Table of Contents
Important Safety Information ........................................1
Internal Flo-Fuse™ ......................................................7
Maintaining your Mixer Hydrostatic Pump and Motor
System..........................................................................9
Gauge Installation Location ........................................15
Troubleshooting Your Mixer Hydrostatic System ....17
How to use the Fault Logic Charts ............................23
Troubleshooting Hydraulic Pumps and Motors ..........24
Diagram Action Steps ..............................................28
Eaton Hydraulic Division, Eaton Hydrostatic Pump - Ball
Guide ..........................................................................30
Control Valve - Old Style ............................................32
Control Valve - New Style S/N 0986 and higher ........33
Charge Pump Rotation Identification ........................34
Valve Plate Rotation ................................................35
Broken Pump Shaft ..................................................36
Hydrostatic Installation and Clean and Flush
Procedures ................................................................37
Recommendations for Hydraulic Fluid
Specifications ..........................................................38
Mixer Oil Specs ........................................................39
Water Tank Measurement ........................................41
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Rear Pedestal Specification Sheet ..........................42
Fender Measurement ..............................................43
Open Center Chute Block ........................................44
Open Center Chute Valve Assembly
HOLD POSITION ......................................................45
Open Center Chute Valve Assembly
RAISE POSITION ....................................................46
Open Center Chute Valve Assembly
LOWER POSITION ..................................................47
Open Center Chute Valve Troubleshooting................48
Maintenance Periodic Inspection ............................49
Roller Adjustments ..................................................51
Universal Drive Shaft ..................................................52
Pump and Universal Alignment ................................53
ZF Drum Drives ........................................................54
ZF Drum Drives ..........................................................55
Fluid Power Equivalents ............................................56
Common Abbreviations ..............................................57
Index ..........................................................................59
Table of Contents i
Important Safety Information
IMPORTANT SAFETY INFORMATION
READ AND UNDERSTAND THIS ENTIRE MANUAL
BEFORE OPERATING, REPAIRING, OR ADJUSTING
YOUR MCNEILUS MIXER. THOSE WHO USE AND
MAINTAIN THIS EQUIPMENT MUST BE
THOROUGHLY TRAINED AND FAMILIAR WITH THE
PRODUCT. IF INCORRECTLY USED OR
MAINTAINED, THIS EQUIPMENT CAN CAUSE
SEVERE INJURY.
Always keep this manual in a location where it is readily
available for persons who operate or maintain the
product. Additional copies of this manual are available
from McNeilus Truck and Manufacturing; (507) 374-
6321 at no charge. Please contact McNeilus Truck and
Manufacturing if you require additional manuals or if you
have any questions concerning the information in this
manual or this product.
Some service operations may require special tools,
equipment, or blocking devices (such as the body hoist
or tailgate). If you require information on these items,
please contact McNeilus Truck and Manufacturing at
(507) 374-6321 before attempting these repairs and
service operations.
THESE SAFETY PROCEDURES ARE FOR YOUR
OWN PROTECTION.
DO NOT OPERATE OR REPAIR THIS EQUIPMENT
UNTIL YOU HAVE READ THIS MANUAL AND
UNDERSTAND ITS CONTENTS THOROUGHLY.
