructed water flow (water cooled)
C. Improper Plumbing (inlet to outlet)
(Electrical Operated Controls) D. Obstructed or insufficient fluid flow
A. Plugged control orifice E. Cooling fan Failure (if used)
B. Damaged mounting gasket
C. Galled, stuck or bent control spool 8. Inspect Heat Exchanger By-Pass
D. Stuck solenoid valve(s) Valve for:
E. Defective solenoid coil(s) A. Improper pressure setting
F. Misadjusted speed sensor (when used) B. Stuck or broken valve
G. Defective speed sensor (when used)
H. Defective electronics module 9. Check Engine R.P.M.
NOTE: When the electronic transit mixer A. Consult owner/operators manual for
control is used, follow the control box minimum engine rpm.
fault dector instructions.
10. Inspect Inlet Filter for:
3. Inspect System Relief A. Plugged or clogged filter
or Power Limiter Valves for: B. Obstructed inlet or outlet
(System Relief Valves) C. Collapsed inlet line to charge pump
A. Improper pressure relief setting D. Open inlet to charge pump
(Consult owners/operator manual
for system relief valve settings.) 11.* Check Charge Pressure:
B. Damaged or missing O-ring and/or A. Consult page 4 in this manual for
back-up ring(s) charge pressure gauge installation
C. Plugged orifice location.
D. Piston galled or stuck B. Consult owner/operators manual for
E. Valve poppet held off seat charge relief valve settings.
12
Diagram Action Step Comments
14. Inspect Charge Pump for: This same code is also used on the power limiter valves. The
(Standard and A-Pad Pumps) code number is stamped on the end of the valve cartridge.
A. Broken drive tang (Power limiter valves must be removed to view pressure code.)
B. Damaged or missing o-ring(s) To determine the pressure setting of each valve, add a zero to
C. Broken drive key the right of the stamped coded number.
E. Galled or broken gerotor set
Charge Pressure Valve Examples
(B-Pad Pumps) 016 = 160 ∆ PSI Setting [ 11,0 ∆ bar ]
A. Stripped or broken drive coupling 022 = 220 ∆ PSI Setting [ 15,2 ∆ bar ]
B. Stripped or broken drive spline
C. Damaged or missing o-ring(s) System and Power Limiter Valve Pressure Examples
D. Broken drive key 400 = 4000 ∆ PSI Setting [ 275 ∆ bar ]
F. Galled or broken gerotor set 500 = 5000 ∆ PSI Setting [ 345 ∆ bar ]
13
Hydraulic Fluid Recommendations
Introduction Fluid Maintenance
The ability of Eaton hydraulic components to provide desired Maintaining correct fluid viscosity and cleanliness level is
performance and life expectancy depends largely on the fluid essential for all hydraulic systems. Since Eaton hydraulic
used. The purpose of this document is to provide readers with components are used in a wide variety of applications it is
the knowledge required to select the appropriate fluids for use impossible for Eaton to publish a fluid maintenance schedule
in systems that employ Eaton hydraulic components. that would cover every situation. Field testing and monitoring
are the only ways to get accurate measurements of system
One of the most important characteristic to consider when cleanliness. OEM’s and distributors who use Eaton hydraulic
choosing a fluid to be used in a hydraulic system is viscosity. components should test and establish fluid maintenance
Viscosity choice is always a compromise; the fluid must be schedules for their products. These maintenance schedules
thin enough to flow easily but thick enough to seal and should be designed to meet the viscosity and cleanliness
maintain a lubricating film between bearing and sealing requirements laid out in this document.
surfaces. Viscosity requirements for each of Eaton’s product
lines are given on the back of this document. Fluid Selection
Premium grade petroleum based hydraulic fluids will provide
Viscosity and Temperature the best performance in Eaton hydraulic components. These
Fluid temperature affects viscosity. In general, as the fluid fluids typically contain additives that are beneficial to hydraulic
warms it gets thinner and its viscosity decreases. The opposite systems. Eaton recommends fluids that contain anti-wear
is true when fluid cools. When choosing a fluid, it is important agents, rust inhibitors, anti-foaming agents, and oxidation
to consider the start-up and operating temperatures of the inhibitors. Premium grade petroleum based hydraulic fluids
hydraulic system . Generally, the fluid is thick when the carry an ISO VG rating.
hydraulic system is started. With movement, the fluid warms to
a point where a cooling system begins to operate. From then SAE grade crankcase oils may be used in systems that employ
on, the fluid is maintained at the temperature for which the Eaton hydraulic components, but it should be noted that these
hydraulic system was designed. In actual applications this oils may not contain all of the recommended additives. This
sequence varies; hydraulic systems are used in many environ- means using crankcase oils may increase fluid maintenance
ments from very cold to very hot. Cooling systems also vary requirements.
from very elaborate to very simple, so ambient temperature
may affect operating temperature. Equipment manufacturers Hydraulic fluids that contain V.I. (viscosity index) improvers,
who use Eaton hydraulic components in their products should sometimes called multi-viscosity oils, may be used in systems
anticipate temperature in their designs and make the appro- that employ Eaton hydraulic components. These V.I. improved
priate fluid recommendations to their customers. fluids are known to “shear-down” with use. This means that
their actual viscosity drops below the rated value. Fluid
Cleanliness maintenance must be increased if V.I. improved fluids are
Cleanliness of the fluid in a hydraulic system is extremely used. Automotive automatic transmission fluids contain V.I.
important. Eaton recommends that the fluid used in its improvers.
hydraulic components be maintained at ISO Cleanliness Code
18/13 per SAE J1165. This code allows a maximum of 2500 Synthetic fluids may be used in Eaton hydraulic components. A
particles per milliliter greater than 5 µm and a maximum of 80 reputable fluid supplier can provide information on synthetic
particles per milliliter greater than 15 µm. When components fluids. Review applications that require the use of synthetic
with different cleanliness requirements are used in the same fluids with your Eaton representative.
system, the cleanest standard should be applied. OEM’s and
distributors who use Eaton hydraulic components in their
products should provide for these requirements in their designs.
A reputable filter supplier can supply filter information.
14
Viscosity Requirements
ISO
Optimum Cleanliness
Product Line Minimum Range Maximum Requirements Comments
Heavy Duty Piston 60 SUS 80 - 180 SUS 10,000 SUS 18/13
Pumps and Motors [10 cSt] [16 - 39 cSt] [2158 cSt]
Additional Notes:
• Fluids too thick to flow in cold weather start-ups will cause should never fall below 70 SUS [13 cSt].
pump cavitation and possible damage. Motor • If the natural color of the fluid has become black it is
cavitation is not a problem during cold start-ups, possible that an overheating problem exists.
except for two speed motors. Thick oil can cause
high case pressures which in turn can blow motor • If the fluid becomes milky, water contamination may be a
shaft seals. problem.
• When choosing a hydraulic fluid, all the components in the • Take fluid level reading when the system is cold.
system must be considered and the optimum
viscosity range adjusted accordingly. For example, • Contact your Eaton representative if you have specific
when a medium duty piston pump is combined with questions about the fluid requirements of Eaton
a Geroler motor the optimum viscosity range hydraulic components.
becomes 100 - 150 SUS [20 - 32 cSt] and viscosity
15
ACCREDITED BY
THE DUTCH COUNCIL
FOR CERTIFICATION
Reg. No. 24
c
i
u
a
r h
y
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Hydraulics
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Models 33 through 76
Hydrostatic Transmissions
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We Manufacture
Solutions
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S o l u t i o n s
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Heavy Duty Features/Benefits
Table of Contents
Pump Performance .................................................................................. 4
3
Pump Performance
Pump Performance
Model 33 39 46 54 64 76
in3/rev 3.32 3.89 4.60 5.44 6.44 7.62
Displacement
cm3/rev 54,4 63,7 75,3 89,1 105,5 124,8
Maximum RPM
Shaft @ 4510** 4160 4160 3720 3720 2775
Speed* 18°
Peak PSI 6000 6000 6000 6000 6000 6000
Pressure*** [bar] [415] [415] [415] [415] [415] [415]
GPM @ 61.5 67.3 79.2 84.1 99.1 87.9
Output 3500 PSI
Flow LPM @ 233 255 300 318 375 333
241 bar
lb-in @ 2049 2346 2786 3285 3900 4552
Input 3500 PSI
Torque Nm @ 232 265 315 371 441 514
241 bar
Pump performance calculated at 96% efficiency.
* The maximum pump shaft speed may be limited by the charge pump speed rating.
** The maximum swashplate angle on model 33 pumps is 15.5°.
*** Peak pressure should not exceed 1% of operating time.
Input 70
Torque [265] 39
lb-in. 54
[Nm]
60
[227] 33
3000
[340] Output
46 Flow 50
GPM [189]
[LPM]
39 40
[151]
33
2000 30
[230] [114]
20
500 1000 1500 2000 2500 3000 3500 4000 [76]
Pump Speed
RPM 10
[38]
4
Motor Performance
Motor Performance
Model 33 39 46 54 64 76
in3/rev 3.32 3.89 4.60 5.44 6.44 7.62
Displacement
cm3/rev 54,4 63,7 75,3 89,1 105,5 124,8
RPM
@ 4510* 4160 4160 3720 3720 2775
Maximum 18°
Shaft RPM
Speed @ 5380˜ 5380˜ 5380˜ 4810˜ 4810˜ 3425˜
10°
Maximum lb-in 2959 3511 4149 4916 5807 6911
Output
Torque † Nm 334 397 469 556 656 781
* The maximum swashplate angle on model 33 motors is 15.5°.
˜ These shaft speeds require maximum charge pressure relief: 340 psi [23 bar] pump and 280 psi [19 bar]
motor.
† Maximum output torque is measured at 6000 psi [415 bar].
1000 1.0
[110]
40 50 60 80 100 200 300 400 500 600 800 1000 2000 3000 4000 40 50 60 80 100 200 300 400 600 800 1000 2000 3000 4000
Motor Speed Motor Speed
RPM RPM
at 3500 psi [240 bar] at 6000 psi [415 bar]
5
Charge Pump Performance
Eaton offers a choice of four charge pump displacements to go with their heavy duty transmission line: .85, 1.28,
1.70, and 2.12 in3/rev [13,9; 21,0; 27,8; 34,7 cm3/rev]. These charge pumps are available with one or more of the
following options:
a pressure sensing port
remote pressure side filter ports
a spin-on pressure side filter
mounting flanges for auxiliary pumps
5.0 26.0
[3.7] [98]
1.70 in3/rev
2.12 in3/rev
4.0 1.70 in3/rev
[3.0] 1.28 in3/rev
2.12 in3/rev 1.28 in3/rev
Input 20.0
Power* 3.0 [76]
HP [2.2]
[kW] .85 in3/rev
.85 in3/rev
Output
2.0
[1.5]
Flow*
GPM
[LPM]
1.0
[.7]
10.0
[38]
6
Charge Pump Dimensions
Charge Pump with Auxiliary Pressure Port Charge Pump with SAE A Auxiliary Mount
G
29,0
[1.14] Charge Pump Options
Displacement Dimension 'G'
Charge Pump Options
cu.in./rev. cc/rev mm in.
Displacement Dimension 'G'
.85 13,9 105,2 4.14
cu.in./rev. cc/rev mm in.
1.28 21,0 111,5 4.39
.85 13,9 92,2 3.63
1.70 27,8 117,8 4.64
1.28 21,0 98,6 3.88
2.12 34,7 124,5 4.89
1.70 27,8 104,9 4.13
2.12 34,7 111,6 4.38
Charge Pump Inlet *Refer to page 18 for for SAE A torque ratings.
29,0 Charge Pump Inlet 1 5/16-12 Straight
[1.14] 1 5/16-12 Straight Thread O-ring Fitting
Thread O-ring Fitting
Charge Pump with SAE B Auxiliary Mount Charge Pump with Remote Filter Ports
19,1
[.75]
G 29,0
61,2 [1.14]
Auxiliary mounting holes [2.41]
Auxiliary Mounting Surface
1/2-13 UNC-2B thread thru
41,4 [1.63] Maximum
4 places.
Allowable Shaft Protrusion
Gasket supplied as loose
item to be installed on
mounting surface prior to
Charge assembly of auxiliary 146,05
Pump pump. [5.750] 17,8 Connect to
Mounting [.70] filter inlet
2 Places
Surface
Pressure Ports
7/8-14 Straight
Thd O-ring Fitting
57,2
[2.25] 73,02 57,2
[2.875] [2.25] 19,1 Connect from
[.75] filter outlet
2 Places
Spline to mate with
internal involute flat
29,0 root side fit, 13 tooth 18,0
[1.14] 16/32 pitch, 30° pressure Charge Pump Inlet [.71]
1 5/16-12 Straight 33,3
angle, per ANSI B-92.1-1970 Thread O-ring Fitting [1.31]
Charge Pump Inlet
1 5/16-12 Straight
Thread O-ring Fitting *Refer to page 18 for for SAE B torque ratings.
19,1 113,2
[.750] [4.46]
Charge Pump with Spin-On 1.375-12 UNF-2A Thread
.750 Min Full Thread
Pressure Side Filter Pad
HYDROSTATIC OIL FILTER
[2.66]
Pump
Mounting 29,5 95,0-93,5 Ø
Surface [1.16] [3.74-3.68 Ø]
57,2
[2.25]
242,1-237,5
[9.53-9.35]
29,0
[1.14]
Charge Pump Inlet
1 5/16-12 Straight
Thread O-ring Fitting All dimensions in millimeters [inches].
7
Heavy Duty Hydrostatic Transmissions
134,6
120,7 [5.30]
112,3
[4.75] [4.42] 101,6
85,3
[3.36] [4.00]
127,00/126,95
[5.000/4.998]
B
57,2
A
DIA.
82,6 [2.25]TYP. 85,3 57,2 [2.25]
[3.25]TYP. [3.36] 133,4
[5.25]
92,2
57,2 TYP. [3.63]
[2.25] 127,00/126,95
114,4 TYP. [5.000/4.998]
[4.50]
DIA.
A
104,9
[4.13]
Variable Motor
Case Drain Port - 1 1/16-12
Straight Thread O-ring Fitting
2 Places 103,6
[4.08] Control Pressure Port
117,1 7/16-20 Straight Thread O-ring Fitting
[4.61]
SAE C 4-Bolt
Mounting Flange
134,6
120,7 [5.30]
[4.75] 101,6
85,3
[3.36] [4.00]
56,9 [2.24]
127,00/126,95
[5.000/4.998]
B
57,2 DIA.
A
12,70/12,19
[.500/.480] 31,8
7,1 [.28] R. TYP. [1.25]
4 Places 57,2 117,1
[2.25] 15,7 [.62]
[4.61] 87,4 87,4
TYP. 102,9 [3.44] [3.44]
[4.05] Valve Block
Mounting Surface 136,4 136,4
198,9 [7.83] [5.37] [5.37]
246,6 [9.71]
278,4 [10.96] 94,5
[3.72]
9
Models 54 and 64 Dimensions
Variable Pump
Gauge Port for Charge Pressure
Case Drain Port - 1 1/16-12 7/16-20 Straight Thread O-ring Fitting
Straight Thread O-ring Fitting
2 Places 122,4
130,8 [4.82] G
[5.15]
156,2
133,4 112,3 [6.15]
92,5 [5.25] [4.42] 114,3
[3.64] [4.50]
127,00/126,95
[5.000/4.998]
B
57,2
A
DIA.
82,6 [2.25]TYP. 92,5 57,2 [2.25]
[3.25]TYP. [3.64] 154,9
[6.10]
Fixed Motor
Valve Block
Mounting Surface
165,2 TYP. 308,4 [12.14] 94,5
[6.50] [3.72]
272,8 [10.74]
82,6
[3.25] 143,3 [5.64]
TYP.
100,3
57,2 TYP. [3.95]
[2.25] 127,00/126,95
114,4 TYP. [5.000/4.998]
[4.50]
DIA.
A
113,0
[4.45]
Variable Motor
Case Drain Port - 1 1/16-12
Straight Thread O-ring Fitting
2 Places 122,4
[4.82] Control Pressure Port
130,8 7/16-20 Straight Thread O-ring Fitting
[5.15] SAE C 4-Bolt
Mounting Flange
156,2
133,4 [6.15]
[5.25] 114,3
92,5
[3.64] [4.50]
63,8 [2.51]
127,00/126,95
[5.000/4.998]
B
57,2 DIA.
A
12,70/12,19
[.500/.480] 32,0
7,1 [.28] R. TYP. [1.26]
4 Places 57,2 130,6
[2.25] 15,7 [.62]
[5.15] 98,6 98,6
TYP. 106,2 [3.88] [3.88]
[4.18] Valve Block
Mounting Surface 151,9 151,9
217,4 [8.56] [5.98] [5.98]
272,5 [10.73]
308,2 [12.13] 94,5
[3.72]
10
Model 76 Dimensions
Variable Pump
Gauge Port for Charge Pressure
126,7 7/16-20 Straight Thread O-ring Fitting
[4.99] 138,9
Case Drain Port - 1 1/16-12
Straight Thread O-ring Fitting 80,8 TYP. [5.47]
[3.18] SAE D 4-Bolt
2 Places Mounting Flange G
169,9
143,1 124,0 [6.69]
107,4 [5.63] 112,3 [4.88]
[4.23] 80,8 TYP. [4.42]
[3.18]
152,40/152,35
[6.000/5.998]
DIA. 57,2 [2.25] B A
107,4
[4.23]
168,1
[6.62]
45° Charge Pump Inlet - 1 5/16-12
TYP. 127,0 TYP. 12,70/12,19 Straight Thread O-ring Fitting
[5.00] [.500/.480]
19,3 [.76]
46,0
10,2 [.40] R. TYP. 126,7 [1.81]
4 Places Charge Pump 106,9 106,9
[4.99] [4.21] [4.21]
129,0 Mounting Surface
[5.08] 155,2 155,2
[6.11] [6.11]
313,2 [12.33]
100,1
80,8 [3.94]
[3.18] TYP.
161,5 152,40/152,35
[6.36] TYP. [6.000/5.998]
DIA. B A
112,8
[4.44]
Variable Motor
126,7
[4.99] 138,9
Case Drain Port - 1 1/16-12 Control Pressure Port
Straight Thread O-ring Fitting 80,8 TYP. [5.47] 7/16-20 Straight Thread O-ring Fitting
[3.18] SAE D 4-Bolt
2 Places Mounting Flange
169,9
143,1 124,0 [6.69]
107,4 [5.63] [4.88]
[4.23] 80,8 TYP.
[3.18] 69,3 [2.73]
152,40/152,35
[6.000/5.998]
DIA. B A
107,4
[4.23]
168,1
[6.62]
45°
TYP. 127,0 TYP. 12,70/12,19
[5.00] [.500/.480]
19.3 [.76]
46,0
10,2 [.40] R. TYP. 126,7 [1.81]
4 Places Valve Block 106,9 106,9
[4.99] Mounting Surface [4.21] [4.21]
129,0
[5.08] 155,2 155,2
[6.11] [6.11]
234,2 [9.22]
313,2 [12.33]
11
Power Limiter Pumps and Integral Shuttle Valve Motors
Models 33 through 64
Power Limiter
Pump
A
Power Limiter
Valves
Integral Shuttle
Valve
Power limiter valve option
not available on Model 54
and Model 64 pumps with
SAE C auxiliary option.
12
Models 33, 39, and 46 Power Limiter Pumps
2X Case drain ports
1 1/16-12 straight 145.0
Gauge port for charge prssure.
thd o-ring fitting. [5.71]
7/16-20 straight thd o-ring fitting.
117.1 126.0 9.7 103.6
[4.61] [4.96] [.38] [4.08
G
162.1
[6.38]
134.6
[5.30] 120.7
[4.75] 112.3
85.3 [4.42]
[3.36]
127.00/126.95 Port-B
[5.000/4.998]
B
57.2 Dia.
A
82.6 4X [2.25] 57.2 [2.25] Port-A
4X [3.25] 85.3
[3.36] 133.4
[5.25]
174.8
[6.88]
156.2
[6.15] 133.4 112.3
92.5 [5.25] [4.42]
[3.64]
127.00/126.95 Port-B
[5.000/4.998]
B
57.2 Dia. A
Port-A
82.6 4X [2.25] 92.5 57.2 [2.25]
4X [3.25]
[3.64] 154.9
[6.10]
Models 33, 39, and 46 Integral Shuttle Motors Side Ports End Ports
285.9 [11.26] 72.1 72.1 72.1 72.1
246.6 [9.71] [2.84] [2.84] [2.84] [2.84]
144.0 [5.67]
122.9
92.2 [4.84] Port 'B' Port 'A'
57.2 CCW CW [3.63]
Typ.
114.4 [2.25] 127.00/126.95 Port 'B' Port 'A'
[4.50] [5.000/4.998]
Typ. Dia.
A A
104.9 B 104.9 B
[4.13] [4.13]
134.4
100.4 [5.29] Port 'B' Port 'A'
57.2 CCW CW [3.95]
Typ.
114.4 [2.25] 127.00/126.95 Port 'B' Port 'A'
[4.50] [5.000/4.998]
Typ. Dia.
A A
113.0 B 113.0 B
[4.45] [4.45]
PL Pump and IS Motor Notes: All dimensions are given in millimeters [inches].
The variable pumps are shown with standard controls. Installation drawings of other controls are
Approximate Weights available from your Eaton representative. Optional controls are shown on page 23.
lb [Kg] The variable pumps are shown with standard charge pumps. Installation drawings of other charge pumps
are available from your Eaton representative.