PLEASE CALL MCNEILUS TRUCK AND
MANUFACTURING AT (507) 374-6321 IF YOU
REQUIRE ASSISTANCE!
SHOULD AN OPERATOR OF THIS EQUIPMENT
HAVE A READING OR LEARNING DISABILITY,
DYSLEXIA, OR OTHER SUCH CONDITION, THEN HE
OR SHE MUST BE ASSIGNED A MENTOR/TRAINER
TO READ AND EXPLAIN TO SUCH INDIVIDUAL THE
ENTIRE CONTENTS OF THIS MANUAL AS WELL AS
THE SAFETY GUIDELINES, DANGER, CAUTION AND
WARNING DECALS AND PLACARDS AFFIXED TO
THIS UNIT. SUCH INDIVIDUAL SHOULD NOT BE
ALLOWED TO OPERATE THIS EQUIPMENT UNTIL
HE OR SHE THOROUGHLY UNDERSTANDS ALL OF
THESE MATERIALS. FAILURE TO DO SO CAN
RESULT IN SERIOUS PERSONAL INJURY OR
DEATH.
SAFETY AND SAFE WORKING PROCEDURES MUST
BE FOLLOWED AT ALL TIMES. OSHA LOCK OUT
PROCEDURES MUST BE FOLLOWED WHEN
MAINTAINING THIS EQUIPMENT. IF YOU ARE
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
UNFAMILIAR WITH THE OSHA LOCK OUT
PROCEDURES OR ANY SAFETY REQUIREMENTS,
PLEASE CONTACT MCNEILUS TRUCK AND
MANUFACTURING AT (507) 374-6321 FOR
ASSISTANCE.
! WARNING
Anytime you are working on this equipment or its
related systems, you must do the following:
1. Inform the truck driver that the equipment is
going to be repaired and locked out and that he
must not attempt to start the truck.
2. Follow all OSHA and Mixer Lock Out procedures.
Remove the keys from the truck’s ignition.
3. Place magnetic signs on both doors of the truck
which read:
“CAUTION - MAN WORKING ON MIXER - DO
NOT START ENGINE”
4. Lock out supplies are available from McNeilus
Truck and Manufacturing. Call (507) 374-6321
for assistance.
READ, UNDERSTAND, AND FOLLOW THE SAFETY
GUIDELINES, DANGERS, AND WARNINGS LISTED
BELOW AND CONTAINED IN THIS MANUAL TO
PROMOTE RELIABLE OPERATION AND PREVENT
SERIOUS PERSONAL INJURY.
! WARNING
Hydraulic hoses, fittings, and pipe must be
inspected on a daily basis for leaks, cuts, abrasions,
damage, aging, improper clearance, and along the
frame for hidden damage. If you find hoses with any
such adverse conditions or damage, they must be
replaced before the mixer is returned to service! In
any event, all hydraulic hoses must be replaced
every two years. Failure to properly inspect and
maintain your mixer may result in serious personal
injury.
! WARNING
Hydraulic systems are hot. DO NOT TOUCH!
Serious personal injury may result from hot oil.
When you have completed working on the hydraulic
systems, thoroughly clean any spilled oil from the
equipment. Do not spill any hydraulic fluids on the
ground. Clean any hydraulic fluids from your skin
as soon as you have completed your maintenance
and repairs. Dispose of used oil and filters as
required by law.
Introduction and Safety Procedures 1
Important Safety Information
! WARNING
Hydraulic systems operate under high pressure -
only experienced persons should attempt repairs or
troubleshooting on hydraulic systems.
! WARNING
Correct hoses, fittings, and adapters with the
correct SAE rating must be used when replacing
hoses to prevent possible serious injury. Always
replace hoses, fittings, and adapters with
replacements that have a proper, suitable working
pressure rating. Replacement hoses must be of the
correct length and must comply with the hose
manufacturer’s installation guidelines and
recommendations. Consult hose and fitting
manufacturers for correct specifications or contact
McNeilus Truck and Manufacturing at (507) 374-
6321. Hydraulic hoses have the SAE ratings marked
on the hose to assist you in selecting the correct
hose. Any replacement hydraulic hoses and fitting
assemblies must be supplied by the same
manufacturer. As an example: Brand “A” hose and
brand “B” fitting will not normally be compatible.
No “twist” is allowed in the hydraulic hoses.
“Twist” may result in premature hose failure. Please
contract McNeilus Truck and Manufacturing at (507)
374-6321 for assistance when required.
! WARNING
Never remove hydraulic lines, fittings, and adapters
until all pressure has been relieved from the
hydraulic system. Contact McNeilus Truck and
Manufacturing at (507) 374-6321 for assistance if
required.
! WARNING
Hydraulic components can be heavy. Use caution
while lifting these components. Serious personal
injury can be avoided with proper handling of the
components.
! WARNING
Any hydraulic pipe which is replaced must conform
to SAE J1065 specifications. If incorrect hydraulic
pipe is installed, the hydraulic system may fail.
Damage or leaking pipes must be replaced before
the mixer is returned to service. Please contact
McNeilus Truck and Manufacturing at (507) 374-6321
for assistance.
2 Introduction and Safety Procedures
! WARNING
Do not heat hydraulic pipe. The carbon content of
this steel tube is such that if heated for bending, and
either water or air quenched, the pipe may lose its
ductility and thereby be subject to failure under high
pressure or hydraulic shock conditions. Damaged
or leaking pipes must be replaced before the mixer
is returned to service. Please contact McNeilus
Truck and Manufacturing at (507) 374-6321 if you
require assistance or have questions.
! WARNING
All hydraulic pressures must be relieved from the
hydraulic system prior to removing any components
from the system to prevent oil from spraying or
functions and systems from falling. Call McNeilus
Truck and Manufacturing at (507) 374-6321 for
information concerning relieving the hydraulic
pressures.
! WARNING
Increasing hydraulic pressure beyond the
recommendations may result in serious damage to
the mixer or serious personal injury. If you have
questions concerning hydraulic pressures or testing
procedures, please contact McNeilus Truck and
Manufacturing at (507) 374-6321 before attempting
the test procedures or making adjustments.
! WARNING
When performing hydraulic test procedures, use the
proper hydraulic gauges. Installing an incorrect test
gauge could result in serious injury if the gauge
fails. Use properly rated hydraulic hoses to allow
the test gauge to be read away from moving parts
and functions. Contact McNeilus Truck and
Manufacturing at (507) 374-6321 for assistance.
! WARNING
Use the proper tools and equipment when servicing
the hydraulic system. Use only the McNeilus
charging kit when recharging the accumulator. Call
McNeilus Truck and Manufacturing at (507) 374-6321
for assistance, if required.
! WARNING
Never operate the hydraulic system if a leak is
present.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Important Safety Information
! WARNING
Never enter under the chassis unless the mixer is in
the Lockout mode. Remember to follow the Lockout
procedures when working under the truck
! WARNING
When working on the mixer, the wheels must be
blocked, the parking brake on, Lock Out procedures
in effect, and the keys out of the truck’s ignition.
! WARNING
The mixer must not be modified in any way without
authorization from McNeilus Truck and
Manufacturing. Modifications may not comply with
safety standards, including ANSI safety standards,
and may result in serious personal injury. Please
contact McNeilus Truck and Manufacturing at (507)
374-6321 if you require assistance.
! WARNING
When using the emergency jumper procedure to
rotate the drum on a disabled mixer the following
must be observed: Before removing the hydraulic
motor from the mixer drive on both the operating
and disabled mixer, be sure the drum has been
allowed to turn freely so that it is balanced with no
forces transmitted to the hydraulic motor
! WARNING
Daily inspection should be performed on the mixer.
This includes proper operation of the controls,
hydraulics lock out systems, electrical systems,
lighting system including turn signals, back up
alarm, brake lights, clearance lights, head lamps, tail
lamps, safety equipment, and work lights. The
truck’s air system must operate properly and have
no leaks. Water and moisture should be drained
from the truck’s air system daily. Call McNeilus
Truck and Manufacturing at (507) 374-6321 for