Model PL Pump IS Motor The lever on the standard pump control has linkage connection holes at 1 and 2 inch radii from the
33 138 [62,6] 70 [31,8] control shaft center.
Detailed drawings of available shafts and ports are shown on page 21.
39 138 [62,6] 70 [31,8]
46 138 [62,6] 70 [31,8]
54 188 [85,3] 93 [42,2]
64 188 [85,3] 93 [42,2]
Heavy Duty Tandem Pumps
Models 33 through 64
Tandem pumps may also be used in industrial, construction or • Pump has standard SAE C flange mount.
mining applications where several sources of hydraulic power • Rear pump can be the same displacement or smaller than
are required while taking advantage of using only one power front pump.
source to drive the two pumps.
15
Tandem Dimensions
Models 33, 39, and 46 Tandem Pumps
Front pump charge
supply port 7/8-14 Straight thd
o-ring fitting. Port-D2
103.5 325.2 2X Gauge port for charge pressure.
[4.08] [12.80] 7/16-20 straight thd o-ring fitting.
Port-D1
G
55.6
[2.19]
112.3
[4.42]
127.00/126.95
[5.000/4.998]
Dia.
57.2 [2.25]
12.45
[.490] 31.8 Port-B1 Port-H
[1.25] Charge supply port.
15.7 [.62] 1 5/16-12 Straight thd
o-ring fitting.
102.9
[4.05]
246.5 [9.71]
Port-B2 Charge Pump Options
283.7 [11.16]
324.9 [12.79] Displacement Dimension 'G'
427.7 [16.84] Charge cu.in./rev. cc/rev mm in.
571.7 [22.51] supply .85 13,9 92.2 3.63
603.3 [23.75] centerline 1.28 21,0 98.6 3.88
633.1 [24.92]
1.70 27,8 104.9 4.13
2.12 34,7 111.6 4.38
Port-F1
2X Case drain ports
1 1/16-12 straight 144.7
thd o-ring fitting. [5.70]
139.7 169.2
117.1 125.8 9.5 [5.50] [6.66]
[4.61] [4.95] [.38] Charge supply
to front pump
162.1
[6.38]
156.2
[6.15] 120.7
85.2 [4.75]
2X [3.36] 54.4
[2.14]
Port-B
B
57.2
A
82.6 4X [2.25] Port-A
4X [3.25] 85.2
133.5 [3.36]
[5.25]
Port-E1 Port-E2
4X 7.5 [.30] R. 4X
57.2 87.3 87.3
[2.25] [3.44] [3.44]
117.1 137.7
[4.61] [5.42]
137.7
[5.42] Charge supply centerline
16
Tandem Dimensions
Models 54 and 64 Tandem Pumps
Front pump charge
supply port 7/8-14 Straight thd
o-ring fitting. Port-D2
122.2 362.1 2X Gauge port for charge pressure.
[4.91] [14.26] 7/16-20 straight thd o-ring fitting.
Port-D1 G
55.6
[2.19]
112.3
[4.42]
127.00/126.95
[5.000/4.998]
Dia.
57.2 [2.25]
12.70/12.19
[.500/.480] 32.0 Port-B1 Port-H
[1.26] Charge supply port.
15.7 [.62] 1 5/16-12 Straight thd
o-ring fitting.
106.2
[4.18]
272.5 [10.73]
Port-B2
322.3 [12.69] Charge Pump Options
362.2 [14.26]
Displacement Dimension 'G'
468.4 [18.44]
634.7 [24.99] Charge cu.in./rev. cc/rev mm in.
670.4 [26.39] supply .85 13,9 92.2 3.63
699.2 [27.53] centerline 1.28 21,0 98.6 3.88
1.70 27,8 104.9 4.13
2.12 34,7 111.6 4.38
Port-F1
2X Case drain ports
1 1/16-12 straight 153.4
thd o-ring fitting. [6.04]
150.6 169.2
130.8 134.4 9.7 [5.93] [6.66]
[5.15] [5.29] [.38] Charge supply
to front pump
174.8
[6.88]
156.2
[6.15] 133.4
92.5 [5.25]
2X [3.64] 61.2
[2.41]
Port-B
B
57.2
A
82.6 4X [2.25] Port-A
4X [3.25] 92.5
154.9 [3.64]
[6.10]
Port-E1 Port-E2
4X 7.5 [.30] R. 4X
57.2 98.6 98.6
[2.25] [3.88] [3.88]
130.8 151.9
[5.15] [5.98]
151.9
[5.98] Charge supply centerline
17
Tandem Application Information
Tandems, Model 54 or 64 Front Pump with Model 33, 39, or 46 Rear Pump
55.6
[2.19]
112.3
[4.42]
127.00/126.95
[5.000/4.998]
Dia.
57.2 [2.25]
12.70/12.19
[.500/.480] 32.0 Port-B1 Port-H
[1.26] Charge supply port.
15.7 [.62] 1 5/16-12 Straight thd
o-ring fitting.
106.2
[4.18]
272.5 [10.73]
Port-B2 Charge Pump Options
322.3 [12.69]
362.2 [14.26] Displacement Dimension 'G'
465.1 [18.31] cu.in./rev. cc/rev mm in.
608.7 [23.96] Charge .85 13,9 92.2 3.63
640.6 [25.22] supply 1.28 21,0 98.6 3.88
670.4 [26.39] centerline
1.70 27,8 104.9 4.13
2.12 34,7 111.6 4.38
For longest shaft life, use the largest shaft possible. B-Pad Auxiliary Pump .................................. 1852 ..... 209
18
Heavy Duty Pumps with C-Pad Rear Mount
Models 33 through 64
Features/Benefits
• The heavy duty pump with a C-Pad rear mount is the
front half of the tandem unit.
Application Information
Maximum Shaft Torque Limitations Rear Pump Mounting Information
The total input torque, as well as, the torque at the drive When an Eaton heavy duty pump is used as the rear
shaft coupling point must be considered when the pump pump, remove its shaft seal so part of the case flow will
with the SAE C rear mount is used. Maximum torque flow past the bearing into the front pump. It is also
values and formulas are given on page 18. necessary to connect the rear pump's upper case drain
port to the front pump's lower case drain port, otherwise
Pumps with SAE C Rear Mount high case pressures may result.
A 14 tooth, 12/24 pitch, internal spline coupling (Part No.
105853) is required between front and rear pump. A In all cases, check case pressures and ensure that they
coupling is provided with each SAE C Pump. Optional do not exceed 40 PSI [3 bar].
couplings with 21 tooth, 16/32 pitch; and 23 tooth, 16/32
pitch, are also available. Heavy Duty Application manual (no. 5-401) gives more
information on proper case flow routing.
Pump requires remote charge pump and charge pres-
sure relief. (Charge pressure relief may be built into See previous page for shaft torque ratings.
pump.)
19
20
Models 33, 39, and 46 Pumps with C-Pad Rear Mount
Port-F
2X Case drain ports
1 1/16-12 straight 144,7 Involute spline fillet root side fit
thd o-ring fitting. [5.70] 14 tooth 12/24 pitch per SAE-J498b
Gauge port for charge pressure.
117,1 125,8 9,5 7/16-20 straight thd o-ring fitting. Class 1 fit with SAE-J498b flat root
103,5 side fit major dia. Will fit ANSI B92.1
[4.61] [4.95] [.38] [4.08] 1970 Class 5 mating splines
Charge supply port
7/8 - 14 straight thd
162,1 55,6 o-ring fitting.
[6.38] [2.19]
156,2
[6.15] 120,7
Dimensions
85,2 [4.75]
2X [3.36]
Port-B
127,00/126,95
[5.000/4.998]
B
A
57,2 Dia.
82,6 4X [2.25] Port-A
4X [3.25] 85,2
[3.36]
133,5
[5.25]
Port-E 12,45
[.490] 31,8
[1.25] 4X 1/2-20
4X 7,5 [.30] R. 4X UNF-2B
57,2 117,1 15,7 [.62]
[4.61] 127,08/127,10 full thd thru
[2.25] 102,9
[4.05] [5.000/5.003]
246,5 [9.71] 87,3 87,3
283,7 [11.16] [3.44] [3.44]
324,9 [12.79] 137,7 137,7
[5.42] [5.42]
57,2 Dia.
82,6 4X [2.25] Port-A
4X [3.25] 92,5
[3.64]
154,9
[6.10]
Port-E 12,70/12,19
[.500/.480] 32,0
[1.26] 4X 1/2-20
4X 7,5 [.30] R. 4X UNF-2B
130,8 15,7 [.62]
57,2 [5.15] 127,08/127,10 full thd thru
[2.25] 106,2
[4.18] [5.000/5.003]
272,5 [10.73] 98,6 98,6
322,3 [12.69] [3.88] [3.88]
362,2 [14.26] 151,9 151,9
[5.98] [5.98]
Clearance
57,7 [2.27] Shaft Dia. B
Dia.
19,30/18,80 48,01
[.760/.740] [1.890] Code Dia. A B C D
Shaft Dia. 61 25,4 [1.00] 26,19 [1.031] 52,37 [2.062] 3/8-16 22,4 [.88]
35,05/34,90 [1.380/1.374] 62 25,4 [1.00] 27,76 [1.093] 57,15 [2.250] 7/16-14 27,0 [1.06]
76,2
38,23/38,08 [1.505/1.499] [3.00]
All dimensions given in millimeters [inches].
Models 33 through 64 Shaft and Port Dimensions
21
22
Keyed Shaft Option Splined Shaft Options
Compatible with ISO 3019/1 87.4 [3.44] Compatible with ISO 3019/1
(SAE-J744) Specifications (SAE-J744) Specifications
74.4 [2.93]
The port plate is the simplest control option The standard variable pump control is the most
available. It fits all Eaton heavy duty pumps and common type of control used on heavy duty
motors. hydrostatic variable displacement pumps. It is
normally actuated by direct mechanical linkages
The port plate is commonly used as a slave or cables.
control that receives commands from other
controls in the same system. A wide band neutral zone controller is available.
It expands the center lever position where the
pump output is zero flow.
P D L U
P T S2 S1 T P
Swashplate S2 S1
Feedback
System System
Pressure Pressure
Port B Port A
23
Pump Controls
Standard Control with Standard Control with
Inching Valve Neutral Detent
The inching valve is an option that is used in The neutral detent feature on the standard
conjunction with the standard variable pump control valve provides a more positive feel when
control. This control option would typically be finding neutral. This control is a good choice for
used on a vehicle propel transmission. When transmissions that have long control linkages or
the inching valve is operated with a foot pedal it cables with varying amounts of free play.
functions like a clutch. A metering orifice in the
inching valveʼs rotary spool cross ports the servo
pressure lines providing the operator with
smooth acceleration and deceleration.
T P T P
Swashplate Swashplate S2 S1
Feedback Feedback
S2 S1
24
Pump Controls
Standard Control with Internal Pressure Override
Neutral Lock-out Control (IPOR)
The neutral lock-out feature is an electrical The internal pressure override (IPOR) protects
switch that is closed when the transmission is in the transmission from running at overload
neutral. This switch can be used to prevent the conditions for extended periods. It senses
activation of certain functions that require the system pressure and allows the pump to
pump to be in neutral. The lock-out feature is destroke if pressures exceed a preset limit. The
commonly used to prevent starting the prime override pressure setting is shim adjustable.
mover or activating auxiliary functions. The Since the IPOR is built into the pump end cover
electrical switch is available as normally open or it is not a field conversion option.
normally closed.
T P
T P
Swashplate S2 S1
Feedback
System System
Pressure Pressure
Port B Port A
25
Pump Controls
Horsepower Limiter Remote Pressure
Control Override
Hydraulic Joystick
(Customer Supplied)
Pilot
Pressure
Port 1
Pilot
Pressure
Port 2
E F D Horsepower
Limiter
Control
Orifice
A Port D
Optional
Orifice
System System
Pressure Port B Pressure Port A
26
Pump Controls
Hydraulic Remote Control Electronic Control (ESC)
Pump Control
The hydraulic remote control uses a remote pilot The electronic control (ESC) uses an electrical
pressure signal to move the control spool. This signal to change the displacement of the vari-
control can be used where cables or mechanical able pump. The input signal may be manually or
linkages are not feasible. automatically controlled. The ESC requires a 0
to 100 milliampere signal.
Pilot Pilot T P
Pressure Pressure
Port 2 T P Port 1
X X
Swashplate S2 S1
Feedback Swashplate S2 S1
Feedback
27
Pump Controls
Destroke Control Destroke Solenoid
The heavy duty Destroke Control is a solenoid The heavy duty Destroke Solenoid is available to field
valve mounted on the standard variable pump convert the standard variable pump control into a
control. When energized, the valve cross-ports destroke control.
control pressure allowing centering springs to
bring the pump out of stroke. It can be ener- An Anti-Stall Electronics Module is available to drive a
gized with a single switch, push-button, or dead normally closed destroke valve. The electronic circuit
man's switch. The solenoid coil is available in monitors engine speed. When engine speed drops the
12 volt or 24 volt DC and normally open and anti-stall electronic reduce the pump's displacement.
normally closed configurations.
T P
Swashplate
Feedback
S2 S1
28
Variable Motor Controls
Manual Control Stroking Valve Control
The manual displacement control for variable The variable motor stroking control provides a
motors permits remote control of motor displace- means of controlling motor displacement re-
ment using mechanical links or cables. The motely via an electrical signal. When no electri-
control operates similarly to the pump manual cal signal is supplied to the solenoid valve, the
control, except the motor is biased to maximum motor will be commanded to maximum displace-
displacement when the control handle is in a ment to provide maximum torque. Conversely,
“neutral” position. Motor displacement may be providing an electrical signal to the solenoid
controlled between maximum and minimum by valve will command minimum displacement for
moving the control lever. maximum output speed. The control is available
in 12 volt and 24 volt DC configurations.
P T P T
Swashplate
S1 S2 Feedback
S1 S2
29
Variable Motor Controls
Pressure Response Control Pressure Response
Control with Stroking Valve
43
The variable motor pressure response control This control valve is a combination of the
automatically adjusts motor displacement to pressure response control and the stroking
meet torque requirements by sensing system valve. With the stroking valve solenoid ener-
pressure. The motor is biased to minimum gized it works like the variable motor pressure
displacement until system pressure reaches the response control. De-energize the stroking
pressure response setting. The control will then valve solenoid and the motor goes to full stroke.
increase motor displacement to maintain the The control is available in 12 volt and 24 volt
control pressure setting until maximum motor configurations.
displacement is reached or the load on the
system is reduced.
System
Pressure
System Port B P T
Pressure
Port B P T
System S1 S2 System
Pressure Pressure
Port A S1 S2
Port A
30
Variable Motor Controls
Hydraulic Remote Control
Variable Motor Control
Swashplate S2 S1
Feedback
31
Eaton Corporation is a global
manufacturer of highly engineered
products that serve industrial, vehicle,
construction, commercial and
semiconductor markets. Principal
products include electrical power
distribution and control equipment,
truck drivetrain systems, engine
components, hydraulic products, ion
implanters and a wide variety of
controls. Headquartered in Cleveland,
the company has 49,000 employees
and 143 manufacturing sites in 26
countries around the world. Sales for
1997 were $7.6 billion.
Information contained in this catalog is accurate as of the publication date and is subject to
change without notice. Performance values are typical values. Customers are responsible for
selecting products for their applications using normal engineering methods.
ACCREDITED BY
Eden Prairie, MN 55344 Scotland, KY7 4NW 40880 Ratingen, Germany Quality System Certified
Products in this catalog are
Telephone +44 (0) 1592-771-771 Telephone: +49 (0) 2102-406-830 manufactured in an
Fax: +44 (0) 1592-773-184 Fax: +49 (0) 2102-406-800 ISO-9001-certified site.
www.eatonhydraulics.com
Form No. 11-866 Copyright Eaton Corporation, 1983, 1994, 1995, 1997
All Rights Reserved
Printed in USA
Oil/Air Cooler TT 10X
12V DC with temperature control
Technical Data
power current revolution air flow noise level weight
order number description protection
[HP] [A] [rpm] [SCFM] [dB(A)] [lbs]
radiator
material: aluminium
working temperature range: -5°F to +210°F (oil temperature)
air fin shape: wavy
working pressure: 26 bar / 375PSI
This data sheet shows a technical overview of our products. Please contact us if more exact information is needed. As we are constantly improving our products, their characteristics, dimensions and weights may
also change, although we do our best to incorporate these changes continually. The information in this data sheet is intended to be used as a first general guideline only. asa assumes no liability for any information
therein, any errors, omissions, misprints, nor any direct or indirect damages, losses or costs resulting therefrom. The cooling performance and the general technical values indicated in this catalogue are measured at a
test bench according to asa testing procedures. Because there is no standardized testing procedure, tests used by other manufacturers could have different results. Due to different conditions in testing and
application environments the cooling performance may also vary by +/- 15%. Therefore we recommend all coolers to be checked under the system operating conditions. This is also true of vibrations and mechanical
stress as well as for pressure peaks and thermal stress and any other relevant factors.
(1x)Thermostat 60°C,IP67,M14x1,5
ILLZTH6067-14
(3x)Rubber - distanceblock
ILLEDISTA
Use only approved Hydraulic Fluid – Do Not Use ATF OR ENGINE OIL
Con-Tech trucks come factory filled with Chevron Rando HD ISO 68.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Relief Valve
# 765095
Dn Flow Control
# 765097
Cylinder
Down
Up Flow Control
# 765091
Cylinder
Up
Return to
Tank
Pressure
In
Chute Lift Cylinder Lines Chute Lift Block From Suction Filter
#6 hose size # 765100 #12 hose size #16 hose size
CB4 Block
www.ctmmixers.com
Troubleshooting BridgeKing Hydraulics
Pump Noise Due to Cavitation...
#2 #3 #4 #5
#1
Suction Reservoir Reservoir Reservoir
Oil Is Too
Filter Is Gate Valve Outlet Is Vent
Heavy
Plugged Is Closed Plugged Clogged
Unplug
Replace With Service or Open Gate Properly Vent
Reservoir
Correct Oil Replace Filter Valve The Reservoir
Outlet
Call #6
Con-Tech #7-15
Improper
Service Check The
Hose
507-374-2239 Pump
Installed
#6 Call
#1 Air #1-6 #7-15 Con-Tech
Oil Level Is Leaking Into Oil Is Check The Service
Low Suction Foaming Pump 507-374-2239
Lines
Repair or
Low Replace
Replace With Repair or
Replace
Correct Oil
if Defective if Defective
Fill To
Correct Level
#12 #8
Check Excessive #13
Pump Internal Compensator
Spool Sticky
Pressure Leakage
Clean
Spool
Measure
or Replace
Leakage Compensator
#7
Excess #12
Flow, Adjust The
Replace Pump
Pump
#12
Check
and Adjust
Pump
Call #15
Con-Tech Check #14
Service “A” Pad Check
507-374-2239 Receptacle Pump Shaft
Replace If Replace If
Worn Worn
#8,
12
#13
Excessive Compensator Pump Is
Internal Spool Sticky Cavitating
Leakage
See “Pump
Clean Noise Due To
Spool Cavitation”
Measure
or Replace
Leakage Compensator
#7
Excess #7
Flow, Adjust The
Replace Pump
Pump
#12
Check
and Adjust
Pump
Call #15
Con-Tech Check #14
Service “A” Pad Check
507-374-2239 Receptacle Pump Shaft
Replace If Replace If
Worn Worn
#11 #1 #1
Measure Oil Oil Supply Hydraulic
Temperature Is Low Oil Is Too
Light
Drain And
Fill to Proper
Refill With
Level
Correct Fluid
#8
#9 #6 Excess
Case Drain Aeration Of Internal
Incorrect Oil Pump
Leakage
Repair the
Plumbing
Check
Hose and Measure
Fittings Leakage
See “Pump
Noise Due To #7
Cavitation” Excess
Leakage,
Replace
Pump
Repair Or
Replace Valve 1
Call
Con-Tech #24 #28
Service Check PTS BridgeKing
507-374-2239 Cylinder
Clean or
Replace PTS
#21
HPRV
#27, 29
CB4
Call
Con-Tech #24 #28
Service Check PTS BridgeKing
507-374-2239 Cylinder
Clean or
Replace PTS
#27, 29
CB4
#17,
#23
#16 #25 #25 18, 19
Operate
Check Dash Do Chutes Do Chutes Chutes Off
Trailer
Gauge Work? Work? Center /
Manually
Raised
Put
Check Axle Center Or
Transmission
Stop Lower Chutes
In Neutral
#24
#28 #27 #21 #20
Check PTS
BridgeKing CB4 Check Check
And Trailer
Cylinder Cartridge HPRV PRV-2
Lock
Check CB4
Call Drain Line
#7-15 Con-Tech
Check Service
Pump 507-374-2239
Perform
Pressure and
Leakage Test
Replace if
Required
Clean Or
Clean Or Recharge
Replace CB4
Replace HPRV Accumulator
Cartridge
Call #22
Con-Tech
#7-15
Check #24 Check
Service Check PTS Chute
507-374-2239 Pump
Function
Clean Or Clean Or
Replace HPRV Replace PTS
#17,
#23
#16 #25 18, 19
Operate
Check Dash Do Chutes Chutes Off
Trailer
Gauge Work Center Or
Manually
Raised
Check
Check Axle Center Or
Directional
Stop Lower Chutes
Valve
#24
#28 #29 #20
Check PTS
BridgeKing Check CB Check
And Trailer
Cylinder Cartridge PRV-2
Lock
Call
#7-15 Con-Tech
Check Service
Pump 507-374-2239
Repair Or
Replace If
Necessary
#33 #34
#16 #32 Check
Check
Check Dash Check 12 3W2P
Up Flow
Gauge Volt Coils Cartridges
Control
Clean Or
#25 Replace Coils If Adjust as
Replace As
Needed Required
Check Required
Mid
Position
Valve
Call
Con-Tech #39
Service P.O. Check
507-374-2239
Clean Or
Replace As
Required
#34 Call
#32 Check Con-Tech
#39
Check 12 3W2P Service
Cross Check
Volt Coils Cartridges 507-374-2239
Clean Or Clean Or
Replace Coils If
Replace As Replace As
Needed
Required Required
#33 #34
#16 #32 Check
Check
Check Dash Check 12 3W2P
Up Flow
Gauge Volt Coils Cartridges
Control
Clean Or
#25 Replace Coils If Adjust as
Replace As
Needed Required
Check Required
Mid
Position
Valve
#38 #37
Check #39
Flo-Fuse
Return Line P.O. Check
Tripped
Call
Con-Tech
Service
507-374-2239
4. Reservoir vent clogged 9. Call the Con-Tech service department for assistant
a. Clean or replace 10 micron breather cap on at 507-374-2239
reservoir
b. 10 micron cap 10. Measure oil temperature
c. If breather cap is not installed on your Con-Tech a. Measure oil temperature in the reservoir with an
reservoir, install breather cap to properly vent the infra red heat gun or candy thermometer
reservoir. b. Determine if the heat is caused by hydrostatic
system or BridgeKing hydraulic system
5. Check for proper hose c. Maximum temperature should be outside
a. SAE100R4 suction hose should be installed temperature plus 100 degrees F
between the reservoir and pump d. Ideal oil temperature should be 170 degrees F- 180
b. Hose should be the same diameter and length as degrees F
original hose
c. Improper hose size or rating may collapse under 11. Check pump pressure
suction a. Deadhead pump pressure line at Parker Filter inlet
d. Inspect for air leaks on suction side with a 0 – 5,000 psi gauge
e. Inspect fittings for air leaks b. Pressure should be adjusted at the compensator
f. Inspect spin on filter gasket for air leaks c. Pressure should be the maximum required amount
on the BridgeKing Axle Placard + 100 psi
6. Install new pump
a. Lightly lubricate spline on pump with moly grease 12. Compensator spool sticky
16. Check red chute light 20. Operate trailer manually (PRV-2 should be
a. If chute hazard LED light is on, chute is not adjusted no higher that 1,000 psi)
centered or fully lowered a. Shift the directional valve manually
b. If the chute is down, centered, and light remains on b. If trailer operates, problem is probably electrical
1. Unplug chute center prox, if light goes out, c. If trailer doesn’t operate, problem is probably
replace the prox hydraulic
2. If light remains on, replace the prox relay d. If trailer safety latch operates, directional valve is
located in the in-cab control box (C48) sending a hydraulic signal to the high flow block
17. Check adjustment PRV-2 valve 21. Check PTS and trailer lock
a. The pressure should reach compensated pressure a. Earlier models have the PTS located in the control
when the PRV-2 is turned fully clockwise with trailer block
in the up position b. The PTS should receive a signal when the
b. Minimum pressure when PRV-2 is turned fully directional valve is shifted
counter clockwise should be approximately 1,000 psi c. The PTS signal also unlatches the trailer lock –
www.ctmmixers.com
BridgeKing Hydraulics Steps And Actions
the lock should open when PTS shifts to the down
position or the lock should relax in the up position 25. BridgeKing Cylinder
d. If the PTS doesn’t shift fully, the trailer speeds may a. If oil bypasses at the piston the trailer may be slow,
be slow of the pressure low not develop adequate pressure, or not move up or
e. Inspect the PTS O-rings and orifice behind PTS down
f. You should be able to push in against the spring on b. When the cylinder barrel end is pressurized, only
the center spool of the PTS and it should return freely drops should bypass to the rod end
g. The PTS can be cleaned and flushed with WD40 c. Check with Con-Tech Service for the proper
(Do not use a parts washer!) procedure to check oil bypass in the BridgeKing
h. Replace the PTS if necessary cylinder
www.ctmmixers.com
BridgeKing Hydraulics Steps And Actions
flow control fully off on later systems d. Clean the cartridge with WD40
d. Isolating the cylinder and chute lift systems one e. Because both cartridges are interchangeable, they
at a time provides a “process of elimination” to help can be swapped into the other cavity which may
locate problems reverse the problem - the chute that wouldn’t go up
probably won’t lower
29. Check 12 volt coils
a. When the chute up button is depressed, the up coil 32. P.O. Check Valves
will be energized a. A pilot operated check valve holds the chute in the
b. When the chute down button is depresses, the up position
down coil will be energized b. If the P.O. check leaks, oil can pass to the reservoir
c. An energized coil will be an electromagnet and will rather that raise the chute
attract a piece of metal such as a knife blade c. If the P.O. check leaks; the chute will drift down
d. You can also hear a “clicking” noise when the coil d. The P.O. check can be cleaned and flushed with
is energized if the cartridge is shifting WD40 (Do not use a parts washer!)
e. If neither coil is energized when the chute up/down e. Replace the P.O. check if necessary
button is depressed, check the electrical circuit and or
fuses 33. Check down flow control
f. If both coils energize correctly when the chute up/ a. If the chute up speed control is turned entirely off
down button is depressed, check the hydraulic system the chutes will not lower
g. Most coils have an O-ring seal which must be in b. If the down speed control is out of adjustment, turn
place when a coil is reinstalled both the up and down speed control to the center of
h. If an electrical circuit malfunctions, partial voltage their adjustment range as a place to start again
may cause a cartridge to shift slightly resulting in c. The down flow control cartridge be cleaned and
chutes drifting up or down flushed with WD40 (Do not use a parts washer!)
d. Replace the cross checks if necessary
30. Check up flow control (chute up speed)
a. If the chute up speed control is turned entirely off, 34. Check return line
no oil will be available for the chutes a. An obstructed return line to the reservoir will
b. If the up speed control is out of adjustment, turn prevent oil from leaving the chute lift system
both the up and down speed control to the center of b. An obstructed return line will result in a chute
their adjustment range as a place to start again which won’t lower
c. If the up speed control is adjusted to approximately
maximum up chute speed, the chute may go up when 35. Flo-Fuse Down
the down button is depressed a. Excess chute speed will trip flo-fuse and chute
will not lower
31. Check 3W2P cartridges b. If flo-fuse is tripped. The chute must be lifted to
a. Both 3W2P (three way/two position) cartridges are reset the flo-fuse
the same and are interchangeable c. If new chute lift cylinder is installed the air must
b. The coil can be removed from the cartridge and the be thoroughly bled from the chute lift cylinder and
3W2P cartridges removed for inspection and cleaning hydraulic hose or the air (which is compressible may
c. Inspect the O-ring on the cartridge to be sure they trip the flo-fuse
are not chipped or damaged
www.ctmmixers.com
High Pressure Filter Assembly
Your BridgeKing high pressure filter assembly has a flow style by-pass indicator (it only
reads while oil is flowing ). During operation of the BridgeKing trailer, if the indicator
is showing, you have a restricted filter.
The high pressure by-pass will function any time the outlet pressure becomes 50 psi
lower than the inlet pressure. If you have 2500 psi going into the housing and your filter
is starting to restrict flow and your outgoing pressure drops below 2450 psi, the by-pass
will open to keep the flow moving.
Your high pressure filter element should be replaced with a Beta Rating of
B10=200. Con-Tech part # 735003
For parts, refer to pages 20 & 21 in the Con-Tech parts book.
If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Input Output
(Non-Filtered Oil) (Filtered Oil)
High Pressure
Filter O-ring
# 725019 Filter Cartridge
# 735003
Part # 735010
This pump is factory preset for 3100 psi. The hydraulic pressure may be required to be
adjusted throughout the life of the pump. Establishing pump pressure is fairly simple.
With the engine turned off and all pressure relieved from the system, simply remove the
high pressure (smaller of the two coming out the end of the pump) hose from the filter
assembly and install a gauge directly into the hose. THE GAUGE MUST BE RATED
FOR 5000 PSI OR GREATER! Start the truck and run at idle. The gauge should read
approximately 100 psi above what the highest pressure setting is on the axle psi placard.
To adjust the pump maximum pressure setting, simply loosen the adjuster “jam nut”
and screw the adjusting stem clockwise until the desired gauge pressure reading is
obtained. Lock down the jam nut, shut off engine and allow hydraulic pressure to relive
from the system, remove gauge and re-install hydraulic hose.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Pressure Compensator
Pressure Port
Adjustment Screw
#8 Hose Size
Part # 745300
Suction Port
Case Drain Port #12 Hose Size
The Main Control Block controls all hydraulic functions for the BridgeKing trailer as
well as the chute raise and lower functions. The following illustrations point out all the
components of the Main Control Block as well as their function and built in overrides.
The overrides are only to be used in EMERGENCY situations. THE OPERATOR
MUST BE AWARE THAT WHEN THE OVERRIDES ARE USED, THAT ALL
SAFETY INTERLOCKS WILL BE DISABLED. The chutes WILL BE DAMAGED if
they are not centered and in the fully down position when utilizing the trailer up/down
overrides.
Also, remember that when the axle mid-position stop is activated, the chute raise/lower
functions will be disabled as well.
Please note, that before ANY repairs or maintenance is performed on any Con-Tech
mixers, all OSHA lock out/tag out procedures must be followed. All hydraulic pressure
must be relieved and/or allowed to dissipate FULLY from the system. Failure to do so
can results in bodily harm or fatal injuries!
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Trailer Pressure
Control Valve
(PRV-2)
# 760027
Part # 760154
Page 213 www.ctmmixers.com
Main Control Block
Chute Up Speed
Control
Pilot Operated
(In = Fast)
Check Valve
# 760160
# 760095
Pilot Operated
Check Valve
# 760095 Chute Down Speed
Control
(Out = Fast)
# 760159
The high flow block also contains the pilot to shift cartridge (PTS). The PTS cartridge
is hydraulically pilot operated. This hydraulic pilot pressure (flow at compensated
pressure) comes from the Directional Control Valve on the Control Block when the
trailer “down” switch is activated in the truck cab. When the PTS spool has a pilot
pressure, oil flows through the PTS spool to the barrel end of the BridgeKing cylinder,
lowering the BridgeKing trailer. When the PTS spool does not have pilot pressure, oil
flows through the PTS spool to the rod end of the BridgeKing cylinder, raising the
BridgeKing trailer. A hydraulic line is routed from the High Flow Block to the spring
·loaded single acting displacement cylinder which opens the BridgeKing trailer hook.
It takes 160 psi to shift the PTS spool against it’s spring forces. It takes 50 psi to open
the trailer hook. That means the hook will open before the PTS spool shifts. When the
PTS receives pilot pressure, the PTS spool shifts against the internal spring, forcing
and allowing the regulated pressure to enter the barrel end of the cylinder. We now
have regulated pressure on both the barrel end and rod end of the BridgeKing cylinder.
Because the barrel end of the cylinder has more area than the rod end of the cylinder,
the barrel end of the cylinder has more force and the cylinder extends (trailer lowers).
Oil leaving the rod end of the cylinder joins the oil flowing to the barrel end of the
cylinder. When the up switch is activated in the truck cab, the directional control valve
on the control block shifts to the opposite position and stops the pilot pressure to the
PTS. When this pilot pressure is stopped, the internal spring force on the PTS spool
returns the PTS spool to it’s spring loaded position. This PTS spool position prevents
regulated pressure from entering the barrel end of the cylinder and at the same time
allows the oil in the barrel end of the BridgeKing cylinder to flow to the reservoir.
Because we always have regulated pressure on the rod end of the cylinder, the cylinder
retracts making the trailer go up.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
3300 psi
Relief Valve
# 760162 Counterbalance
To CB4
Pilot Pressure
From Combo
Block
To CB4 Block
Main Line
To BK
Latch
Cylinder Pilot To
Shift Valve
# 760163
Part # 760403
Return to Regulated
Reservoir Pressure
From Combo
Block
CB4 Block
Main Line
From High
Flow Block
Part # 760155
Counterbalance Counterbalance
From High Flow Block Valve # 760157
Bushing Maintenance
Trailer Axle
www.ctmmixers.com
Pivot Bushing Maintenance
The BridgeKing is fitted with 4 polyurethane bushings that are specially designed for
performance and longevity. Maintain your bushings with a routine lubrication. Grease
your bushings once a week to ensure proper performance and optimal life. Make sure
to align the grease zerk & “O” in the polyurethane to ensure grease flow to the entire
bushing.
Bushings are located at the chassis and BridgeKing trailer, as well as both ends of your
BridgeKing cylinder.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
BridgeKing
Pivot
Bushing
# 750051
Trailer
Arm
Truck
Frame
Part # 750051
BridgeKing
Pivot
BridgeKing
Bushing
Cylinder
# 750051
# 750050
Trailer
Cylinder
Mount
For proper maintenance of your Hendrickson Axle see the Hendrickson Installation
and Preventative Maintenance Procedures at the end of this section.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Bridge King
Bridge King Trailer
Fender
# 245115 - RH
# 245116 - LH
Bridge King
Fender
Mount
# 245194 - RH
# 245193 - LH Bridge King
Trailer Axle
# 791200
Part # 791200
Bridge King
Fender Bridge King
Mount Trailer
# 245194 - RH
# 245193 - LH
Bridge King
Trailer Axle
# 791200
2. When the trailer is lowered, turn off the engine. Turn the
key back on and operate the Up/Down switch for the trailer
to relieve the pressure in the BridgeKing system. Turn the A.
key back off.
D.
Page 223 www.ctmmixers.com
Charging The BK Accumulator
9. Using a 3/4” wrench on the stem mounting nut, and
another 3/4” wrench on the charge stem, carefully loosen the
nut. Turn the nut one full rotation counterclockwise before
the tapered seat begins to open. Turn the nut an additional
1/4 turn and read the gauge on the accumulator charge
kit. The reading is the current pressure in the BridgeKing
Accumulator. (Image E)
10. After the air has been purged, and the stem opened, open
the nitrogen bottle until the accumulator charge kit gauge
E.
reads 1100 psi. When this achieved, carefully close the stem.
Do not overtighten the stem. This can cause damage to the
charge stem. (Image F)
11. After the charge stem is closed, check the seal with some
soapy water for leaks. If the stem is not sealed properly, the
soapy water will bubble.
Part # 750005
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Preventative Maintenance . . . . . . . . . . . . . . . . .5
Special Notes . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Kingpin Lubrication . . . . . . . . . . . . . . . . . .5
Required Equipment and Materials for Installation .3 Kingpin Bushing Inspection . . . . . . . . . . . . . . . .6
Installation Instructions . . . . . . . . . . . . . . . . . . . .3 Inspection Procedure . . . . . . . . . . . . . . . . .6
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Checking the Upper Kingpin Bushing . . . . . .6
Parts Handling . . . . . . . . . . . . . . . . . . . . . . .3 Checking the Lower Kingpin Bushing . . . . .6
Unpack Axle . . . . . . . . . . . . . . . . . . . . . . . . .3 Steering Knuckle Inspection and Adjustment . . . .6
Pre-lnstallation Checklist and Procedures . . . . . . .3 Checking Vertical End Play . . . . . . . . . . . . .6
Prior to Installation . . . . . . . . . . . . . . . . . . . . . . .4 Adjusting Vertical End Play . . . . . . . . . . . . .7
Axle Identification . . . . . . . . . . . . . . . . . . .4 Steering Knuckle Disassembly . . . . . . . . . . . . . .7
Axle Adjustments . . . . . . . . . . . . . . . . . . . . . . . .4 Kingpin Preparation and Measurement . . . . . . . .7
Toe Setting . . . . . . . . . . . . . . . . . . . . . . . . . .4
Fabricated Knuckle Kingpin Bushing Installation...9
Turn Angle Mechanical Stop . . . . . . . . . . . . . . . .4
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Bridge Axle (BA) and Tie Rod . . . . . . . . . . . . . . .10
Axle Controls . . . . . . . . . . . . . . . . . . . . . . . .4 Round Tube Tie Rod Adjustment . . . . . . . . . . . . . .10
Manual and Automatic Lift . . . . . . . . . . . . . . .4 Steering Knuckle Assembly . . . . . . . . . . . . . . . .10
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . .5 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . .5 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . .14
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
INTRODUCTION Systems, in exchange for replacement components,
Why use a Bridge Axle? Hendrickson suspensions provided product warranty conditions are met.
and axles carry countless loads of freight and raw
materials off-road and over the highways. Bridge Hendrickson auxiliary axles with factory installed axles
Axles lengthen the distance from front steer axle to may require toe setting adjustments. Also, check for
increase the GVW, in accordance with federal bridge sufficient wheel bearing lubrication (oil).
laws. Hendrickson Bridge Axles also reduce weight
over standard booster axles and allow for increased It is the responsibility of the installer to ensure that
payload. the vehicle will function properly under the increased
weight conditions and loading that will exist when an
additional axle is installed, particularly braking.
The Hendrickson Bridge Axle also helps to meet U.S.
Department of Transportation FHWA-HOP-O6-105. It is the responsibility of the installer to determine the
correct location of the suspension in order to provide
For further information, contact: the proper vehicle load distribution. The load carried
U.S. Department of Transportation by each axle must not exceed the rated capacity of
Federal Highway Administration the components involved or the applicable State and
Office of Freight Management and Operations Federal laws where the truck is to be operated.
Phone: 202-366-9210
Fax: 202-366-3302
Web site: http://www.ops.fhwa.dot.gov/freight/
It is the installer’s responsibility to ensure that proper
publications/brdg_frm_wghts/
clearances exist:
The following instructions are intended for use with
• Between the trailing arms and bridge axle
Hendrickson Bridge Axles.
(if applicable)
NOTE: Read the entire installation instruction docu-
• Around the tires—laterally, fore, aft, and
ment thoroughly before proceeding with a
vertically
suspension installation.
• Around any moving components
It is very important that the proper Bridge Axle is
selected for the vehicle application. The following No welding to any of the Bridge Axle components
criteria must be considered when selecting a bridge is permitted, except where specified by Hendrickson
axle: Specialty Products - Auxiliary Axle Systems.
• trailer and fender interface compatibility
• required capacity No alteration of any of the Bridge Axle components
• loaded caster is permitted.
• tire size
Any installation deviations must be approved, in
For additional information concerning bridge axle
writing, by Hendrickson Specialty Products - Auxiliary
selection, or other suspension models contact the
Axle Systems Product Engineering Department. Failure
Hendrickson Auxiliary Axle System’s Customer
to comply with these installation instructions without
Service Department.
written permission will void the suspension warranty.
CAUTION: The vehicle manufacturer should CAUTION: Subjecting aluminum components to
be consulted before making any certain acid washes may result in
changes to the vehicle’s frame. premature corrosion and warranty
Typically, vehicle manufacturers do could be affected. It is recommended
not permit cutting or altering the that you monitor which cleaning
vehicle and doing so could void any solvents are being used on your vehicle.
applicable manufacturer warranty
coverage. CAUTION: Acid washes also degrade the rubber,
SPECIAL NOTES urethane and plastic parts or the axle
Non-functioning components are to be returned assembly.
to Hendrickson Specialty Products - Auxiliary Axle
H751
2
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
REQUIRED EQUIPMENT AND PRE-INSTALLATION CHECKLIST
MATERIALS FOR INSTALLATION AND PROCEDURES
The following equipment and materials are needed
when installing a Hendrickson Bridge Axle: Before beginning the installation:
1. Check that the new axle matches the
1. Trammel bar. specifications provided by your Production
or Engineering Department.
2. Crane or other lifting device.
2. On all Bridge Axle applications:
3. Compressed air supply.
a. Verify that the axle spacing conforms to
4. Air impact gun.
Federal and local bridge laws.
5. Air fittings, tubing and associated tools.
b. Verify that the Bridge Axle location is
based on: front axle steer angle, vehicle
6. Socket set and wrenches, including the
following sizes: wheel-base and maximum recommended
• 1-5/16”-Tie Rod auxiliary axle spacing.
• 1-1/8” - Steering Knucke & Stop Bolt
c. Verify that the vehicle will have the proper
load distribution after installation.
7. Angle measuring instrument (magnetic protractor)
for self-steer axle. WARNING: ADEQUATE BRIDGE AXLE
SUPPORT MUST BE PROVIDED.
8. Wheel chocks. FAILURE TO PROVIDE ADEQUATE
SUSPENSION SUPPORT COULD
9. Frame jacks or supports. RESULT IN SUSPENSION
DAMAGE AND/OR DAMAGE
INSTALLATION INSTRUCTIONS TO THE VEHICLE.
SAFETY FIRST
Be sure to read and follow all installation and 4. Confirm that the components listed on the axle
maintenance procedures. assembly drawing have been provided in
sufficient quantities. Contact the Hendrickson
Auxiliary Axle Customer Service Department if
LIFTING
any components are missing or damaged.
Practice safe lifting procedures. Consider size, shape
and weight of assemblies. Obtain help or the
assistance of a crane or lift truck when lifting heavy
assemblies. Make sure the path of travel is clear.
PARTS HANDLING
When handling parts, be sure to wear appropriate
gloves, safety glasses and other safety equipment to
prevent serious injury.
UNPACK AXLE
Separate any kitted parts for use during
installation.
H751
3
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
PRIOR TO INSTALLATION 3. Loosen the tie rod clamp bolts. Rotate tie rod tube
to provide a toe-in setting of 1/16” to 1/8” toe-in in
AXLE IDENTIFICATION
the loaded condition.