assistance.
! WARNING
Do not wear watches, rings, and jewelry while
operating or working with this equipment or its
electrical and mechanical systems. These items can
be hazardous and can cause serious and painful
injuries if they come into contact with electrical
wires, moving parts, or hydraulic equipment.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
! WARNING
Use slower speeds when going around curves or
corners. You are carrying a higher center of gravity
load.
! WARNING
At the job site use the lowest transmission gear and
proceed at low speed, 3 MPH maximum, to the
discharge area.
! WARNING
Always keep hands and feet clear of the mixer drum,
revolving parts, and moving parts while checking
load or washing down the mixer.
! WARNING
Do not climb on ladders or ride on platforms while
the truck is in motion or when ladders or platforms
are wet or slippery. Serious personal injury may
result due to a fall.
! WARNING
All personnel must stand clear of the chutes during
raising and lowering and when chutes are loaded
with concrete. Position chutes while they are not
loaded. A loaded chute falling on a person may
cause serious injury. All chutes must be handled
with great care to avoid injury. Do not stand on
chutes.
! WARNING
Main, foldover, and extension chutes must be
inspected on a daily basis for damage, excessive
wear, proper hardware fit, twist, and overall
condition to determine that they are safe to use. Do
not attempt to repair chutes. Unsafe chutes must be
replaced with new chutes.
! WARNING
Optional air chute lock is intended for use only on
the job site. The manual chute lock should always
be engaged during transport. Excessive wear or
injury may result due to improper usage.
Introduction and Safety Procedures 3
Important Safety Information
! WARNING
Do not let persons, other than the driver, handle the
chutes, unfold the foldover, and/or remove
extension, or stow and secure the extensions for
transit. Keep hands away from chute hardware
where the chutes connect. Never stand in the path
of the chute as it is being unfolded or while in use.
Failure to follow the warnings concerning chute
safety may result in serious injury.
! WARNING
No passenger must be allowed in the cab unless a
manufacturer’s approved passenger seat and seat
belt are provided.
! WARNING
The mixer and chassis should not be overloaded.
Gross Vehicle Weights must not exceed the
Manufacturer’s gross vehicle weight of this vehicle.
Gross Vehicle Weights must meet Federal, State,
and Local laws.
! DANGER
Never drive the truck with the water tank
pressurized.
! DANGER
The water tank must be operated at no more than 55
psi.
! WARNING
Safety decals must be replaced anytime they are
damaged or missing or cannot be read clearly. If
you require safety decals, please contact McNeilus
Truck and Manufacturing at (507) 374-6321 for no
charge replacement safety decals.
! WARNING
Thoroughly understand the controls before
operating the mixer. Be sure everyone is clear of
the area around the truck before operating the
mixer. Remain attentive at all times when operating
the controls.
4 Maintaining your Mixer Hydrostatic Pump and Motor System
! DANGER
Never back up without taking every precaution to be
sure the rear is clear. Check behind truck before
backing up. Watch the mirrors for activity. Never
back up the mixer unless and until you are
completely sure it is safe. Use a spotter/ observer
and/or get out and check yourself to ensure it is safe
to do so.
! WARNING
Wear the proper protective clothing when operating
or maintaining the mixer. Hard hats, safety glasses,
gloves, and safety shoes should be worn. Reflective
clothing is recommended for drivers and
employees.
! WARNING
The mixer should not be overloaded. Load
pressures must match the load to be transported.
! WARNING
Be sure to maintain correct accumulator charge
pressure for correct and safe operation. Do not
attempt to check or charge the accumulator until