The serial number tag is an identification label
attached to the suspension system. It contains a NOTE: Setting toe on an Bridge Axle is often best
unique serial number and the model identification performed in the unloaded state, off the
number for that specific axle. (Label is located on ground. Confirm that the toe-in for the
the rear center of the axle or side rail.) operating, loaded, condition has been
achieved as it may differ between the
unloaded and loaded state.
AXLE ADJUSTMENTS
TOE SETTING
Toe is the relationship of the distance between the
front of the tires and the distance between the rear
of the tires on the same self-steer axle measured Figure 3. Axle Turn Limiting Stop Screw
at spindle height. When the front distance is less
than the rear distance, the wheels are in a “toe-in” 1. Adjust the axle turn limiting stop screw for
condition. (See Figure 2) maximum turn angle (See Assembly Drawing)
while providing adequate chassis clearance.
OPTIONS
AXLE CONTROLS
When operating a truck in reverse (backing),
a conventional Bridge Axle must be raised into
Figure 2. Determining TOE
a non-steering configuration. See [H] HAC Series Air
Kit Literature for all options.
1. Lift axle until tires are free to spin. Scribe a line on
center tread of each tire while rotating tires.
MANUAL AND AUTOMATIC LIFT
2. Use a trammel bar or tape measure to measure An alternative method to locking the steering
the distance between the scribed lines on the mech-anism is to lift the suspension when reversing.
front and rear of the tires at spindle height. Various manual and electric air control kits are
available as options. Contact Customer Service for
more details.
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4
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
FINAL ASSEMBLY PREVENTATIVE MAINTENANCE
1. Install all miscellaneous hardware and torque the Regular lubrication intervals should be followed to
mounting bolts as per the chassis manufacturers help prevent premature wear to the kingpin bushings.
specifications.
GREASING AND LUBRICATION SPECIFICATIONS
2. Install wheels and torque lug nuts. COMPONENT GREASING INTERVAL GREASE
2. Check the air control system for leaks and 4. Force the required lubricant into the upper and
propevalve function. lower kingpin grease fittings until new lubricant
flows from locations A and B. (See Figure 4)
3. Move the Bridge Axle through its entire travel
range including full wheel cut with wheels and NOTE: Greasing at the lower zerk should purge
tires installed to ensure adequate component grease from the thrust bearing shell.
clearances (i.e., fenders, brake chambers,etc.)
have been provided.
H751 5
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
IMPORTANT: If one bushing is worn or damaged, it 8. Raise the jack until the dial indicator shows the
is mandatory to replace both the top end of vertical travel. Measure and record the dial
and bottom bushings on that knuckle indicator reading. Vertical (up and down)
assembly. inspection clearance must be between 0.008”
and 0.030”.
H751
6
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
ADJUSTING VERTICAL END PLAY WARNING: REMOVAL OF THE BOLTS WILL ALLOW
1. If vertical clearance is greater than 0.030”, THE BACKBONE TO SEPARATE FROM
replace the thrust bearing. THE AXLE WHICH CAN RESULT IN
COMPONENT DAMAGE AND/OR
PERSONAL INJURY. BACKBONE MUST
2. After replacing the thrust bearing, if vertical BE SUPPORTED BEFORE REMOVAL OF
clearance is greater than 0.018”, install shims THE TWO BOLTS.
(Hendrickson part no. R-001764-1Q12) between
the top of the axle and the bottom of the upper HINT: Remove the grease zerks from the knuckle
kingpin connection to obtain the proper clearance assemblies. This will allow the knuckle
specification. See the Steering Knuckle assemblies to freely slide up and down the
Disassembly section. kingpins without creating back pressure.
3. If vertical clearance is less than 0.008”, remove 5. Remove the backbone from the kingpin by
the shims from between the top of the axle and sliding it down the kingpin.
the bottom of the upper kingpin connection to
obtain the proper clearance specification. 6. Remove the upper kingpin assembly from the
axle by sliding it up and off the kingpin.
4. Repeat steps 2 or 3 until proper clearance is
achieved.
KINGPIN PREPARATION AND
5. Lower the jack. MEASUREMENT
STEERING KNUCKLE DISASSEMBLY CLEANING THE GROUND OR
1. Remove the wheel and hub assembly. POLISHED PARTS
• Use a cleaning solvent to clean ground or
2. Remove the brake components from the polished parts and surfaces. DO NOT USE GASOLINE.
steering knuckle.
CAUTION: Do not use hot solution tanks or
3. Remove the tie rod assembly. (See Figure 7) water and alkaline solutions to clean
ground or polished parts. Damage to the
WARNING: REMOVAL OF TIE ROD BOLTS
ALLOWS SHOCKS TO FULLY parts will result.
EXTEND
CLEANING THE ROUGH PARTS
• Rough parts can be cleaned with the ground or
polished parts. Rough parts can also be cleaned
in hot solution tanks with a weak alkaline
solution. The parts must remain in the hot
solution tanks until they are completely cleaned
and heated.
H751
7
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
PREVENTING CORROSION ON
CLEANED PARTS
• Apply a light coating of oil to all cleaned and
dried parts that are going to be reused. Do not
apply oil to the brake lining or the brake drums.
If parts are to be stored, apply an effective rust
inhibitor to all surfaces.
WARNING: TO HELP PREVENT SERIOUS EYE
INJURY, ALWAYS WEAR PROPER
EYE PROTECTION WHEN YOU Figure 8.
PERFORM VEHICLE MAINTENANCE
OR SERVICE.
H751
8
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
2. Inspect the kingpin for wear or damage. Use a FABRICATED KNUCKLE KINGPIN
micrometer and measure the upper and lower
kingpin in two locations. Positions must be 90
BUSHING INSTALLATION
degrees (perpendicular) from each other. (See 1. A hydraulic press with a minimum forcing
Figures 12 through 15) If the kingpin diameter capacity of 5 tons will be required.
is less than 1.802”, kingpin replacement may
be necessary. Contact the Hendrickson WARNING: BEFORE APPLYING HYDRAULIC
Customer Service Department at 800-660-2843. PRESSURE TO ANY TOOLING SET-UP,
ALWAYS CHECK TO BE SURE THE
PRESS PLATE, ADAPTERS AND
COMPONENTS BEING WORKED ON
ARE POSITIONED PROPERLY, I.E.
“IN LINE” WITH THE RAM. IMPROPER
POSITIONING CAN CAUSE PERSONAL
INJURY AND/OR COMPONENT DAMAGE.
2. Install the backbone assembly or upper kingpin
connection in the press.
Figure 13.
Figure 16.
Figure 14.
Figure 17.
Figure 15.
H751
9
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
BRIDGE AXLE (BA) AND TIE ROD the distance between the scribed lines on the back
STRUCTURAL side of the tires at spindle height.
INSPECTION 6. Subtract the distance between the front side and
Periodic inspection of the Bridge Axle and tie rod are back side of the tires. This is the toe setting. Toe
strongly recommended. Cleaning the BA and tie rod Setting = Rear Distance - Front Distance
prior to the inspection will improve the ability to see
all structural component condition. 7. If the toe setting is set in between 1/16” and 1/8”,
for a standard tie rod, no adjustment is required.
Contact Hendrickson Auxiliary Axle Customer Service If the toe setting is set in more or less than the
for replacement parts or parts kits (800) 660-2843. 1/16” to 1/8” range, refer to the Adjusting the Toe
Setting section of this publication as adjustment is
ROUND TUBE TIE ROD necessary.
ADJUSTMENT
In order for a steerable suspension system to steer or
track correctly, it is necessary for the wheels to be in ADJUSTING THE TOE SETTING
a “toe-in” condition. Toe is the difference between the 1. Loosen the tie rod clamp bolts, stabilizer
foremost and rearmost point on the tires at spindle mounting u-bolts (if applicable) and nuts.
height. When the foremost distance is less than the
rearmost distance, the wheel pair is said to have 2. Rotate tie rod tube to provide a toe-in setting of
toe-in. Toe not only affects tire wear, but also straight- 1/16” to 1/8”.
line stability and corner handling. Having a proper
toe setting is important for directional stability. On 3. Torque the clamp bolts to 50 ft-lbs.
steerable axles, the toe is pre-set during assembly,
however sometimes it becomes necessary to adjust STEERING KNUCKLE ASSEMBLY
the toe. It is also necessary to verify the toe upon axle After replacing the kingpin housings, it is necessary
installation. For additional information regarding toe to reassemble the steering knuckle assemblies.
settings or lift axle systems, please contact the Hen-
drickson Customer Service Department at 1. Install the thrust bearing on the lower kingpin,
800-660-2829. so the top side is up (the thrust bearing may be
To adjust the toe setting, follow these instructions. stamped “TOP” or the black seal will designate
the top side), when the axle is in the operating
DETERMINING THE TOE SETTING position.
WARNING: NEVER PERFORM MAINTENANCE ON 2. Pack the bearing dimples with multipurpose
A SUSPENSION WITHOUT FIRST RE- grease (NLGI Grade 2).
LEASING AIR PRESSURE FROM AIR
SPRINGS. COMPONENT DAMAGE,
3. Install the backbone assembly on the kingpin.
INJURY OR DEATH CAN OTHERWISE
It will be necessary to support the backbone
RESULT.
assembly with a bottle jack and a block of wood
under the backbone assembly. (See Figure 18)
1. Lift axle until tires are free to spin.
Hint: The easiest way to install the knuckle is with the
2. Support the suspension with jack stands.
zerk grease fitting not installed in the backbone
assemblies. In this manner, it does not create
3. Scribe a line on center tread of each tire while back pressure. The assembly can then freely
rotating tires.
slide up and down on the kingpin.
4. Use a trammel bar or tape measure to measure
4. Raise the bottle jack so that there is no free play
the distance between the scribed lines on the
between the backbone, thrust bearing and the
front side of the tires at spindle height.
bottom of the axle.
5. Use a trammel bar or tape measure to measure
5. Install the upper kingpin connection on the upper
kingpin. (See Figure 18)
H751
10
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
5/8” Brake
Backing
Plate Bolts
Figure 20.
Magnification of
kingpin bushing NOTE: Two guide studs may be substituted in place
Figure 18. and lip seal of the brake backing plate bolts.
installed in steer-
ing knuckle. 6. Install the two new 3/4”-10 x 2.25” Grade 8 HEX
bolts and secure with washer and nuts to finger
tight.
Figure 21.
H751
11
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
12. Install the upper kingpin connection onto the 18. Raise the bottle jack until there is no clearance
kingpin. between the backbone and the bottom of the
axle.
13. Slide two 0.010” feeler gauges on each side
of the kingpin between the axle and the upper 19. Check the reading on the dial indicator. The
kingpin connection. specification for vertical travel on the steering
knuckle assemblies is 0.008” to 0.018”.
WARNING: PRIOR TO INSTALLATION ENSURE
THAT ALL RESIDUAL LOCTITE MATE- 20. If the clearance is not within the required specifi-
RIAL IS REMOVED FROM THE MOUNT- cation, repeat steps 3 through 9 until the proper
ING BOLTS AND THE THREADED HOLES clearance is obtained by adding or removing
IN THE UPPER KINGPIN CONNECTION, shims.
AND NEW LOCTITE 277 OR EQUIVA-
LENT IS APPLIED TO HELP ENSURE 21. If the vertical travel is not within the specification,
THAT THE BOLTS SUSTAIN THE PROPER repeat steps 3 through 16 until the proper verti-
TORQUE REQUIREMENT. FAILURE TO cal travel is obtained.
DO SO CAN CAUSE LOSS OF VEHICLE
CONTROL RESULTING IN PERSONAL 22. Remove the bottle jack to remove the load off the
INJURY OR PROPERTY DAMAGE. knuckle assembly and continue assembling the
wheel ends.
14. Install the hex head bolts and tighten
to 175-200 ft-lbs torque. 23. Install the tie rod cross tube into the tie rod arm.
NOTE: The Hendrickson Genuine Part 3/4- 24. Tighten the castle nuts to 185 ft-lbs torque, then
10 x 2-1/2 GRADE 8 HEX bolt rotate the castle nut to the next castle slot and
(PN: R-6110C125H4H8). Apply LocTite. install the cotter pin.
15. Once the final torque of the hex nuts has been 25. Tighten bolts to 140-160 ft-lbs torque.
obtained, remove the two 0.010” feeler gauges
and lower the bottle jack. NOTE: LocTite applied to knuckle assembly bolts is
a critical procedure to ensure that these bolts
Vertical End Play sustain the torque requirement of the kingpin
connection.
26. Install new o-rings on the grease caps and
lubricate the o-rings with grease.
Figure 22.
H751
12
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
APPENDIX A
RECOMMENDED BOLT TORQUES
Refer to table below for bolt torque values.
TORQUE TABLE
Item Part Number Quantity Torque
Stabilizer nut 6112C350H4H8 2 80-120 ft. lbs.
Stabilizer bolt 6112C550H4H8 2
Tie rod castle nut Included in tie rod end 2 180 ft. lbs.
Knuckle main nut 6012CH2LC 4 250-300 ft. lbs.
Knuckle main bolt 6112C225H4H8 4
Brake anchor pin nut 6010CH2LC 2 160-200 ft. lbs.
Brake anchor pin bolt 6110C500H4H8 2
Brake chamber mounting nut Included in brake chamber 4 130-150 ft. lbs.
Jam nut Included in brake chamber 2 33-90 ft. lbs
H751
13
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
APPENDIX B
BRAKE REPLACEMENT
1. Raise and support the suspension to which the Figure 28. Removal of Return Spring
brakes are to be replaced. Remove wheel, brake
drum and axle end components to expose the 4. Remove the brake bolts and brake anchor pin.
brake shoes. If lock straight target is present, note position
for proper reassembly location.
2. Remove the outer retaining spring and inner
retaining spring.
H751
14
BRIDGE AXLE INSTALLATION AND MAINTENANCE PROCEDURES
NOTES:
Call Hendrickson at 1.800.660.2829 or 1.800.668.5360 in Canada for additional information and application specifications.
H751 10-13
Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected. © 2013 Hendrickson USA, L.L.C. All Rights Printed in United States of America
SD-03-953
®
1.5"
3/8 P.T. .340”
SUPPLY PORT MOUNTING
HOLES (2)
STAMPED LQ-5
REPLACEMENT
PC. NO.
1/8 P.T.
CONTROL PORT
3/8 P.T.
DELIVERY PORT
DESCRIPTION
The LQ-5™ bobtail ratio valve is used on the front (steering) Although it is not mandatory, the LQ-5™ valve is used in
axle of tractor air brake systems to reduce brake applica- conjunction with the BP-R1™ bobtail brake proportioning relay
tion pressure during normal tractor-trailer operation. It is valve, only when a customer specifies a front axle ratio valve.
designed for tractor systems only and replaces the existing The BP-R1™ valve and LQ-5™ valve combine to reduce
front axle limiting valve. It is not to be used on straight trucks stopping distance and improve tractor control in bobtail mode.
or towing trucks. Also, a quick release valve must be in- (For more information on the BP-R1™ valve, see SD-03-1067.)
stalled between the LQ-5™ valve delivery and the brake
chambers. OPERATION
IMPORTANT: Do not replace the BP-1™ front brake pro- GENERAL
portioning valve with the LQ-5™ valve. The LQ-5™ valve After an initial delivery, the LQ-5™ valve limits front axle brake
will not function properly in the BP-1™ valve system. pressure during normal tractor-trailer operation. The LQ-5™
Caution: The LQ-5™ valve can replace the LQ-4™ ratio valve valve has two spring-loaded pistons: a blend back piston
on tractors. The LQ-5™ valve control port must be connected and a proportioning piston. The “stepped” proportioning piston
to the trailer supply line. When the tractor is disconnected determines actual air pressure reduction and the blend back
from the trailer, bobtail tractor braking performance is improved piston allows the valveʼs delivery pressure to “blend back”
because full brake valve pressure will be applied to the and reach a 1:1 ratio during high pressure brake applications.
steering axle brakes.
1
BRAKE
CHAMBER
PP-7™
TRAILER
SUPPLY BRAKE
VALVE VALVE
SUPPLY
QUICK RELEASE
VALVE LP-3™ LOW
PRESSURE
LQ-5™ INDICATOR
VALVE GAUGE
DELIVERY
FRONT AXLE
SERVICE RESERVOIR
BRAKE CHAMBER
The LQ-5™ valve also allows full service pressure to pass TRACTOR-TRAILER MODE
through it when the trailer supply valve (red octagonal button)
Brake Application—LQ-5™ Valve Limiting
is pulled out—when the tractor is running in bobtail mode.
During tractor-trailer operation, the trailer supply valve (red
Note: LQ-5™ valve control pressure, which comes from the octagonal button) is depressed and delivers air pressure
trailer supply line, will vary. As a result, the LQ-5™ valve simultaneously to the trailer and to the LQ-5™ valve control
delivery and blend back ranges will also vary, because the port. Air pressure enters the LQ-5™ valve control port and
blend back piston works against control pressure. Figure 3 displaces the blend back piston, against the resistance of
shows the LQ-5™ valve delivery range at two control its spring, until the piston contacts the cover.
pressures: 90 psi and 120 psi.
Control pressure holds the blend back piston against the
CONTROL PRESSURE
120 PSI cover and the “initial delivery” spring forces the proportioning
FRONT piston to its seat in the body, which opens the inlet. The
AXLE “initial delivery” pressure is designed to ensure that the brake
BRAKE
CHAMBER linings contact the brake drums before proportioning occurs.
PRESSURE The exhaust valve is sealed due to its spring. Brake valve air
pressure enters the supply port, moves through the center
CONTROL of the pistons, around the inlet/exhaust valve, and out to the
NO CONTROL PRESSURE
PRESSURE 90 PSI front axle actuators.
BLEND
BACK
SPRING
BODY
TRAILER
SUPPLY BLEND
VALVE BACK
PISTON
INITIAL
DELIVERY
PISTON
PROPORTIONING
PISTON
FRONT
BRAKE INLET/
CHAMBER EXHAUST
VALVE
FIGURE 4 - LQ-5™ BOBTAIL RATIO VALVE LIMITING: TRACTOR-TRAILER MODE (SHOWN DURING INITIAL DELIVERY)
BOBTAIL MODE
BRAKE VALVE APPLICATION, BALANCE,
RELEASE
When the trailer supply valve is pulled out, air in the LQ-5™
valve control port flows back to the trailer supply valve and
exhausts to atmosphere. With no control pressure, the blend
back piston is forced by its spring to contact the proportioning
piston. The inlet/exhaust valve is held by its spring and seals
the exhaust passage. Both pistons, now moving as one,
reach their stop in the body.
This is the position for bobtail mode apply, hold and release.
FIGURE 7 - LQ-5™ BOBTAIL RATIO VALVE BLENDING The LQ-5™ valve delivers full service application pressure in
BACK: TRACTOR-TRAILER MODE
4
bobtail mode. Upon brake valve release, delivery air pressure PREVENTIVE MAINTENANCE
flows back through the LQ-5™ valve, to the brake valve and
out to atmosphere. Air from the actuators exhausts through GENERAL
the quick release valve.
Perform the following tests and inspections at the prescribed
WARNING! PLEASE READ AND FOLLOW intervals. If the LQ-5™ valve fails to function as described or
THESE INSTRUCTIONS TO AVOID if leakage is excessive, repair the valve or replace it with a
PERSONAL INJURY OR DEATH: new or genuine Bendix remanufactured unit, available at any
authorized parts outlet.
When working on or around a vehicle, the following
general precautions should be observed at all times. Important: Review the Bendix Warranty Policy before
1. Park the vehicle on a level surface, apply the performing any intrusive maintenance procedures. A warranty
parking brakes, and always block the wheels. may be voided if intrusive maintenance is performed during
Always wear safety glasses. the warranty period.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When No two vehicles operate under identical conditions, as a
working in the engine compartment, the engine result, maintenance intervals may vary. Experience is a
should be shut off and the ignition key should be valuable guide in determining the best maintenance interval
removed. Where circumstances require that the for air brake system components. At a minimum, the valve
engine be in operation, EXTREME CAUTION should should be inspected every 6 months or 1500 operating hours,
be used to prevent personal injury resulting from whichever comes first, for proper operation. Should the valve
contact with moving, rotating, leaking, heated or not meet the elements of the operational tests noted in this
electrically charged components. document, further investigation and service of the valve may
3. Do not attempt to install, remove, disassemble or be required.
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and observe
OPERATION & LEAKAGE TESTS
all precautions pertaining to use of those tools. OPERATION TEST
4. If the work is being performed on the vehicleʼs air
brake system, or any auxiliary pressurized air To properly test the LQ-5™ valve, use a pair of test gauges or
systems, make certain to drain the air pressure from gauges of known accuracy.
all reservoirs before beginning ANY work on the 1. With the trailer supply valve pushed in (tractor-trailer
vehicle. If the vehicle is equipped with an AD-IS™
mode), install two air gauges in the front axle service
air dryer system or a dryer reservoir module, be
system: one between the brake valve and the LQ-5™
sure to drain the purge reservoir.
5. Following the vehicle manufacturerʼs valve and one at a front axle actuator.
recommended procedures, deactivate the electrical 2 Build system pressure to governor cut-out setting.
system in a manner that safely removes all 3. Make a service brake application with the foot valve and
electrical power from the vehicle.
have someone observe the gauges. When the gauge
6. Never exceed manufacturerʼs recommended
between the foot valve and the LQ-5™ valve reaches 40
pressures.
7. Never connect or disconnect a hose or line psi, the actuator gauge should read approximately 20
containing pressure; it may whip. Never remove a psi (±5 psi).
component or plug unless you are certain all 4. Make a full service brake application. Both gauges should
system pressure has been depleted. read the same pressure.