you have read and understand the instructions.
Contact McNeilus Truck and Manufacturing at (507)
374-6321 for assistance.
! WARNING
When working on the hydraulic or electrical system
of a Bridgemaster or Tuck-A-Weigh unit the trailer
should be in the down position or chained in the up
position to prevent the trailer from lowering
unexpectedly. Never stand behind the Bridgemaster
or Tuck-A-Weigh when in the up position. If the
Bridgemaster or Tuck-A-Weigh cylinder will not
lower or raise, call McNeilus for assistance at (507)
374-6321 and ask for service.
! WARNING
When working on the hydraulic system with the
trailer raised, always chain the assembly to the
upright or retracted position to prevent the
assembly from coming down.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Important Safety Information
! WARNING
Recheck the Hydraulic Down Pressure against the
load to be transported. If their is too much
pressure the truck driving tandem could be
affected by loss of traction. Always set pressure to
the lowest setting when mixer is unloaded. Do not
run with trailer down when the mixer is not loaded.
! WARNING
When recharging or checking the charge on the
Bridgemaster or Tuck-A-Weigh accumulator, the
following safety guidelines must be followed:
The cylinder rod must be extended (trailer
on the ground) before the accumulator is
charged.
Do not stand behind the cylinder when
charging the accumulator. The hose on the
McNeilus accumulator charge kit is long
enough to allow the accumulator to be
charged from the side of the mixer.
Do not attempt to disassemble the cylinder.
Use only McNeilus P/N 160.85455
Accumulator Charge Kit.
Purge air from the Accumulator Charge Kit
Hose by allowing a slight flow of nitrogen
to escape while attaching the Accumulator
Charge Kit to the Accumulator Charge
Stem.
The truck ignition key should be removed
while charging the accumulator.
Read these instructions thoroughly before
attempting to charge the accumulator.
Loosen only the top nut of the accumulator
charge stem. If the bottom nut is loosened,
damage to the o-ring seal could result. All
gas pressure must be released from the
accumulator before the accumulator charge
stem can be removed for service.
If you have any questions or experience
difficulty with the cylinder or charging the
accumulator, please call the McNeilus
Service Department at (507) 374-6321.
We’re glad to assist!
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
! DANGER
The trailer should be lowered when servicing the
accumulator. Do not stand behind the cylinder
when charging the accumulator.
! WARNING
The trailer pressures must match the load chart
supplied with the mixer. If the pressure is too
great for the load it is possible to raise the rear
chassis wheels of the truck and the operator may
lose control of the unit.
! WARNING
Check trailer king pins, toe-in, tie rods, and
components for proper adjustment. Replace any
worn or loose components immediately. Contact
McNeilus at (507) 374-6321 for any specifications
or assistance you may require.
! WARNING
With the trailer raised on the return trip, slower
speeds are required when going around curves or
corners as the unit could upset or roll over.
! WARNING
Always be sure the area behind the mixer is clear
of people or other obstacles when raising or lower
the trailer.
! WARNING
Always check indicator lights in the cab or at
control panel at the front of the mixer for trailer and
chute position. Replace lights or bulbs when
required. NOTE: all models may not have indicator
lights. Physically check position when indicator
lights are absent.
! WARNING
Check the tire condition and tire pressure of the
trailer wheels daily to be sure the tires are inflated
to proper pressure to withstand the applied loads.
Do not exceed the recommended tire pressure
marked on the tire sidewalls.
Introduction and Safety Procedures 5
Important Safety Information