8. Use only genuine Bendix ® replacement parts, 5. With the trailer supply valve pulled out (bobtail mode),
components and kits. Replacement hardware,
make a 30-40 psi service brake application. Both gauges
tubing, hose, fittings, etc. must be of equivalent
should read the same pressure.
size, type and strength as original equipment and
be designed specifically for such applications and 6. Remove the test gauges.
systems.
9. Components with stripped threads or damaged LEAKAGE TEST
parts should be replaced rather than repaired. Do 1. Build system pressure to governor cut-out. With the trailer
not attempt repairs requiring machining or welding supply valve pushed in (tractor-trailer mode), apply a soap
unless specifically stated and approved by the solution to the LQ-5™ valve exhaust port. The leakage
vehicle and component manufacturer. should not exceed a 1" bubble in less than 3 seconds.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored to
their proper operating condition.
5
2. Make and hold a full brake application and apply a soap
solution to the exhaust port and around the cover where
it joins the body. The leakage should not exceed a 1" COVER
bubble in less than 3 seconds.
VALVE INSTALLATION 5
3
4
6
5. Make certain all air channels are clear and free of 4. Insert the proportioning piston into the small bore of the
obstruction. blend back piston and install the piston assembly in the
6. Inspect all pipe threads and make sure they are clean body.
and free of thread sealant. 5. Install spring seat into the piston assembly bore, small
7. Inspect all air line fittings for corrosion and replace as end first.
necessary. 6. Install the “initial delivery” spring on the inner wall of the
spring seat.
ASSEMBLY
7. Install the blend back spring in the inner diameter of the
1. Before assembly, lubricate o-rings, pistons, and body blend back piston so that it surrounds the “initial
and cover bores with the lubricant in the Bendix mainte- delivery” spring.
nance kit.
8. Place the cover on the body in the proper position, as
2. Install o-rings (3 & 4) on proportioning piston. Install marked in Disassembly, Step 2. Make sure the springs
o-rings (2 & 4) on blend back piston. Install o-ring (1) on are square when the cover is attached to the body.
cover.
9. Using the Phillips head screws and their lock-washers,
3. Place inlet/exhaust valve (5) into the inner diameter of secure the cover to the body. Torque the screws to 50-
the proportioning piston and retain with valve spring (6). 80 inch pounds.
Use needle nose pliers to install the spring by grasping
10. Install all air line fittings, making sure thread sealing
it on the bar that intersects its end and turning clock-
material does not enter the valve.
wise while pressing down. The bar must be away from
(not touching) the valve. 11. Mount LQ-5™ valve on the vehicle and perform Operation
and Leakage Tests before returning the vehicle to
Note: Make sure spring coils do not overlap each other
service.
as the spring compresses into the proportioning piston.
Also, make sure the valve is square, contacts the seat,
and doesnʼt bind.
7
BW1625 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 4/2004 Printed in U.S.A.
8
Drum Drive - Gearbox
ZF Maintenance
P/PK/CML
www.ctmmixers.com
ZF Transmission Maintenance
The ECOMIX I range of hydrostatic transmissions is part of the well-proven technology
from ZF. It facilitates economical and low-maintenance operation of mixer trucks,
even under the highest stresses. The compact and space-saving transmissions are
characterized by their high power density and a long service life.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Fan Cooler
Motor
Part # 748008
Service-friendliness has also been improved. The ECOMIX II is easily accessible due to
its compact design. Lifetime (10,000 hr) oil filling does not only save oil changes, it also
protects the environment. A cassette-type seal is used instead of the previous sealing
collar, which makes the transmission more robust and increases service life.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
Front Fan
Slump Cooler
Gauge # 740010
CML
Gear
Box
# 748010
Part # 748010
Oil
Reservoir
¡
¡
¡
¡
¡
¡
¡
¡
Spare Parts Catalog
P 7300
Material number: 4108.017.100
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Tecnical Cover
Page 1 from 3
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Tecnical Cover
Page 2 from 3
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Tecnical Cover
Page 3 from 3
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Assembly group overview
Page 1 from 1
Amend. Amend.
Graphics Pos. Material number Name VKF Prod. no. Material feature / tech. info. ID
no. start
410810101400 001 4108.101.097 HOUSING 1 00.00.0000 0
410810200100 002 4108.102.053 INPUT 1 00.00.0000 0
K01247/
410810301100 003 4108.103.132 OUTPUT 1 00.00.0000 0
06
410819600100 004 4108.196.021 LOOSE PARTS 1 00.00.0000 0
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Parts list Plant: 410810101400
Page 1 from 1
Material-assembly-group-no: 4108.101.097
VKF Incidence factor OTK Optional technical kit ID Identification (output code) SP Supplier plant
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Plant Page 1 from 1 Plant: 410810200100 INPUT
Material-assembly-group-no: 4108.102.053
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Parts list Plant: 410810200100
Page 1 from 1
Material-assembly-group-no: 4108.102.053
VKF Incidence factor OTK Optional technical kit ID Identification (output code) SP Supplier plant
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Plant Page 1 from 1 Plant: 410810301100 OUTPUT
Material-assembly-group-no: 4108.103.132
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Parts list Plant: 410810301100
Page 1 from 1
Material-assembly-group-no: 4108.103.132
VKF Incidence factor OTK Optional technical kit ID Identification (output code) SP Supplier plant
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Plant Page 1 from 1 Plant: 410819600100 LOOSE PARTS
Material-assembly-group-no: 4108.196.021
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Material number: 4108.017.100 P 7300 /
Parts list Plant: 410819600100
Page 1 from 1
Material-assembly-group-no: 4108.196.021
VKF Incidence factor OTK Optional technical kit ID Identification (output code) SP Supplier plant
© All rights reserved by ZF Passau, even in the event of applications for copyright. We hold all rights of disposal, such as the right to copy and disseminate. 05.02.2007
For information only, not subject to the amendment service.
Ersatzteilkatalog
Spare-parts catalog
CML 10
© Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. 19.10.2010
© The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.
Produkt / Product: 4108.072.003 CML 10 Ersatzteilkatalog / Spare-parts catalog
19.10.2010
© Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. Seite / Page: 2-6
© The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.
Produkt / Product: 4108.072.003 CML 10 Ersatzteilkatalog / Spare-parts catalog
Bildtafel / Figure:
Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info
4108.102.066-070-1-PLT 4108.102.066 ANTRIEB CML 10
410810206670 DRIVE
100
110 090/010
090/010/010
120
090/010/020
090
19.10.2010
© Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. Seite / Page: 3-6
© The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.
Produkt / Product: 4108.072.003 CML 10 Ersatzteilkatalog / Spare-parts catalog
Bildtafel / Figure:
Dokument / Document Materialnr. / Material number Benennung / Description Technische Info / Technical info
4108.103.160-070-1-PLT 4108.103.160 ABTRIEB n/a
410810316070 OUTPUT
270
245
185
190
170
200
180
19.10.2010
© Die vorliegende Dokumentation ist urheberrechtlich geschützt. Eine Vervielfältigung und Verbreitung in jeglicher Form, die nicht ausschließlich der Zweckbestimmung der Dokumentation entspricht, ist ohne Genehmigung der ZF Friedrichshafen AG untersagt. Seite / Page: 5-6
© The present documentation is protected by copyright. Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.
Produkt / Product: 4108.072.003 CML 10 Ersatzteilkatalog / Spare-parts catalog
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REPAIR MANUAL
ZF - ECOMIX II
CML8/10
Repair Level I
5871.790.202 en
REPAIR MANUAL
ZF Ecomix II
CML10
Repair Level I
IMPORTANT INFORMATION:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to
acurrent ZF production unit. Continuous technical upgrading of the ZF units and extensions
concerning design options may require deviating work steps which can be carried out by qualified
specialists without greater difficulties by means of the perspective views included in the
corresponding spare parts lists.
This disassembly and reassembly manual is based on the design level of a ZF production unit
at the time of issue of the manual.
ATTENTION:
Observe the vehicle manufacturer’s instructions and specifications for the
installation and commissioning of the unit!
ZF Friedrichshafen AG
Donaustr. 25 - 71
D - 94034 Passau
Section.: MAIP21
Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction
or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Design level 2009/11
2. Edition 2011/11
TABLE OF CONTENTS Chapter/Page
Preface 0/1
PREFACE
This documentation has been developed for specialized staff trained by ZF Friedrichshafen
AG for repair and maintenance work to be done on ZF units.
This documentation describes a ZF series product with a design level valid at the date
of edition
Due to the continuous technical upgrading of the product, however, the repair of the unit at
your disposal may require both deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters and servicemen with the work on
your ZF product whose practical and theoretical training is constantly updated in our training
school.
The Service Stations established by ZF Friedrichshafen AG all over the world offer you:
Any damage resulting from work which is done in an improper and unprofessional manner
by third parties and any consequential costs incurred shall be excluded from this contractual
liability.
This shall also be applicable if other than genuine ZF spare parts are used.
ZF Friedrichshafen AG
5871.790.202 en 0/1
PREFACE
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the unit, ensure utmost cleanliness and excellent workmanship.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or
nuts, loosen covers and housing parts which were installed with seals by slight blows with a
plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the
shafts, such as bearings, bearing rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools
which have been developed for this purpose. Prior to reinstallation of the parts, clean contact
faces of housings and lids from residues of seals. Remove any burrs or similar irregularities
with an oil stone. Clean housings and end covers, in particular corners and angles, with a
suitable detergent. Damaged or heavily worn parts must be replaced, with an expert
assessing whether parts subject to normal wear during operation, such as bearings, thrust
washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial
seal rings with worn or broken sealing lip must also be renewed. In particular, ensure that no
chips or other foreign bodies remain in the housing. Check the lube oil holes and grooves
regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their
installation.
NOTE: Only a heating furnace or an electric drier is permitted to be used for heating
parts such as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a
perfect contact.
CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated
in the manual. Tighten screws and nuts according to the enclosed standard table, unless
otherwise specified.
When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves!
NEVER wash disks having organic friction linings (e.g. paper disks) since this would have an
adverse effect on lining adhesion!
Only dry-cleaning is permitted (leather cloth).
DANGER
When using detergents, observe the manufacturer’s instructions regarding their
handling.
5871.790.202 en 0/2
PREFACE
The structure of this repair manual reflects the sequence of work steps for completely
dismantling the removed unit.
Tools required for carrying out the repair work are listed in the current text as well as in
chapters “WS” (List of Special Tools) and “WH” (Commercial Tools).
As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall
be fully responsible for labor safety.
The observance of all valid safety regulations and legal requirements is a prerequisite
for avoiding any damage to persons and products during maintenance and repair
work.
Repair workshops must familiarize themselves with these regulations prior to starting
any work.
A suitably trained and skilled staff is required for a proper repair of these ZF products.
NOTE: Thoroughly study this manual before starting any inspections or repair work.
NOTE: Figures, drawings and parts in this manual do not always represent the original;
they show the working procedure.
Since the figures, drawings and parts are not shown to scale, do not draw any
conclusions on size and weight (not even within one and the same illustration).
Carry out work according to the legend.
NOTE: After repair work and tests, the expert staff must verify that the product is
perfectly functioning again.
5871.790.202 en 0/3
PREFACE
INSTALLATION SHEET
ZF ECOMIX II
CML10
5 6
7
2
3 9
4 10
5871.790.202 en 0/4
PREFACE
3
1
4
2 5
1. = Unit type
2. = Serial number You will find this information on the identification plate!
3. = ZF parts list number
4. = Make and type of spare part
5. = Denomination of spare part
6. = Spare part number
7. = Shipping mode
Please indicate all the a.m. details to avoid any mistakes in the delivery of the ordered spare
parts!
5871.790.202 en 0/5
RECTIFICATION OF LEAKAGES
Figure 2
3
Figure 3
Place O-rings 7x1.5 (2) into the mounting holes and grease
them.
5871.790.202 en 1/1
RECTIFICATION OF LEAKAGES
Figure 5
Figure 6
1
Figure 7
Figure 8
5871.790.202 en 1/2
RECTIFICATION OF LEAKAGES
Tightening torque MA = 4 Nm
1
Figure 9
5871.790.202 en 1/3
EXCHANGE OF HYDRAULIC MOTOR
Figure 2
Figure 3
Figure 4
5871.790.202 en 2/1
EXCHANGE OF HYDRAULIC MOTOR
Pull off hydraulic motor (1) and remove seal ring (2).
Figure 5
Figure 6
Figure 7
Figure 8
5871.790.202 en 2/2
EXCHANGE OF HYDRAULIC MOTOR
A B
High pressure connections (arrows) must be arranged
horizontally!
Figure 9
Figure 10
Figure 11
Figure 12
5871.790.202 en 2/3
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Revised 6-30-2010 Page 1 of 3
www.ctmmixers.com
Drum Roller Maintenance
Drum roller adjustment and maintenance is CRITICAL to maintaining optimum
performance of your Con-Tech mixer. Failing to follow a regular WEEKLY
maintenance schedule can result in premature wear, costly repairs, and downtime.
The drum rollers should be inspected every week (for alignment and bearing wear) and
greased using a General Purpose EP #2 Lithium grease. The greasing procedure should
consist of pumping enough grease into the rollers until it comes OUT of the seal area
clean and free of contaminates.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
4 - Roller Alignment:
Using a straight edge or a 4’ level, align both 3/4” Spacer
front edges of the roller foot to be flush with or Tape Measure
Flush w/ Roller
the straight edge. This must be done while
maintaining the 3/4” offset spacing on the roller
track face. See Images D & E
C.
*Visually inspect roller to roller track contact
area when loaded to verify proper shimming.
Variances in chassis frames and size of load will
affect how much shimming is required.
Flush w/ Roller
LUBRIPLATE No. 1500, 1550, 1551, and 1552 are lithium complex greases that can be used for a
variety of industrial, automotive and heavy-duty construction applications. These rugged, extreme
pressure lubricants can withstand higher operating temperatures than traditional lithium multi-purpose
greases as well as most lithium complex greases.
LUBRIPLATE No. 1552 and No. 1551 are tacky, adhesive and very water resistant. The film strength
and shear stability of these products are exceptional resulting in wear reduction and long lubricant life.
LUBRIPLATE No. 1552 and No. 1551 provide outstanding lubrication in a variety of applications
including:
LUBRIPLATE No. 1550 is ideal for heavy load, tight tolerance situations and can be pumped easily
through automatic dispensing systems on construction and mining equipment as well as industrial
applications.
LUBRIPLATE No. 1500 can be used for a variety of industrial and automotive applications. It is
ideally suited for use in leaky gear cases that require a semi-fluid grease. It is also recommended for use
in new on-highway trailer wheel bearings where a semi-fluid grease is required. LUBRIPLATE No.
1500 can also be used in centralized lubrication systems, especially those operating at higher
temperatures.
(Over)
Typical Characteristics
Timken EP Test (ASTM D-2509) 60 lb. OK Load 50 lb. OK Load 50 lb. OK Load 50 lb. OK Load
Four Ball EP Test (ASTM D-2596) 680 kg. OK Load 480 kg. OK Load 460 kg. OK Load 420 kg. OK Load
Oil Separation (ASTM D-1742) 1.1% 5.0% Not Applicable Not Applicable
Packaging Availability No. 1552 No. 1551 No. 1550 No. 1500
Printed in USA
Revised 6/21/07
Pusher Axle
If your chassis came with a factory mounted pusher, please reference the chassis service
manual.
If you have any service issues with a pusher installed by Con-Tech, call Con-Tech
service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of
work or maintenance on your vehicles.
www.ctmmixers.com
TECHNICAL
PROCEDURE
STEERABLE SUSPENSION SYSTEM
SUBJECT: Installation and Preventative
Maintenance Procedures
LIT NO: H633
DATE: May 2011 REVISION: E
SCT13 SCO13 / 20
SCT10
SCR13 SCT20
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Manual and Automatic Lift . . . . . . . . . . . . . . .9
Special Notes . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . .9
Required Equipment and Materials for Installation .3 Final Inspection . . . . . . . . . . . . . . . . . . . . . . . .10
Installation Instructions . . . . . . . . . . . . . . . . . . . .4 Preventative Maintenance . . . . . . . . . . . . . . . . .10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Kingpin Lubrication . . . . . . . . . . . . . . . . . .10
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Kingpin Bushing Inspection . . . . . . . . . . . . . . . .11
Parts Handling . . . . . . . . . . . . . . . . . . . . . . .4 Inspection Procedure . . . . . . . . . . . . . . . . .11
Unpack Axle . . . . . . . . . . . . . . . . . . . . . . . . .4 Checking the Upper Kingpin Bushing . . . . . .11
Pre-lnstallation Checklist and Procedures . . . . . . .4 Checking the Lower Kingpin Bushing . . . . . .12
Prior to Installation . . . . . . . . . . . . . . . . . . . . . . .5 Steering Knuckle Inspection and Adjustment . . . .12
Axle Identification . . . . . . . . . . . . . . . . . . . . .5 Checking Vertical End Play . . . . . . . . . . . . .12
Suspension Adjustability . . . . . . . . . . . . . . . .5 Adjusting Vertical End Play . . . . . . . . . . . . .12
Adjustable Ride Height . . . . . . . . . . . . . . . . .5 Steering Knuckle Disassembly . . . . . . . . . . . . . .13
Ride Height Spacer Installation . . . . . . . . . . . .5 Kingpin Preparation and Measurement . . . . . . . .13
Adjustable Frame Width . . . . . . . . . . . . . . . .5 Fabricated Knuckle Kingpin Bushing Installation .14
Frame Width Adjustment Procedures . . . . . . .6 Lift Axle (LA) and Compliant Tie Rod (CTR) Lift
Suspension Mounting Installation Procedures . . . .6 Beam Urethane Bushings . . . . . . . . . . . . . . . . .15
Suspension Frame Rail Installation . . . . . . . . . . . .7 Pre SC Round Tube Tie Rod Adjustment . . . . . . .15
Upper Air Spring Plate Assembly and Air Spring Cast Knuckle Kingpin Bushing Removal . . . . . . .16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Cast Steering Knuckle Bore Measurement . . . . . .16
Axle Adjustments . . . . . . . . . . . . . . . . . . . . . . . .9 Kingpin Bushing Installation . . . . . . . . . . . . . . .17
Toe Setting . . . . . . . . . . . . . . . . . . . . . . . . . .9 Kingpin Bushing Reaming . . . . . . . . . . . . . . . . .17
Turn Angle Mechanical Stop . . . . . . . . . . . . . . . .9 Kingpin Seal Installation . . . . . . . . . . . . . . . . . .19
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Steering Knuckle Assembly . . . . . . . . . . . . . . . .19
Axle Controls . . . . . . . . . . . . . . . . . . . . . . . .9 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Lock Straight . . . . . . . . . . . . . . . . . . . . . . . .9 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . .23
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
The following instructions are intended for use with SPECIAL NOTES
Hendrickson COMPOSILITE™Auxiliary Liftable Air Non-functioning components are to be returned to
Ride Suspensions. Hendrickson Auxiliary Axle Systems, in exchange for
replacement components, provided product warranty
NOTE: Read the entire installation instruction conditions are met.
document thoroughly before proceeding with
a suspension installation. Hendrickson Auxiliary Liftable Air Ride Suspensions
with factory installed axles may require toe setting
It is very important that the proper suspension is adjustments. Also, check for sufficient wheel bearing
selected for the vehicle application. The following lubrication (oil).
criteria must be considered when selecting a
suspension: It is the responsibility of the installer to ensure that
• required capacity the vehicle will function properly under the increased
• loaded frame-to-ground measurement weight conditions and loading that will exist when
• driveline clearance an additional axle is installed, particularly braking.
• axle travel
• axle spacing It is the responsibility of the installer to determine the
• tire size for auxiliary axle correct location of the suspension in order to provide
• Requirement for a steerable or non-steerable the proper vehicle load distribution. The load carried
suspension by each axle must not exceed the rated capacity of
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
the components involved or the applicable State and 2. Torque wrench (capability of 450 ft. Ibs. for
Federal laws where the truck is to be operated. frame bolt installation).
It is the installer’s responsibility to ensure that proper 3. Tape measure or scale(s) and machinist
clearances exist: square.
• Around the air springs when they are at their 7. Compressed air supply.
maximum diameter (refer to suspension
assembly drawing for specifications) 8. Air impact gun.
• Around any moving suspension components 9. Air fittings, tubing and associated tools.
No welding to any of the suspension components is 10. Socket set and wrenches, including the
permitted, except where specified by Hendrickson following sizes:
Auxiliary Axle Systems. • 3/8"
• 9/16"
No alteration of any of the suspension components • 3/4"
is permitted. • 15/16"
• 1-1/8"
Any installation deviations must be approved, in • 1-1/4" deep well socket
writing, by Hendrickson Auxiliary Axle Systems
Product Engineering Department. Failure to comply 11. C-clamps or bar clamps with the minimum
with these installation instructions without written opening equal to the vehicle frame height.
permission will void the suspension warranty.
12. Suspension assembly drawing supplied by
CAUTION: Subjecting aluminum components to Hendrickson. Plumbing schematics supplied
certain acid washes may result in for pre-plumb suspensions only.
premature corrosion and warranty
could be affected. It is 13. Angle measuring instrument (magnetic
recommended that you monitor protractor) for self-steer axle.
which cleaning solvents are being
used on your vehicle. 14. Wheel chocks.