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

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

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

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

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

KNOW THE CLEARANCE OF OVERHEAD

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

6 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Internal Flo-Fuse™
With a continuing emphasis on safety, McNeilus recommends its internal Flo-Fuse. The internal
Flo-Fuse is located on the inside of the McNeilus replacement chute lift cylinder. This protects the
Flo-Fuse from damage and concrete build up. If the Flo-Fuse sees a sudden, abnormal increase
in flow, it will close and stop the cylinder from retracting.
This will stop your chutes.
The internal Flo-Fuse is now standard on all McNeilus
replacement chute lift cylinders for McNeilus Mixers. All
owners of McNeilus Mixers should ensure they have a
McNeilus replacement chute lift cylinder with the internal
Flo-Fuse on each of their McNeilus Mixers.

INTERNAL FLO-FUSE

• Update your fleet • P/N 200.107625 McNeilus 2-1/2” x 16”

• Resets automatically Cylinder
• Will not change chute speed
• Premium quality Please call McNeilus Truck and Manufacturing
at (507) 374-6321 if you require assistance or
• Recommended for all McNeilus Mixers
have any questions.

WEATHER-PAK KIT
P/N 9800.620080

10 MICRON FILTER ASSEMBLY

P/N 140.00436

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Internal Flo-Fuse 7
8 © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Maintaining your Mixer Hydrostatic Pump and Motor System
MAINTAINING YOUR HYDROSTATIC PUMP AND V. Multiple Viscosity Hydraulic Fluid (MV)
MOTOR SYSTEM
A. Shear Factor

THE HYDRAULIC FLUID 1. Viscosity Index Improver (VIP)

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

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

VI. Automatic Transmission Fluid (ATF)

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

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

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

1. Use a 10 Micron Filter 3. Burst

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

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

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

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

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

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

II. Suction Hose Applications 4. 92 Rockwell Hardness

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

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

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

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

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

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

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

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

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

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

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

II. High Pressure Relief Valves

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

III. Displacement Sizes

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

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

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

CHANGING HYDROSTATIC PUMPS AND MOTORS

I. Important Items to Complete

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

14 Maintaining your Mixer Hydrostatic Pump and Motor System © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Gauge Installation Location
2. Charge Pump Pressure Test
• Use 0-600 PSI gauge
3. Case Pressure Test • Normal reading in neutral is 220 PSI ∆
• Use 0-400 PSI gauge (approximately 250 PSIG)
• Normal reading is 40-60 PSI • Normal reading in charge or discharge is 60 PSI
• See step #3 - Checking Case less than neutral reading
Pressure • See step #2 - Charge Pressure

1. Vacuum Test
• Use 0-30” vacuum gauge
• Test at operating temperature
• Normal reading should not exceed
10” of vacuum
• See step #1 - The Vacuum Check

4. High Pressure Test

• Use 0-10,000 PSI gauge
• Gauge will read pressure to turn
the drum
• Noram reading for an empty drum
will be ±500 PSI.
• Normal reading for a loaded drum
will be 2,500 - 3,500 PSI
depending on the slump of the
concrete
• See step #4 - Checking
Hydrostatic High Pressure

Motor WITH high pressure relief valve Motor WITHOUT high pressure relief valve
manifold block. (used by McNeilus through manifold block. (used by McNeilus since
1987) Readings vary with load. 1988) Readings vary with load.

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Gauge Installation Location 15
16 © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Troubleshooting Your Mixer Hydrostatic System

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

Gauges, fittings, adapters, and hoses are required to

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

STEP #1—THE VACUUM CHECK

The charge pump develops the amount of vacuum

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

The vacuum-pressure gauge is installed directly into the

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

The vacuum reading should be taken when the oil is

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

Photo 1

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

The following areas are common causes of high vacuum

readings:

STEP # 2 - CHARGE PRESSURE Photo 2

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

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

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

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

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

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

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

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

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

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

Two high pressure relief valves on older style

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

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

Pressure Gauge for

Checking System Pressure
10,000 psi

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Troubleshooting Your Mixer Hydrostatic System 21
22 © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
How to use the Fault Logic Charts

These fault-logic charts are designed to help you

troubleshoot problems with hydrostatic pumps and
motors at your location. Find the symptom and follow the
steps shown in the box. The steps are laid out in the
normal logical order, so start at the beginning and work
your way through the steps in the order they are shown.
Each step will have a number shown in the box. These
numbers refer to the action steps listed on the page
following the fault logic charts. As an example: If the
symptom is neutral is difficult to find, the first step is
“Inspect Control Linkage”. In the box is the number “1”.
Turning to the page following the fault logic chart and
looking at action stop number one gives you additional
ideas for items to check. Anytime you have questions or
require assistance, please feel free to call McNeilus
Companies at one of the numbers shown in action step
number 16.

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

NEUTRAL, DIFFICULT OR IMPOSSIBLE TO FIND

Inspect Inspect Call McNeilus for

OK Assistance
Control Linkage Control Valve
1 2 16

Defective Defective

Repair or Replace Repair or Replace

MIXER DRUM TURNS IN ONE DIRECTION ONLY

Inspect Inspect Inspect

OK OK Relief Valves
Control Linkage Control Valve
1 2 3

Defective Defective Defective

Repair or Replace Repair or Replace Repair or Replace

OK

Call McNeilus for Inspect Charge Inspect Shuttle

Assistance
OK Check Valves OK Valve
16 5 4

Defective Defective

Repair or Replace Repair or Replace

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

SYSTEM RESPONSE SLUGGISH

Call
Inspect
Check Charge McNeilus
OK Control OK for
Pressure
Valve Assistance
12 2 16

Defective

Repair or Replace OK

Low in Neutral,
Low in Neutral Low in Charge
Charge or
or Discharge
Discharge

Inspect Charge Inspect Charge Inspect

Relief Valve Relief Valve at Charge Relief Inspect Inlet Inspect
OK OK
at Pump Motor Valve at Pump Filter Charge Pump
13 14 13 9, 10 15

Defective Defective Defective Clogged Defective

Repair or Replace Repair or Replace Repair or Replace Replace Repair or Replace

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

SYSTEM OPERATING HOT

Inspect
Check
Check Oil Level Inspect Oil External Oil
OK OK Cooler Bypass OK Charge
in Reservoir Cooler
(If used) Pressure
6 7 8 12
OK
Low Defective Defective

Low in Neutral, High in Charge or

Fill to Correct Level Replace Repair or Replace Charge or Discharge
Discharge

Inspect Inspect Charge

Inspect Inspect Inlet Charge Relief Relief Valve
OK OK
Charge Pump Filter Valve at Pump at Motor
15 9, 10 13 14

Defective Clogged Defective Defective

Repair or Replace Replace Repair or Replace Repair or Replace

OK

Call Check
McNeilus System High
for OK
Pressure
Assistance
16 11

Low

Inspect Relief
Valves
3

Defective

Replace

NOTE: Normal reservoir oil temperature will be outside

(ambient) temperature plus 100°F.

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

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

Inspect Inspect
Inspect Check
Check Oil Level Control External Oil
OK OK Control OK Cooler Bypass OK Charge
in Reservoir Linkage Valve (if used) Pressure
6 1 2 8
OK
Low Defective Defective Defective

Low in High in
Neutral,
Fill to Correct Level Repair or Replace Repair or Replace Repair or Replace Charge Charge
or or
Discharge Discharge

Inspect Inspect Charge

Inspect Inspect Inlet Charge Relief Relief Valve
OK OK
Charge Pump Filter Valve at Pump at Motor
15 9, 10 13 14