CAUTION: Acid washes also degrade the 15. Frame jacks or supports.
rubber, urethane and plastic parts or
the axle assembly.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
RIDE HEIGHT SPACER INSTALLATION (IF Figure 3 - Air spring plate spacer
EQUIPPED)
1. Determine if a spacer is needed based on the
ride height required and the base ride height of
suspension model to be installed.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
4. If a 34.5 inch frame width is needed, loosen but 2. If the vehicle frame is forward-sloping or tapered,
do not remove the four pivot bolts connecting the see Caster Angle Section before drilling.
hanger to the bushing saddle. Next, loosen the
four bolts connecting the cross member to the 3. Position the vehicle on a flat level surface.
hangers. Add one frame width spacer to both sides
of the suspension. Retorque the pivot bolts and 4. Determine the location of the auxiliary axle
cross member bolts. See torque values below. mounting position on the outside of the vehicle
(See figure 3 for frame width spacer reference) frame rails. Refer to the suspension assembly
drawing and mark the front edge of the auxiliary
suspension side rails on the vehicle frame.
(See Figure 5)
FRAME WIDTH
SPACER IN POSITION 5. Correct any interferences that occur between
FRAME WIDTH SPACER the auxiliary suspension mounting surface and
READY TO ROTATE INTO
POSITION any existing frame bolts or brackets (located
in the marked areas). The auxiliary suspension
side rail(s) can be drilled to accommodate
existing bolts.
Figure 4 - Frame width spacer
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
6. Before any modifications to the hanger are NOTE: The entire auxiliary suspension mounting
made, contact Engineering at (800) 660-2843. surfaces must be flush with both the side and
Refer to the suspension assembly drawing to bottom of the vehicle frame rails or spacers.
verify that vehicle cross members and backing Failure to do so will void the suspension
plates are positioned correctly for the intended warranty. (See Figure 8)
axle location. (See Figure 5)
3. The auxiliary suspension must remain aligned
WARNING: FAILURE TO PROPERLY AND (parallel) to the other properly aligned axles on
SUFFICIENTLY ATTACH FRAME BOLT the vehicle during the entire installation process.
CONNECTIONS TO SUPPORT THE Verify the alignment of the suspension using a
SUSPENSION OR REINFORCE THE trammel bar or measuring tape.
VEHICLE FRAME CAN RESULT IN
PREMATURE FRAME FAILURE, LOSS NOTE: Due to the steering of the axle, measuring to
OF VEHICLE CONTROL, AND LOSS the wheel centers is not recommended. For a
OF SUSPENSION WARRANTY proper alignment measure to the front edge
COVERAGE. A CROSS MEMBER of the suspension side rail.
MUST BE WITHIN 12 INCHES
(MINIMUM), FORE OR AFT OF THE 4. Verify that the measurements between the
FRAME BRACKET PIVOT BOLT suspension hanger brackets (see Figure 9) at
CENTERLINE. the frame and at the bottom of the brackets are
within the allowable tolerance. Hangers must
be parallel to one another vertically.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
5/8-11 x 2 1/4"
long Grade 8
Flange Bolt
Upper Air Spring Vehicle
Plate Assembly Frame Rail
2. With the upper air spring plate assembly tight 6. Remove the clamps from both sides of the
against the vehicle frame rail, mark the location vehicle frame rail.
of the mounting holes on the outward side of the
assembly. Punch mark all hole centers. (See the 7. Align the upper air spring stud with the hole on
supplied suspension assembly drawing for the upper air spring plate assembly. Insert and
recommended hole locations.) reinstall fasteners.
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
AXLE ADJUSTMENTS
TOE SETTING
Toe is the relationship of the distance between the
front of the tires and the distance between the rear
of the tires on the same self-steer axle measured at
spindle height. When the front distance is less than
the rear distance, the wheels are in a “toe-in”
condition. (See Figure 12)
4. Torque the clamp bolts to Hendrickson Auxiliary MANUAL AND AUTOMATIC LIFT
Axle System’s recommended values. (See An alternative method to locking the steering mech-
Appendix) anism is to lift the suspension when reversing. Various
manual and electric air control kits are available as
options. Contact Customer Service for more details.
TURN ANGLE - MECHANICAL STOP
A mechanical turn angle stop (bolt) is an adjustable
fastener that limits the steer axle's turn radius angle FINAL ASSEMBLY
and allows users to avoid tire contact with vehicle 1. Install all miscellaneous hardware and torque
accessories. Customer supplied axle(s) must have a the mounting bolts as per the suspension
turn angle stop. It is important that the stop is set so assembly drawing.
wheel interference does not occur.
2. Install air controls and plumbing.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
3. Install wheels and torque lug nuts. KINGPIN LUBRICATION
On the Hendrickson COMPOSILITE™, the kingpin
4. Check that the steer axle wheel bearings are grease fittings are located on the top and bottom
filled with oil by inspecting hub cap fill level. of the kingpin grease caps.
5. Install air brake lines for the steer axle brakes, 1. Prior to greasing the kingpins on the vehicle
per the chassis manufacturer's specifications. the suspension must be in a loaded condition.
6. Inspect brakes and adjust if necessary. 2. Clean off all the grease fittings with a clean
shop towel prior to lubrication.
NOTE: Suspensions purchased from Hendrickson
Auxiliary Axle Systems require brake 3. Lubricate the kingpins through the grease fittings
adjustment, however they are supplied on the top and bottom of the steering knuckle.
with automatic slack adjusters.
4. Force the required lubricant into the upper and
FINAL INSPECTION lower kingpin grease fittings until new lubricant
1. Check that all suspension bolts are tightened flows from locations A and B. (See Figure 14)
to Hendrickson Auxiliary Axle System’s
recommended torque values. (See Suspension NOTE: Greasing at the lower zerk should purge
Assembly Drawing) grease from the thrust bearing shell.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
4. If necessary, remove the wheels, hubs and
drums.
8. Set the dial indicator to “0” zero. Figure 16. Vertical End Play Checking
IMPORTANT: If one bushing is worn or damaged, it 8. Raise the jack until the dial indicator shows the
is mandatory to replace both the top end of vertical travel. Measure and record the
and bottom bushings on that knuckle dial indicator reading. Vertical (up and down)
assembly. inspection clearance must be between 0.008"
and 0.030".
STEERING KNUCKLE INSPECTION
AND ADJUSTMENT ADJUSTING VERTICAL END PLAY
1. If vertical clearance is greater than 0.030",
CHECKING VERTICAL END PLAY replace the thrust bearing.
(UP AND DOWN MOVEMENT)
1. Chock the tires to help prevent the vehicle from 2. After replacing the thrust bearing, if vertical
moving. clearance is greater than 0.018", install shims
(Hendrickson part no. R-001764-1Q12)
2. Set the parking brake. between the top of the axle and the bottom
of the upper kingpin connection to obtain the
3. Raise the lift axle off the ground. proper clearance specification. See the Steering
Knuckle Disassembly section.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
3. If vertical clearance is less than 0.008", remove HINT: Remove the grease zerks from the knuckle
the shims from between the top of the axle and assemblies. This will allow the knuckle
the bottom of the upper kingpin connection to assemblies to freely slide up and down the
obtain the proper clearance specification. kingpins without creating back pressure.
4. Repeat steps 2 or 3 until proper clearance is 5. Remove the backbone from the kingpin by
achieved. sliding it down the kingpin.
5. Lower the jack. 6. Remove the upper kingpin assembly from the
axle by sliding it up and off the kingpin.
STEERING KNUCKLE DISASSEMBLY
1. Remove the wheel and hub assembly.
KINGPIN PREPARATION AND
2. Remove the brake components from the MEASUREMENT
steering knuckle.
CLEANING THE GROUND OR
3. Remove the tie rod assembly. (See Figure 17) POLISHED PARTS
• Use a cleaning solvent to clean ground or
polished parts and surfaces. DO NOT USE
GASOLINE.
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
PREVENTING CORROSION ON
CLEANED PARTS
• Apply a light coating of oil to all cleaned and
dried parts that are going to be reused. Do not
apply oil to the brake lining or the brake drums.
If parts are to be stored, apply an effective rust
inhibitor to all surfaces.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
2. Inspect the kingpin for wear or damage. Use a FABRICATED KNUCKLE KINGPIN
micrometer and measure the upper and lower
kingpin in two locations. Positions must be
BUSHING INSTALLATION
1. A hydraulic press with a minimum forcing
90 degrees (perpendicular) from each other.
capacity of 5 tons will be required.
(See Figures 23 through 26) If the kingpin
diameter is less than 1.802", kingpin
WARNING: BEFORE APPLYING HYDRAULIC
replacement may be necessary. Contact the
PRESSURE TO ANY TOOLING SET-UP,
Hendrickson Customer Service Department
ALWAYS CHECK TO BE SURE THE
at 800-660-2843.
PRESS PLATE, ADAPTERS AND
COMPONENTS BEING WORKED ON
ARE POSITIONED PROPERLY, I.E. “IN
LINE” WITH THE RAM. IMPROPER
POSITIONING CAN CAUSE
PERSONAL INJURY AND/OR
COMPONENT DAMAGE.
Figure 24.
Figure 27.
Figure 25.
Figure 28.
Figure 26.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
LIFT BEAM URETHANE BUSHINGS stability and corner handling. Having a proper toe
REPLACEMENT OF THE LIFT BEAM URETHANE setting is important for directional stability. On
BUSHINGS AND INNER SLEEVE. steerable axles, the toe is pre-set during assembly,
however sometimes it becomes necessary to adjust
the toe. It is also necessary to verify the toe upon
axle installation.
Remove all urethane bushings and internal metal 3. Scribe a line on center tread of each tire while
sleeves. Clean the ID of the lift beam bushing holes. rotating tires.
Press in the urethane bushings. Lube the ID of the
bushings and the OD of the sleeves with lubricant 4. Use a trammel bar or tape measure to measure
provided in service kit. Press in the internal metal the distance between the scribed lines on the
sleeves. Once completed, ensure that the inner metal front side of the tires at spindle height.
sleeves are flush with the urethane bushing.
5. Use a trammel bar or tape measure to measure
LIFT AXLE (LA) AND COMPLIANT TIE the distance between the scribed lines on the
back side of the tires at spindle height.
ROD (CTR) STRUCTURAL INSPECTION
Periodic inspection of the LA and CTR are strongly 6. Subtract the distance between the front side and
recommended. Cleaning the LA and CTR prior to the back side of the tires. This is the toe setting.
inspection will improve the ability to see all structural Toe Setting = Rear Distance - Front Distance
component condition.
7. If the toe setting is set in between 1/16"
Contact Hendrickson Auxiliary Axle Customer Service and1/8", no adjustment is required. If the toe
for replacement parts or parts kits (800) 660-2843. setting is set in more or less than the 1/16" to
1/8" range, refer to the Adjusting the Toe Setting
PRE SC ROUND TUBE TIE ROD section of this publication as adjustment is
ADJUSTMENT necessary.
In order for a steerable suspension system to steer or
track correctly, it is necessary for the wheels to be in
a “toe-in” condition. Toe is the difference between the
foremost and rearmost point on the tires at spindle
height. When the foremost distance is less than the
rearmost distance, the wheel pair is said to have toe-
in. Toe not only affects tire wear, but also straight-line
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
ADJUSTING THE TOE SETTING 4. Use the same procedure to remove the kingpin
1. Loosen the tie rod clamp bolts, stabilizer bushing in the upper kingpin connection.
mounting u-bolts (if applicable) and nuts.
5. Clean the parts and then inspect before
2. Rotate tie rod tube to provide a toe-in setting reassembling.
of 1/16" to 1/8".
CAST STEERING KNUCKLE BORE
3. Torque the clamp bolts to 50 ft-lbs. MEASUREMENT
CAST KNUCKLE KINGPIN BUSHING Complete the following steering knuckle bore
REMOVAL inspection and the measurement instructions prior
NOTE: A hydraulic press with a minimum forcing to installing the kingpin bushing.
capacity of 2.5 tons (minimum press
capacity of 5,000 psi or use an arbor press) 1. Measure the upper knuckle bore inside diameter
is required. at two locations. Always use an inside
micrometer or a telescoping gauge when taking
WARNING: BEFORE APPLYING HYDRAULIC a knuckle bore measurement. Some out-of-
PRESSURE TO ANY TOOLING SETUP, roundness at the top and bottom of the bore
ALWAYS CHECK TO BE SURE THE edges is acceptable. The steering knuckle bore
PRESS PLATE, ADAPTERS AND diameter is 1.938" +/- 0.003".
COMPONENTS BEING WORKED ON
ARE POSITIONED PROPERLY, I.E. 2. Measure the upper and lower bore in two
“IN LINE” WITH THE RAM. positions and at two locations. The two positions
IMPROPER POSITIONING CAN must be 90 degrees opposed from each other.
CAUSE PERSONAL INJURY OR (See Figures 31 through 32) If the average
COMPONENT DAMAGE. measurement is more than the knuckle bore
maximum diameter specification, replace the
1. Remove the grease cap retaining ring. knuckle.
Figure 31.
Figure 30.
H633 E
16
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
Machined Surface
Kingpin Bushing
Figure 34.
Figure 33.
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
GOUGES AND/OR MARRING BY out with brake cleaner and dry with compressed
USING BRASS JAWS. FAILURE TO air.
DO SO CAN CAUSE PREMATURE
PART DAMAGE, DAMAGE TO THE 7. Repeat steps 1 through 6 to the upper kingpin
STEERING KNUCKLE COMPONENTS, connection.
LOSS OF WARRANTY, LOSS OF
VEHICLE CONTROL, PERSONAL WARNING: PRIOR TO INSTALLATION ENSURE
INJURY OR PROPERTY DAMAGE. THAT ALL RESIDUAL LOCTITE
MATERIAL IS REMOVED FROM THE
1. Install the backbone assembly in a vise with MOUNTING BOLTS AND THE
brass jaws. It is acceptable to mount the knuckle THREADED HOLES IN THE UPPER
components in a vise either vertically or KINGPIN CONNECTION, AND NEW
horizontally when performing the reaming LOCTITE 277 OR EQUIVALENT IS
procedure. APPLIED TO HELP ENSURE THAT
THE BOLTS SUSTAIN THE PROPER
2. Install the reamer into the backbone until the TORQUE REQUIREMENT. FAILURE TO
blades touch the kingpin bushing. DO SO CAN CAUSE LOSS OF
VEHICLE CONTROL RESULTING IN
NOTE: The bushing bore diameter is to be 0.001 PERSONAL INJURY OR PROPERTY
larger than the kingpin diameter. DAMAGE.
3. Rotate the reamer smoothly with light downward NOTE: The Hendrickson Genuine Part socket head
pressure. Do not apply too much pressure. (See cap screw (PN: 6110C125H4A8) comes
Figure 36) with a pre-applied loctite compound.
Figure 36.
6. Clean the 5/8" brake backing plate bolts with a Figure 37.
wire wheel and run a tap through the threads of
the backbone / upper kingpin connection. Flush
H633 E
18
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
Magnification of
kingpin bushing
Figure 38. and lip seal
installed in
steering knuckle.
Figure 39.
KINGPIN SEAL INSTALLATION
1. Place the backbone in a vise with brass jaws
or place on a suitable workbench. The backbone
will have the machined surface facing up (axle
side up).
5/8" Brake 14. Slide two 0.010" feeler gauges on each side
Backing of the kingpin between the axle and the upper
Plate Bolts
kingpin connection.
12. Install the appropriate amount of shims to 16. Once the final torque of the socket cap screws
achieve 0.008" to 0.011" clearance between the has been obtained, remove the two 0.010" feeler
upper kingpin connection and the top of the axle. gauges and lower the bottle jack. Check the
remaining bolt holes to ensure that the bolts will
thread in.
Block of Wood
Figure 42.
Figure 43.
H633 E
20
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
17. Affix a magnetic base dial indicator on the axle 24. Install the tie rod cross tube into the tie rod arm.
and place the tip of the dial indicator on top of
the upper kingpin connection. (See Figure 43) NOTE: For compliant tie rod see step 25a. For rigid
tie rod see steps 25b and 26.
18. Zero the dial indicator.
25a. CTR mounting bolts are torqued to 250- 300
19. Raise the bottle jack until there is no clearance ft-lbs and refer back to the toe setting
between the backbone and the bottom of the portion after this.
axle.
25b. Tighten the castle nuts to 185 ft-lbs torque,
20. Check the reading on the dial indicator. The then rotate the castle nut to the next castle
specification for vertical travel on the steering slot and install the cotter pin.
knuckle assemblies is 0.008" to 0.011".
26. Tighten bolts to 140-160 ft-lbs torque.
21. If the clearance is not within the required
specification, repeat steps 3 through 9 until the NOTE: LocTite applied to knuckle assembly bolts is
proper clearance is obtained by adding or a critical procedure to ensure that these bolts
removing shims. sustain the torque requirement of the kingpin
connection.
22. If the vertical travel is not within the specification,
repeat steps 3 through 16 until the proper
27. Install new o-rings on the grease caps and
vertical travel is obtained.
lubricate the o-rings with grease.
23. Remove the bottle jack to remove the load off
28. Install grease caps and new retaining rings.
the knuckle assembly and continue assembling
the wheel ends.
NOTES:
H633 E
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STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
H633 E
22
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
APPENDIX B
BRAKE REPLACEMENT
H633 E
23
STEERABLE INSTALLATION AND MAINTENANCE PROCEDURES
Figure 46. Removal of Outer and Inner Retaining Spring Figure 48. Removal of Brake Bolts and Anchor Pin
3. Support the lower brake shoe assembly and 5. Replacement brake kit for each specific axle
remove the return spring. Set parts aside and will have the necessary parts to be replaced.
remove the upper brake shoe. Discard worn or damaged parts. If a part is
not included in the kit, contact customer
service (800) 660-2843.
www.hendrickson-intl.com
Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected.
H633 Rev E 5-11 © 2011 Hendrickson USA, L.L.C. (U.S. Rights) Hendrickson International Corporation (Rights Outside U.S.) All Rights Reserved Printed in United States of America
PARTS LIST
REPLACEMENT PARTS
COMPOSILITE™ SC STEERABLE
SUSPENSION SYSTEMS
LIT NO: H732
DATE: October 2011 REVISION: A
SCT10 /13/ 20
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
TRUCK MOUNT
10
11 5
17
USE THESE 1
12 8
SPACERS FOR
ADDITIONAL 1"
16 RIDE HEIGHT
10 4
12
1
9 15
6
12 14 7 18
2
5
8
5
4
7
7 3
13 6 2
12 1
3
NO ADJUSTMENT PLATES 2 3
33.5" FRAME WIDTH
ONE ADJUSTMENT PLATE PER SIDE FOR
34.0" FRAME WIDTH (INSTALLED)
TWO ADJUSTMENT PLATES PER SIDE FOR 3
34.5" FRAME WIDTH (IN PARTS BOX)
SEE AXLE INFORMATION
18
SHEET FOR BREAK DOWN
19 COMPLETE BRAKE
5
ASSEMBLIES IF APPLICABLE
H732
2
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
TRUCK MOUNT
YEARS OF SUSPENSION TRUCK
ITEM DESCRIPTION SERVICE SERIES PREFIX QTY. PART NO.
1 BEAM ASSEMBLY 2010 - Present SC 10K SCT10 4 R-009690
2010 - Present SC10K ADJ SCT10 4 R-009690
2010 - Present SC13K SCT13 4 R-008940
2010 - Present SC13K ADJ SCT13 4 R-008940
2010 - Present SC20K SCT20 4 R-010125
2010 - Present SC 20K ADJ SCT20 4 R-010125
1–8
2010 - Present SC13K ADJ SCT13 1 R-007659
2010 - Present SC20K SCT20 1 R-007040
2010 - Present SC 20K ADJ SCT20 1 R-007961
3 BUSHING & PIVOT BOLT KIT 2010 - Present SC 10K SCT10 1 R-008839
2010 - Present SC10K ADJ SCT10 1 R-008839-1
2010 - Present SC13K SCT13 1 R-008839
2010 - Present SC13K ADJ SCT13 1 R-008839-1
2010 - Present SC20K SCT20 1 R-008839-2
2010 - Present SC 20K ADJ SCT20 1 R-008839-3
NOTE: -1 Driver’s Side, -2 Passanger’s Side (Typical). Check page 3 for Inboard/Outboard clarification.
H732
3
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
TRUCK MOUNT
NOTE: -1 Driver’s Side, -2 Passanger’s Side (Typical). Check page 3 for Inboard/Outboard clarification.
H732
4
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
YEARS OF SUSPENSION TRAILER
ITEM DESCRIPTION SERVICE SERIES PREFIX QTY. PART NO.
TRAILER MOUNT
2010 - Present SCB SCB13 2 R-001015
1 – 19
9 2 SADDLES AND 2010 - Present SCW SCW13 1 R-005021
CROSSMEMBER 2010 - Present SCB SCB13 1 R-005503
WELDMENT
NOTE: -1 Driver’s Side, -2 Passanger’s Side (Typical). Check page 3 for Inboard/Outboard clarification.
H732
5
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
19 11 1 2 0
6
10
20
3 14
7
12
8 17
13 14 5 18
AXLE ASSEMBLIES
12
15“A”
16
15“B”
15“A”
H732
6
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
SUSPENSION MODEL
ITEM DESCRIPTION SERIES PREFIX QTY. PART NO.
AXLE ASSEMBLIES
8 TURN STOP SCREW SC SCT13 2 R-6108C125H4S8
SC SCT20 2 R-6108C150H4S8
1 – 14
12 TIE ROD ASSEMBLY SC SCT10 1 R-009889
SC SCT13 1 R-009426
SC SCT20 1 R-009989
H732
7
REPLACEMENT PARTS FOR AFTERMARKET SUSPENSIONS
SUSPENSION MODEL
ITEM DESCRIPTION SERIES PREFIX QTY. PART NO.
A B
15 KINGPIN BUSHING KIT SC SCT10 1 R-010300 R-010300-1
WITH KINGPIN “A” SC SCT13 1 R-010300 R-010300-1
KINGPIN BUSHING KIT SC SCT20 1 R-010300 R-010300-1
WITHOUT KINGPIN “B”
NOTE: -1 Driver’s Side, -2 Passanger’s Side (Typical). Check page 3 for Inboard/Outboard clarification.
15 – 20
www.hendrickson-intl.com
Specialty Products – Auxiliary Axle Systems Specialty Products – Auxiliary Axle Systems
277 North High Street 250 Chrysler Drive, Unit #3
Hebron, OH 43025 USA Brampton, ON L6S 6B6 Canada
740.929.5600 905.789.1030
Fax 740.929.5601 Fax 905.789.1033
Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected.
H732 10-11 © 2011 Hendrickson USA, L.L.C. (U.S. Rights) Hendrickson International Corporation (Rights Outside U.S.) All Rights Reserved Printed in United States of America
PTO / Drive Shaft
www.ctmmixers.com
PTO
Inspecting and maintaining your driveline components will ensure proper function and prevent
serious mechanical failures. This should be done on a daily level.
When you driveline is not properly maintained it can cause:
• Premature wear in the u-joint and slip joint.
• Slip spline wear, seizure, and galling.
• Excessive driveline vibration.
• Transmission, bell housing, and clutch housing failures.
• Transmission tail shaft housing and seal failures.
• Shaft Support housing and rubber insulator failures.
When your driveline is properly maintained and routinely lubricated, it will provide reliable and
safe vehicle operation. If you have any service issues, call Con-Tech service @ 507-374-2239.
Please observe ALL OSHA lockout-tag out procedures when performing any type of work or
maintenance on your vehicles.
Engine
Pump
Drive Shaft
SAFETY DECAL
PLACEMENT
NOTE: Appearance of the truck, and the location of the decals may vary.
WARNING!
Safety decals must be replaced anytime they are damaged or
missing or cannot be read clearly. Please contact Con-Tech Mfg.
If you need replacement decals at 507-374-2239.
DANGER
WARNING
CAUTION
OPERATOR’S INSTRUCTION
SAFETY NOTICE
36
47
40 4
* All extension chutes
should have proper
17 decals on both sides.
32 26
1, 2
19, 28
25 (Passenger Door)
33, 37, 59
23, 27 41
2, 11, 42, 22
39, 50, 51, 52
SAFETY DECAL
PLACEMENT
NOTE: Appearance of the truck, and the location of the decals may vary.
38, 21
14, 16
3
10, (7 Passenger Side)
12 (Both Sides) 15, 34
18, 24, 29, 31, 32 5
6
10, 30, 48 (Both Sides)
8 45
13, 20 (Both Sides)
9 (Both Sides) 46, 49, 53
DANGER
Designer: MAP
WARN NG WARN NG
799300_sheet 1 of 1
Serious personal injury or death can occur.
OF THE UNIT.
and KEEP AWAY FROM THE METAL PARTS
contact with a power line, stay in the cab
though the unit. If unit does come in
electric cable for the electricity to go
for the mixer to be in contact with the
overhead power lines. It is not necessary
enough clearance between a mixer and
LOOK UP AND LIVE. Make sure there is
OPERATOR’S INSTRUCTION
COMMENCE À DÉVERSER
NOT A STEP
INSTRUCCIONES PARA EL OPERADOR
burns to the skin.
This could result in
may exceed 120º F.
Oil temperatures
EMPIECE A VACIAR
DANGER
No passenger is allowed in the cab
START POURING
PULL FORWARD
Standard
unless a manufacturer’s approved
DRIVE IN
DANGER
AVANCE
August 5, 2013
PELIGRO
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799241
FUERA DE LAS PUNTAS DEL PIVOTE
CON-TECH DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
quemaduras en la piel.
Esto puede ocacionar
puede exceder 120º F.
La temperatura del aceite
799200_sheet 1
PRECAUCION
12.5 in No se permite ningún pasajero dentro de la cabina salvo This diagram shows the function Use only the mixer ladder and platform assembly provided when checking the load of concrete,
que se provea un asiento para pasajeros y un cinturón de of each of the valves on the pneumatic manifold slump, washing down, cleaning the mixer, etc.
KEEP HANDS AND BODY AWAY
11.75 in
ENTRE EN RECULANT
48 in
ADVERTENCIA
PRECAUCION
□
Printed on White X Clear □ Una frenada repentina o un accidente pueden ocasionar MANUAL OVERRIDE BUTTONS Unless you have followed OSHA lockout / tagout procedures (see 29 CFR 1910.147) and have
MORE WATER
RETROCEDA
SIGNAL LIGHTS
BACK IN
ARRÊTE
799223
Podría sufrir lesiones graves o fatales.
PARTES METÁLICAS DE LA UNIDAD.
cabina y manténgase LEJOS DE LAS
de alimentación, permanezca en la
Si la unidad contacta con una línea
unidad.
que se transmita electricidad a la
esté en contacto con los cables para
No es necesario que la hormigonera
las líneas de alimentación aéreas.
distancia entre una hormigonera y
Asegúrese de que exista suficiente
MIRE HACIA ARRIBA Y VIVA.
STOP
ALTO
CON-TECH
Serious personal injury can occur.
Check hoses and hardware on a daily basis.
because of breaks, cuts or wear abrasions.
Chutes, hoses and hardware can rupture
discharging.
pull chutes over himself during concrete
Operator should not stand beneath or
PRESSURE GAUGE
• Never suspend yourself from the collector or charge hopper at the rear of the mixer or
DANGER
WARNING
FROM PIVOT POINTS
799300
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
stand on the Bridgeking trailer while checking the load of concrete, checking slump,
PELIGRO
799227
OPERATOR’S INSTRUCTION
INSTRUCCIONES PARA EL OPERADOR
REGULATOR
12.5 in washing down, cleaning, or working on the mixer.
manual cuando esté en tránsito.
Enganche el seguro de la canaleja
CAUTION
Avoid Turnover
AXLE LOCK AXLE
11.75 in
1 2
You are hauling a high • Never place your body between the Bridgeking trailer and rear pedestal.
ANSI SAFETY COLORS center of gravity fluid load! 30 in
□ □
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
Failure to use the rear ladder and platform assembly or follow OSHA lockout / tagout
LEVANTE EL CONDUCTO
ARRÊTE DE DÉVERSER
PELIGRO
procedure may result in serious personal injury or death.
MONTE LA CHUTE
LOWER CHUTE
RAISE CHUTE
RETROCEDA
UP UP UP
or death.
BACK UP
RECULE
PELIGRO
El diagrama muestra la función
799322
799220
1 799223_6 in x 4.25 in Evite que se voltee el vehículo
injury.
result in serious personal puede ocasionar graves lesiones
clothing, or yourself could herramientas, vestimenta o su persona
A slip or snagging of tools, Un deslizamiento o enganche de
Stay clear of rotating drum. Retírese cuando el tambor está girando.
OPERATOR’S INSTRUCTION
!
1 799224_6 in x 4.75 in Usted está transportando una carga de fluido que tiene
1 799322_7.5 in x 4 in un centro de gravedad alto! OPERATOR’S INSTRUCTION
799206
Under no circumstances should you overload the mixer. Be sure that you never
Use sólo el conjunto de escalerilla y plataforma de la mezcladora que se suministra para revisar la carga de concreto, el
799229
1 799234_5.5 in x 3 in cause your unit to exceed applicable state or federal weight restrictions as well
En caso contrario pueden ocurrir lesiones
CAUTION
m
personales graves o fatales. limits/equipment ratings, and tire, spring or suspension capacities. Overloading Change Hydraulic Oil and Filters after First 100 Hours and
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
DANGER
1 799215_6 in x 4.75 in can void warranties, shorten equipment life and create serious potential safety every 6 months/1000 hours thereafter
ANSI SAFETY COLORS
799224
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
hazards. If your loads/needs require additional load carrying capacity, Con-Tech Temperature over 80º F use ISO100 Hydraulic Oil
1 799250_5 in x 3 in has available optional/auxiliary axles, including pushers, tags, and tandems.
Temperature under 80º F use ISO68 Hydraulic Oil A menos que haya seguido los procedimientos de bloqueo / rotulado de la OSHA (véase 29 CFR 1910.147) y haya
Minimum Filter Rating for Hydrostats:
personales.
Una caída puede ocasionar graves lesiones
plataforma, que pueden estar resbaladizas.
Tenga cuidado al subirse a la escalera o la
1 799232_6 in x 3.25 in These options are available to help you comply with applicable state or federal
restringido / asegurado el tráiler para que no se mueva:
OPERATOR’S INSTRUCTION weight restrictions/equipment restrictions as well as GVWR and GAWR limits. Beta 10=2 with 28" of Vacuum Capability
personales pueden
canalón. Lesiones
extremo final del
Nunca sostenga el
1 799238_5.75 in x 5.25 in ISO 18/13 Cleanliness Must Be Maintained Use extreme care when on ladder or
1 799239_3.75 in x 3.75 in INSTRUCCIONES PARA EL OPERADOR Call Con-Tech for Assistance if Required at: (507) 374-2239
injury can occur.
Serious personal
end of a chute.
Never hold the
1 799242_6 in x 3 in
When in transit rotate drum. If equipped Factory filled with Chevron Rando HD. For info call: 800-822-5823 platform. • Nunca se suspenda del colector ni de la tolva de carga en la parte posterior de la mezcladora, ni se pare en el tráiler
PRECAUCION
m
Do not place any part of your body
personales.
CAUTION
1 799221_5.5 in x 5.5 in
INSTRUCCIONES PARA EL OPERADOR
bruto de ejes), ni la capacidad de los neumáticos, muelles o suspensión. El
exceso de carga puede anular la garantía, reducir la vida útil del equipo y
Cambie el aceite hidráulico y los filtros después de las primeras 100 horas y
cada 6 meses/1000 horas en lo sucesivo. inside the drum.
• Nunca se coloque entre el tráiler Bridgeking y el pedestal posterior.
1 799226_5.25 in x 3.75 in crear posibles riesgos graves a la seguridad. Si requiere más capacidad de
occur due to a fall.
Serious personal injury can
may be slippery.
ladder or platform, which
Use care when climbing on
PELIGRO
799234 DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA Llame a Con-Tech para asistencia se es necesaro al: (507) 374-2239 799235
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
1 799307_4.75 in x 2.75 in
WARNING WARNING
DANGER
1 799232_6 in x 3.25 in
del borde del canalón.
a los lados exteriores
con sus dedos situados
Siempre ponga sus manos El operador no debe permanecer de pie debajo de las
DANGER
of the truck (as shown on the certification label
1 799303_7.5 in x 5.5 in
parte en movimiento o rodando. Do not stand behind cylinder when
m m
Exceeding the vehicle manufacturer’s GVWR No ponga ninguna parte de su cuerpo dentro del tambor. 1 799306_3.25 in x 5.25 in
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799203
injury or death.
serious personal
do so can result in
serviced. Failure to
is empty or being
stop) whenever mixer cuando la mezcladora esté
(counterclockwise to la izquierda para pararlas)
possible pressure
be adjusted to lowest ajustadas a la presión
Limiting Valve must
Adjustable Pressure La válvula de presión
operator and others. cuando es en camino y el area de trabajo. una lesión personal seria o la muerte.
CAUTION
799207
ADVERTENCIA
799212
799250
1 799241_4.5 in x 2.5 in (Bridgeking down) before accumulator
En caso contrario pueden ocurrir lesiones personales graves.
y recogerse a la posicíon de transporte.
La canaleja principal debe oscilarse en 90º
DANGER
Before unfolding chute be sure people is charged.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA / NE PAS PEINTUREZ CET ÉTIQUETTE
INSTRUCTIONS À L’OPÉRATEUR
OPERATOR’S INSTRUCTION
coalescent quotidiennement
Vidangez le bol du filtre
ADVERTENCIA
coalescente.
receptáculo Del Siltro
Drene diariamente el
DESPUÉS DE PONER EN MARCHA REVISAR:
GREASE:
LISTA DE VERIFICACION DIARIA:
GREASE:
DAILY CHECKLIST
de 10.
el motor o la transmisión.
and damage
and damage
or transmission
m
de certificación del fabricante del vehículo) se exceda.
PELIGRO
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
ADVERTENCIA
PELIGRO
para este equipo, provista por el fabricante del vehículo, puede dañar el equipo o
LEAN OR CLIMB
WARNING
PRECAUCION
causar serias lesiones personales al operador y a otras personas.
can occur due to a fall.
Serious personal injury or death
platform while truck is in motion.
Do not climb on ladder or stand on
graves o fatales.
ocurrir lesiones personales
En caso contrario pueden
servicio.
vacía o se le esté dando
799215
OVER RAILING.
799243
DANGER
SAFETY NOTICE
WEEKLY CHECK LIST:
CAUTION:
WARNING
nadie en el otro lado.
LISTA DE VERIFACACION SEMANAL:
CIUDADO:
ajustados.
directo estén ajustados.
de la mezcladora estén ajustados.
Do not operate or service this machine until you have read and from contact with rotating
799209
Burst hazard. DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
Bridgeking) antes de cargar el acumulador.
PELIGRO
Manuals can be obtained from Con-Tech Manufacturing, Inc.,
799307
67079 170th Ave., Dodge Center, MN 55927 Inspect tank daily for damage
AVISO DE SEGURIDAD or leaks. SAFETY NOTICE CAUTION Pueden ocurrir lesiones personales graves o fatales.
IMPORTANT FACTS:
799302
3. Air pressure in water tank should not
Replace (do not repair) NUNCA Before unfolding chute be sure people
exceed 60 lbs. pressure.
be changed.
after warm up period oil filter should
1. BEFORE ENTERING DRUM, read and follow OSHA Regulations concerning entry DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
No haga funcionar ni revise esta máquina antes de leer y entender el
DATOS IMPORTANTES:
SAFETY NOTICE
Puede solicitar su manual a la siguiente dirección: Con-Tech 2. Refer to safety lockout procedure for Con-Tech Transit and Stationary Mixers Instruction
Keep hands away when folding or
Manufacturing, Inc., 67079 170th Ave., Dodge Center, MN 55927, EE.UU. Drain pressure before driving. Bulletin for additional procedures. Following procedures pertain to the use of Con-Tech
Mantèngase lejos de los componentes móviles del tambor. unfolding chute.
3. Shut off truck engine and carry all sets of ignition keys in your pocket.
El contacto con el equipo giratorio puede provocar lesiones graves.
799222
PRECAUCION
Never exceed 55 psi in tank.
4. NOTE: Position of control valve arm. Remove hydrostatic pump control valve arm. 799214
Place lockout with red “Danger Lockout” tag thru splined hole of control valve arm,
Do not operate or service this machine until you have read and
799238
OPERATOR’S INSTRUCTION
attach padlocks and carry all keys in your pocket.
Bursting tank may injure or kill.
understood the operation manual supplied with this equipment.
5. Place magnetic “DANGER” signs on both cab doors.
ADVERTENCIA
death can occur.
Serious damage to the cab console and control track and rollers. Evenly snug up turnbuckles
PELIGRO
No use como barra de
AVISO DE SEGURIDAD
No activar la mezcladora ni girar el tambor. drum rotation. Tighten the turnbuckle jam nuts
remolque bajo ninguna 799213
Pueden ocurrir lesiones personales graves o fatales.
breakers and fuses are not disconnected to secure the wedges in place.
hydraulic cylinders, or any indirect damage resulting from the under any circumstances.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
before jump starting or charging the battery!!! Inspeccionar diariamente el tanque por daños of fugas. 7. When finished, remove dual turnbuckle wedge assembly FIRST, then unlock control
use of acid based cleaners on this mixer. valve arm and remove “DANGER” sign from doors. circunstancia. De lo
WARNING
INSTRUCCIONES PARA EL OPERADOR (Replazar) no repare el tanque dañado o con fugas. Serious personal injury or death can occur. Doing so could result in contrario podría ocasionar
INSTRUCCIONES PARA EL OPERADOR
Pueden ocurrir graves lesiones personales.
o cualquier otro tipo/estilo de canaleja.
No exceda más de tres (3) canalejas de extensión
Vaciar osacar la precion del tanque antes de operar. No haga funcionar ni revise esta máquina antes de leer y entender el
AVISO DE SEGURIDAD serious injury or death. lesiones graves of fatales.
Todos los cortacircuitos y fusibles hacia la consola de
799218
due to a fall.
injury can occur
Serious personal
ride on.
Never use to
as a step.
Do not use
antes de arrancar la batería en emergencias o cargarla. Con-Tech no se hace responsable por daños en la pintura. Los DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
Pueden ocurrir daños graves a los sistemas de la consola de Nunca exeda mas de 55 psi en el tanque. 1. ANTES DE ENTRAR AL TAMBOR lea y siga los Reglamentos de OSHA referentes Puede solicitar su manual a la siguiente dirección: Con-Tech
cilindros hidraulicos, o cualquier otro daño ocacionado por el al ingreso y trabajo en “ESPACIOS REDUCIDOS” (”CONFINED SPACE”) OSHA
la cabina y la consola de control si no se desconectan los
Manufacturing, Inc., 67079 170th Ave., Dodge Center, MN 55927, EE.UU.
799202
cortacircuitos y fusibles antes de arrancar la batería en uso de limpiadores que contengan acido. La explocion del tanque puede ocacionar graves leciones 1910.146 y “CERRAR/MARCAR” (”LOCKOUT/TAGOUT”) OSHA 1910.147.
asi como con los limites de GVWR y GAWR.
ayudaric a cumplir con las limitaciones estatales o federales de equipo/peso
remolcádores, tiradores y tandems. Estás opciones estan disponibles para
carga, Con-Tech tiene disponibles ejes opcionales/auxiliares, inclusive
crear posibles riesgos graves a la seguridad. Si requiere más capacidad de
exceso de carga puede anular la garantía, reducir la vida útil del equipo y
bruto de ejes), ni la capacidad de los neumáticos, muelles o suspensión. El
(GVWR), clasificaciones de límites/equipo de GAWR (Clasificacíon de peso
estatales o federales aplicables, la Clasificacion de peso bruto de vehículos
Asegúrese de nunca permitir que su unidad exceda las limitaciones de peso
Bajo ninguna circunstancia debe cargar excesivamente la mezcladora.
799232
de que pueda reaccionar.
tambor cuando gira. El tambor lo puede agarrar antes
Mantenga su cuerpo y herramientas a distancia del
lo puede aplastar contra el eliminador de rebote.
Peligro de aplastamiento - El tambor en movimiento
OPERATOR’S INSTRUCTION
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA 799046
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA Cierre Con-Tech #799060.
3. Apague el motor de camión y llévese todos los juegos de llaves de encendido en
m
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
CAUTION
el bolsillo.
WARNING
SAFETY NOTICE
Always pos
ADVERTENCIA
• No exceda la carga utíl maxima legal, o las cargas GVWR o GAWR, cualquiera sea menor.
• Cuando conduzca una mezcladora cargada con el eje del remolque Bridgeking levantado, la
• No retroceda el vehículo con el eje del remolque Bridgeking hacia abajo.
• SIEMPRE levante el eje del remolque Bridgeking antes de retroceder.
• Siempre ajuste la presión al peso de la carga utíl a transportar.
• Nunca baje o ponga presión sobre el eje del remolque Bridgeking cuando la mezcladora está vacía.
AVISO DE SEGURIDAD
Left
SAFETY NOTICE
5. Coloque letreros de “Peligro” en ambas puertas de la cabina.
you before you can react.
when drum turns. Drum can snag
yourself and tools clear of Debouncer
crush you against Debouncer. Keep
Crush Hazard - Moving drum can
WARNING
OPERATOR’S INSTRUCTION
lesiones personales.
ocasionar graves
Una caída puede
transporte.
Nunca usar como
No usar como escalera.
Burst hazard.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
OPERATOR’S INSTRUCTION
del tambor y los rodillos. Ajuste los torniquetes con una vuelta o más si es necessario,
m
para evitar la posibilidad de que el tambor se ruede. Ajuste las tuercas de inmobilización
de los torniquetes, para asegurarse que las cuñas estén fijas.
Never tamper with or remove 7. Cuando termine, PRIMERO retire el conjunto de cuña de doble torniquete, luego
Change oil after first 100 hours. pressure regulator or relief valve. desconecte el seguro del brazo de la válvula de control y retire los letreros de “Peligro”
de las puertas.
Thereafter change every six months. Never pressure test without tank full Pueden ocurrir lesiones personales graves o fatales.
799201
ADVERTENC A
of water.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799308
SAFETY NOTICE
Recommended lubricant: GL5 spec. Bursting tank may injure or kill.
799304
ADVERTENCIA
85W-140
1. BEFORE ENTERING DRUM, read and follow OSHA Regulations concerning entry
Pueden ocurrir graves lesiones personales.
Verifique a diario las mangueras y los componentes.
romperse debido a roturas, cortes o abrasiones por desgaste. acurrir.
Las mangueras, las canalejas y sus componentes pueden
la descarga del concreto.
canalejas ni moverlas por encima de su persona durante
799211
OSHA 1910.147.
ADVERTENCA
Riesgo de reventar oestallar. 2. Refer to safety lockout procedure for Con-Tech Transit and Stationary Mixers Instruction
Cambie el aceite después de las primeras 100 horas. Bulletin for additional procedures. Following procedures pertain to the use of Con-Tech
OPERATOR’S INSTRUCTION
INSTRUCCIONES PARA EL OPERADOR
WARNING
50 - 70 in. Lbs.
4 - 5.5 ft. Lbs.
3. Shut off truck engine and carry all sets of ignition keys in your pocket.
pueden ocasionar graves lesiones personales.
Un deslizamiento o enganche de herramientas, vestimenta o su persona
cualquier otra parte de la mezcladora, mientras que esté en movimiento.
parte del cuerpo o ropa cerca de las aletas, los rodillos, el tambor o
Nunca ponga herramientas, mangueras, las manos, los brazos o cualquier
regulador. Place lockout with red “Danger Lockout” tag thru splined hole of control valve arm,
attach padlocks and carry all keys in your pocket.
mirilla de adeite.
WARNING
Nunca pruebe la precion del tanque vacio o sin agua. 5. Place magnetic “DANGER” signs on both cab doors.
o fatales.
ADVERTENCIA
ADVERTENCIA
DANGER
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA PELIGRO one-turn or more if necessary to prevent possible
Hombre trabajando dentro o fuera del tambor.
drum rotation. Tighten the turnbuckle jam nuts
WARNING
WARNING
due to a fall.
injury can occur
Serious personal
ride on.
Never use to
as a step.
Do not use
7. When finished, remove dual turnbuckle wedge assembly FIRST, then unlock control
799205
personal injury.
or yourself could result in serious
A slip or snagging of tools, clothing,
the mixer while it is in motion.
rollers, drum or any other part of
clothing in the vicinity of fins,
arms, or any part of the body or
Never place tools, hoses, hands,
personal injury.
or yourself could result in serious
A slip or snagging of tools, clothing,
the mixer while it is in motion.
rollers, drum or any other part of
clothing in the vicinity of fins,
arms, or any part of the body or
Never place tools, hoses, hands,
O-Ring
Bottom Nut
Top Nut
out procedures are followed.
Do not work on PTO or shaft (with or GENUINE REPLACEMENT PARTS
injury can occur.
Serious personal
type/style of chute.
or any other
(3) extension chutes
Do not exceed three
without a guard) when engine is 1. ANTES DE ENTRAR AL TAMBOR lea y siga los Reglamentos de OSHA referentes
PRECAUCION
799306
1910.146 y “CERRAR/MARCAR” (”LOCKOUT/TAGOUT”) OSHA 1910.147.
Protect your investment in Con-Tech equipment.
Do not engage or disengage the PTO
ADVERTENCIA
Do not jeopardize your warranty. Use only 2. Consulte el Procedimiento de cierre de seguridad para el Boletín de Instrucción de Operator should not stand beneath
or driven equipment by hand from Tránsito y Mezcladoras Estacionarias Con-Tech para ver procedimientos adicionales.
genuine Con-Tech replacement parts. Original Los procedimientos siguientes se refieren al uso del Juego para Procedimiento de or pull chutes over himself during
under the vehicle when the engine is
Con-Tech parts insure the finest quality, the Cierre Con-Tech #799060.
running. concrete discharging.
lesiones personales.
ocasionar graves
Una caída puede
transporte.
Nunca usar como
No usar como escalera.
PELIGRO
de la válvula de control de la bomba hidrostatíca. Coloque un letrero de color rojo
indicando “Pelgro-Cierre” por la ranura del brazo de la válvula de control, coloque rupture because of breaks, cuts
CALL CON-TECH MANUFACTURING, INC. Main and fold-over must be in bottom Main and fold-over must be in bottom
799210
799210
799303
FAX: 507-374-2548 Phone: 507-374-2239 torniquetes para que las cuñas estén firmemente colocadas entre la pista de rodadura
se hayan detenido y se hayan quitado las llaves de contacto. del tambor y los rodillos. Ajuste los torniquetes con una vuelta o más si es necessario,
INSTRUCCIONES PARA EL OPERADOR INSTRUCCIONES PARA EL OPERADOR
www.ctmmixers.com Serious personal injury can occur.
67079 170th Ave., Dodge Center, MN 55927
Manuals can be obtained from Con-Tech Manufacturing, Inc.,
understood the operation manual supplied with this equipment.
Do not operate or service this machine until you have read and
Manufacturing, Inc., 67079 170th Ave., Dodge Center, MN 55927, EE.UU.
Puede solicitar su manual a la siguiente dirección: Con-Tech
manual de funcionamiento, que viene con este equipo.
No haga funcionar ni revise esta máquina antes de leer y entender el
para evitar la posibilidad de que el tambor se ruede. Ajuste las tuercas de inmobilización
No trabajar en la toma de fuerza o el eje (con o sin resguardo) cuando el
de los torniquetes, para asegurarse que las cuñas estén fijas.
SAFETY NOTICE
motor está funcionando. El soporte matriz los de deflexión deben El soporte matriz los de deflexión deben
MADE IN THE U.S.A.
ADVERTENCIA
7. Cuando termine, PRIMERO retire el conjunto de cuña de doble torniquete, luego
No engranar o desengranar la toma de fuerza o el equipo impulsado estar en la posición baja antes de elevar estar en la posición baja antes de elevar
STOWED POSITION
STOWED POSITION
desconecte el seguro del brazo de la válvula de control y retire los letreros de “Peligro”
manualmente debajo del vehículo cuando el motor está funcionando. WITH PRIDE. 799245 de las puertas. o bajar el eje de remolque Bridgeking. o bajar el eje de remolque Bridgeking.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
Always secure
OPERATOR’S INSTRUCTION
No retroceda con el eje de remolque No retroceda con el eje de remolque
LOCKED POSITION
LOCKED POSITION
799201
graves o fatales.
ADVERTENCIA
799221
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA Bridgeking hacia abajo. 799309
Bridgeking hacia abajo. 799309
799211
WARNING
OPERATOR’S INSRUCTION
INSTRUCCIONES PARA EL OPERADOR
Serious internal
doblada con la cadena de
ADVERTENCIA
verse afectada.
personal injury.
or yourself could result in serious
A slip or snagging of tools, clothing,
the mixer while it is in motion.
rollers, drum or any other part of
clothing in the vicinity of fins,
arms, or any part of the body or
Never place tools, hoses, hands,
799228
or wear abrasions.
m
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
7. When finished, remove dual turnbuckle wedge assembly FIRST, then unlock control
4. NOTE: Position of control valve arm. Remove hydrostatic pump control valve arm.
3. Shut off truck engine and carry all sets of ignition keys in your pocket.
2. Refer to safety lockout procedure for Con-Tech Transit and Stationary Mixers Instruction
1. BEFORE ENTERING DRUM, read and follow OSHA Regulations concerning entry
el bolsillo.
OSHA 1910.147.
and working in “CONFINED SPACE” OSHA 1910.146 and “LOCKOUT/TAGOUT”
ADVERTENCIA
Pueden ocurrir lesiones personales graves o fatales.
No activar la mezcladora ni girar el tambor.
Hombre trabajando dentro o fuera del tambor.
AVISO DE SEGURIDAD
SAFETY NOTICE
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
PELIGRO
DANGER
death can occur.
Serious personal injury or
or rotate drum.
Do not start mixer
or outside of the drum.
Man working on the inside
799209
3 4 5 6
799201 799202 799203 799204
DECAL DECAL DECAL DECAL
Confined Space Warn ng Extens on Warn ng P vot Po nt Warn ng 3 Ext Chutes
SAFETY NOT CE Chute
WARN NG CAUT ON CAUT ON
D
O G
ADVERTENC A PRECAUC ON
MAN NGA A MANO CU R O
U RA D A UN A D O
PRECAUC ON
N m
7 8 9 10
799205 799206 799207 799208
DECAL DECAL DECAL DECAL
Fresh Concrete Hand S gna Warn ng/Stay C ear Warn ng/Operator
SAFETY NOT CE CAU ON PRECAUC ON
WARN NG
F esh Conc e e
AV SO DE SEGUR DAD
Conc e o F esco
ADVERTENC A
11 12 13 14
799209 799210 799211 799212
DECAL DECAL DECAL DECAL
Warn ng/Never P ace Ro er Danger Warn ng/No Step Warn ng/Ladder Care
WARN NG WARN NG WARN NG ADVERTENC A
m
DANGER
m
ADVERTENC A
ADVERTENC A PEL GRO
OVER RAILING.
of the vehicle manufacturer) to be exceeded.
PRECAUCION
can void warranties, shorten equipment life and create serious potential safety
Exceeding the vehicle manufacturer’s GVWR hazards. If your loads/needs require additional load carrying capacity, Con-Tech
Stay clear of moving drum or parts. or GAWR certification limits or limits of this has available optional/auxiliary axles, including pushers, tags, and tandems.
Antes de desdoblar la canaleja, asegúrese de que no hay Serious personal injury may result equipment can cause damage to the These options are available to help you comply with applicable state or federal
nadie en el otro lado. from contact with rotating
equipment or serious personal injury to the weight restrictions/equipment restrictions as well as GVWR and GAWR limits.
Retire las manos al doblar o desdoblar la canaleja. operator and others.
Puede ocurrir graves lesiones personales. equipment.
ADVERTENCIA
INSTRUCCIONES PARA EL OPERADOR
PELIGRO
799213
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
19 20 21 22
799217 799218 799219 799220
DECAL DECAL DECAL DECAL
Change Filter Do Not Use Warning/Hazzard Inst./Diagram Shows
Debouncer
OPERATOR’S INSTRUCTION DANGER PELIGRO WARNING This diagram shows the function
No use como barra de
of each of the valves on the pneumatic manifold
DO NOT use as a tow bar
Crush Hazard - Moving drum can
Change oil after first 100 hours. under any circumstances.
remolque bajo ninguna
circunstancia. De lo crush you against Debouncer. Keep MANUAL OVERRIDE BUTTONS
Doing so could result in
Thereafter change every six months. serious injury or death.
contrario podría ocasionar
lesiones graves of fatales.
yourself and tools clear of Debouncer DOWN DOWN UNLOCK DOWN
SIGNAL LIGHTS
when drum turns. Drum can snag
Capacity: fill to check plug or site glass. DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799218
mirilla de adeite.
El diagrama muestra la función
Lubricante recomendado: GL5 spec. 85W-140 de cada una de las válvulas del múltiple neumático
799217
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799220
23 24 25 26
799221 799206 799207 799208
DECAL DECAL DECAL DECAL
Warning/Do Not Enter Warning/Do Not Climb Warning/No Passengers Warning/Hauling
High Center of Gravity
DANGER
Do not enter under chassis unless
engine or power units are stopped,
DANGER DANGER DANGER
ingnition keys removed and lock
out procedures are followed.
Do not climb on ladder or stand on No passenger is allowed in the cab Avoid Turnover
platform while truck is in motion. unless a manufacturer’s approved
Do not work on PTO or shaft (with or
You are hauling a high
without a guard) when engine is passenger seat and seat belt are provided.
running. Serious personal injury or death center of gravity fluid load!
Do not engage or disengage the PTO Serious personal injury or death can occur
or driven equipment by hand from can occur due to a fall. in the case of a sudden stop or vehicle Failure to do so can result
under the vehicle when the engine is
in serious personal injury
PELIGRO
running.
accident.
PELIGRO
Rotating shafts are dangerous and can or death.
cause serious injury or death.
PELIGRO
No se suba a la escalerilla ni se pare en la
plataforma mientras el camión esté en movimiento. No se permite ningún pasajero dentro de la cabina salvo
que se provea un asiento para pasajeros y un cinturón de
PELIGRO
Podría ocurrir una lesión personal seria debido a Evite que se voltee el vehículo
No trabajar bajo el chasis a menos que el motor o las unidades impulsoras seguridad aprobados por el fabricante. !
se hayan detenido y se hayan quitado las llaves de contacto.
No trabajar en la toma de fuerza o el eje (con o sin resguardo) cuando el una caída. Una frenada repentina o un accidente pueden ocasionar Usted está transportando una carga de fluido que tiene
motor está funcionando. DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799222
lesiones personales graves o fatales. un centro de gravedad alto!
No engranar o desengranar la toma de fuerza o el equipo impulsado 799223
manualmente debajo del vehículo cuando el motor está funcionando. DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
En caso contrario pueden ocurrir lesiones
Los ejes en funcionamiento son peligrosos y pueden ocasionar lesiones
graves o fatales.
799221
personales graves o fatales.
799224
DO NOT PAINT THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
27 28 29 30
799226 799227 799228 799229
DECAL DECAL DECAL DECAL
PTO Shaft Caution, Oil Temp Warning/Do Not Drink Warning/Engage
Manual
OPERATOR’S INSRUCTION CAUTION PRECAUCION WARNING OPERATOR’S INSTRUCTION
Oil temperatures La temperatura del aceite
PTO Shaft, Universal Joints Do not drink
may exceed 120º F. puede exceder 120º F.
Engage manual chute
and Spline must be This could result in Esto puede ocacionar the water.
lubricated weekly.
burns to the skin. quemaduras en la piel.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799227
Serious internal lock when in transit.
injury may result. INSTRUCCIONES PARA EL OPERADOR
INSTRUCCIONES PARA EL OPERADOR
La flecha del PTO, las juntas universales ADVERTENCIA Enganche el seguro de la canaleja
y la acanaladura deben lubricarse
semanalmente. No beber esta agua. manual cuando esté en tránsito.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799226 Puede producir serias DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799229
lesiones internas.
799228
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
35 36 37 38
799237 799238 799239 799240
DECAL DECAL DECAL DECAL
Instructions/Main Chute Daily Checklist No Step Hopper Prop Pins
ADVERTENCIA
Drum rotates both directions
Inspect hoses for cuts, abrasions,
and damage
39 40 41 42
799241 799242 799243 799245
DECAL DECAL DECAL DECAL
Not A Step Warning/Will Not Except Instructions/Drain Filter Genuine Replacement
OPERATOR’S INSTRUCTION
Parts
Note: Prints on Polycarb
OPERATOR’S INSTRUCTION
NOT A STEP Con-Tech will not accept responsibility for damage to paint,
hydraulic cylinders, or any indirect damage resulting from the
use of acid based cleaners on this mixer.
Drain Coalescing
Filter Bowl Daily.
INSTRUCCIONES PARA EL OPERADOR GENUINE REPLACEMENT PARTS
NO ES UN ESCALON
Con-Tech no se hace responsable por daños en la pintura. Los Protect your investment in Con-Tech equipment.
Do not jeopardize your warranty. Use only
cilindros hidraulicos, o cualquier otro daño ocacionado por el
uso de limpiadores que contengan acido. Drene diariamente el genuine Con-Tech replacement parts. Original
Con-Tech parts insure the finest quality, the
799241 DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799242
receptáculo Del Siltro longest life and proper, reliable operation.
coalescente.
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
43 44 45 46
799246 799250 799301 799302
DECAL DECAL DECAL DECAL
Con-Tech Fender Turn Drum Slowly DANGER! DANGER!
Use Ladder Only BK Arm in Motion
WARNING DANGER
Use only the mixer ladder and platform assembly provided when checking the load of concrete,
DANGER
Do not stand behind cylinder when
slump, washing down, cleaning the mixer, etc.
charging accumulator.
799246
Rotate drum at lowest possible setting, Unless you have followed OSHA lockout / tagout procedures (see 29 CFR 1910.147) and have
restrained / secured the trailer from moving:
Cylinder rod must be extended
• Never suspend yourself from the collector or charge hopper at the rear of the mixer or
• Never place your body between the Bridgeking trailer and rear pedestal. is charged.
PELIGRO
Failure to use the rear ladder and platform assembly or follow OSHA lockout / tagout
Serious personal injury or death can occur.
PELIGRO
procedure may result in serious personal injury or death.
PELIGRO
Girar el trompo lo mas lento posible, Use sólo el conjunto de escalerilla y plataforma de la mezcladora que se suministra para revisar la carga de concreto, el
asentamiento, el enjuague, el lavado de la mezcladora, etc.
No se pare detrás del cilindro cuando se esté cargando el acumulador.
La varilla del cilindro debe estar extendida (con el eje de remolque
cuando es en camino y el area de trabajo. A menos que haya seguido los procedimientos de bloqueo / rotulado de la OSHA (véase 29 CFR 1910.147) y haya
restringido / asegurado el tráiler para que no se mueva:
Bridgeking) antes de cargar el acumulador.
799250 • Nunca se suspenda del colector ni de la tolva de carga en la parte posterior de la mezcladora, ni se pare en el tráiler
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA Bridgeking para revisar la carga de concreto o el asentamiento, enjuagar, lavar o trabajar en la mezcladora. Pueden ocurrir lesiones personales graves o fatales.
• Nunca se coloque entre el tráiler Bridgeking y el pedestal posterior. 799302
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
•
OPERATOR’S INSTRUCTION
Never lower and pressurize Bridgeking with an empty mixer.
WARNING 8 - 9 ft. Lbs.
100 - 110 in. Lbs.
Top Nut
DANGER PEL GRO
Bottom Nut
• Always adjust pressure to weight of payload to be carried. When Bridgeking is in up configuration,
4 - 5.5 ft. Lbs.
• ALWAYS raise Bridgeking before backing. main chute must be swung 90º and 50 - 70 in. Lbs. O-Ring
• Do not coast rearward with Bridgeking down.
stowed in transport position.
• When driving a loaded mixer with the Bridgeking raised,
the recommended MAXIMUM SPEED IS 3 M.P.H. Failure to do so can result in serious
• Do not exceed maximum legal payload, maximum GVWR or GAWR, personal injury or death.
Secure lower nut with wrench before
ADVERTENCIA
whichever is less.
adjusting. Loosen only the top nut.
INSTRUCCIONES PARA EL OPERADOR If the bottom nut is loosened, damage
Cuando el equipo Bridgeking está en posición hacia arriba, la to the o-ring seal could result.
• Nunca baje o ponga presión sobre el eje del remolque Bridgeking cuando la mezcladora está vacía.
• Siempre ajuste la presión al peso de la carga utíl a transportar. canaleja principal debe estar puesta a 90º y acomodada en la
• SIEMPRE levante el eje del remolque Bridgeking antes de retroceder.
posición para transportarla. INSTRUCCIONES PARA EL OPERADOR
• No retroceda el vehículo con el eje del remolque Bridgeking hacia abajo.
• Cuando conduzca una mezcladora cargada con el eje del remolque Bridgeking levantado, la En caso contrario pueden ocurrir lesiones personales graves o fatales.
VELOCIDAD MAXIMA recomendada es 5 KPH (3 mph). 799304
Asegurar la tuerca inferior con usa
• No exceda la carga utíl maxima legal, o las cargas GVWR o GAWR, cualquiera sea menor. DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
llave de tuercas antes de ajustar.
799303
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
Aflojar solamente la tuerca superior.
Si se aflorja la tuerca inferior se
podría causar daño a la junta tórica.
799306
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
51 52 53 54
799308 799309 799310 799322
DECAL PLACARD DECAL DECAL
Sa ety/Emergency Ax e PS Sett ngs Operator/No Expose Look Up and L ve
V M nu d Op do
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
E opo
m o d d ón d b n
n
po ón b n d
ob d mo qu B dg ng
No o d on d mo qu
B dg ng h b o
55
799500 56
799501 57
799503 58
799504
DECAL DECAL DECAL DECAL
Extreme Duty Extreme Duty Br dgeK ng Fender Br dgeK ng Arm
Fender 3x11 3x17 V ny Cut 7x36 V ny Cut
59 60 61 62
799757 799758 799700 799701
DECAL DECAL PACKET PACKET
Fuse Pane C rcuts Fuse Pane Ram Mount French Extreme Duty French Br dgeK ng
Deca K t Deca K t
Fu e Pane C u Designer: MAP
CON-TECH CON-TECH CON-TECH CON-TECH CON-TECH
Cab 799200_sheet 1 Right 799200_sheet 2 RP 799200_sheet 3 Chute 799200_sheet 4 CON-TECH
Chute 799200_sheet 5
Chute 799200_sheet 6
Standard
DANGER
Serious personal injury or death can occur.
OF THE UNIT.
and KEEP AWAY FROM THE METAL PARTS
contact with a power line, stay in the cab
though the unit. If unit does come in
electric cable for the electricity to go
for the mixer to be in contact with the
overhead power lines. It is not necessary
enough clearance between a mixer and
LOOK UP AND LIVE. Make sure there is
OPERATOR’S INSTRUCTION
COMMENCE À DÉVERSER
NOT A STEP
INSTRUCCIONES PARA EL OPERADOR
burns to the skin.
This could result in
may exceed 120º F.
Oil temperatures
CON-TECH
CAUTION
EMPIECE A VACIAR
PULL FORWARD
Ch 799200_sheet 7
unless a manufacturer’s approved
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
DRIVE IN
DANGER
AVANCE
August 5, 2013
PELIGRO
DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
799241
FUERA DE LAS PUNTAS DEL PIVOTE
CON-TECH DO NOT PAINT OVER THIS LABEL / NO PINTAR ENCIMA DE ESTA ETIQUETA
quemaduras en la piel.
Esto puede ocacionar
puede exceder 120º F.
La temperatura del aceite
799200_sheet 1
PRECAUCION
12.5 in No se permite ningún pasajero dentro de la cabina salvo This diagram shows the function
que se provea un asiento para pasajeros y un cinturón de of each of the valves on the pneumatic manifold
KEEP HANDS AND BODY AWAY
11.75 in
ENTRE EN RECULANT
48 in
ADVERTENCIA
□ □
PRECAUCION
ADVERTENCIA
RETROCEDA
SIGNAL LIGHTS
ARRÊTE
BACK IN