Defective Clogged Defective Defective

OK Repair or Replace Replace Repair or Replace Repair or Replace

Call Check
McNeilus System High
for OK
Pressure
Assistance
16 11

Low

Inspect Relief
Valves
3

Defective

Replace

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved System will not operate in either direction 27
Diagram Action Steps
1. Inspect control linkage for:
a. Cables out of adjustment, binding, broken, etc.
b. Cables not coordinated with control valve
neutral
c. Arm on control valve slipping on control valve
shaft spline
d. Cable bracket loose or installed incorrectly
2. Inspect control valve for:
a. Plugged control orifice
b. Damaged mounting gasket
c. Misadjusted, damaged or broken neutral return
spring
d. Broken control connector pin
e. Broken or missing control linkage pins
f. Galled, stuck, or contaminated control spool
g. Exchange control valves with a units which
works properly to verify the control valve is at
fault
3.* Inspect relief valves for:
a. Improper pressure relief setting
b. Damaged or missing o-ring and backing ring
c. Plugged orifices
d. Center spool galled, stuck, or contaminated
e. Poppet style relief valve may be stuck open or
contaminated
f. Older style motors have the high pressure relief
valves installed in a manifold on the rear of the
motor. These relief valves can normally be
exchanged from port to port for test purposes
(1987 and earlier on McNeilus mixers).
g. Newer Eaton systems have poppet style high
pressure relief valves (called power limiters)
installed in the pump. These power limiters can
be exchanged from port to port for test purposes
(1988 and newer on McNeilus mixers).
4. Inspect shuttle valve (located on the end of the
motor) for:
a. Bent or broken return centering spring
b. Galled, stuck, or contaminated spool
c. Bent or broken shuttle spool
d. Excess wear
5. Inspect Charge Check Valves (located behind
charge pump) for:
a. Damaged or missing o-ring
b. Damaged check ball seat
c. Stuck check ball
28 Diagram Action Steps
6. Check Oil Level In Reservoir:
a. Follow the manufacturer’s recommendations
b. Normally oil should be to the sight glass with all
cylinders retracted
c. Do not overfill reservoir
7. Inspect Oil Cooler for:
a. Obstructed air flow from dirt, grease, etc. on the
outside of the cooler
b. Improper plumbing
c. Obstructed oil flow through the cooler; may
require flushing the cooler or a new cooler
8. Inspect External Oil Cooler Bypass (if used):
a. Broken, clogged, or defective bypass valve
b. The McNeilus cooler has an internal bypass
rather than an external bypass
9. Vacuum Hose Should Be Inspected for:
a. SAE 100R4 rating - This hose must be correct
or the internal liner may collapse under vacuum
applications. Pressure hose will not work.
10. Inspect Inlet Filter for:
a. Plugged or clogged filter element
b. Obstructed inlet or outlet
c. Incorrect rating filter (should be 10 micron filter
designed for vacuum applications)
d. High vacuum (10” maximum vacuum when oil is
warm)
11. Check System High Pressure:
a. See the test pages showing gauge installation
and test procedures.
b. An empty drum will normally register
approximately 500 PSI on the test gauge
c. A loaded drum will normally register from 2,500 -
3,500 PSI on the gauge depending on the load
and slump of the concrete in the drum
d. WARNING: Do not attempt to “lock up” the
system or prevent the drum from turning to test
high pressure. The result may be serious
damage to the system and serious personal
injury.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
12.*Check charge pressure: 16. Call McNeilus for Assistance:
a. Charge pressure is checked by installing a 0- a. Call your local McNeilus Branch:
600 PSI gauge in the o-ring port on the top of
the pump. See the test pages showing gauge 1. Colton, CA (909)370-2100
installation and test procedures. 2. Commerce City, CO (303)287-7486
b. Charge pressure on the Eaton hydrostatic 3. Villa Rica, GA (770)459-5151
systems normally reads 240 - 260 PSI on the 4. Gahanna, OH (614)868-0760
gauge when the pump is in neutral. The reading 5. Morgantown, PA (610)286-0400
should drop 60 PSI when the pump is put in 6. Hutchins, TX (972)225-2313
charge or discharge. 7. Tacoma, WA (253)536-0260
c. A minimum reading of approximately 150 PSI on 8. Dodge Center, MN (507)374-6321
the gauge is required to turn the drum
*Charge Relief Valve and High Pressure Relief Valve
13.*Inspect Charge Relief Valve at Pump for: Identification:
a. Improper charge relief pressure setting
b. Plugged orifice The relief valves are factory preset. The pressure code
c. Spool galled, contaminated, or stuck open or is stamped on the hex plug located on the end of the
closed valve cartridge. To determine the pressure setting on the
d. Damaged or missing o-ring motor manifold high pressure relief valves, add a zero to
e. Poppet valve held off seat the right of the stamped number (Eaton up to 1987).
f. Exchange a known good charge relief valve 1988 and newer high pressure relief valves (power
from another pump to verify the relief is the limiter) located in the Eaton pump are marked internally.
problem They must be removed to see the number.

14.*Inspect Charge Relief Valve at Motor for: Charge Pressure High Pressure
a. Improper charge relief pressure setting Relief Valves Relief Valves
b. Plugged orifice
c. Spool galled, contaminated, or stuck open or 016 = 160 PSI 500 = 5,000 PSI
closed 022 = 220 PSI 550 = 5,500 PSI
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

15. Inspect Charge Pump for:

a. Broken tang
b. Damaged or missing o-ring
c. Broken drive key
d. Excessive gerotor clearance
e. Galled or broken gerotor set

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Diagram Action Steps 29
Eaton Hydraulic Division, Eaton Hydrostatic Pump - Ball Guide

30 Eaton Hydrostatic Pump - Ball Guide © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved.
Eaton Hydraulic Division, Eaton Hydrostatic Pump - F.C.

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

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

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

Ridges are not aligned on body and pump section.

Counterclockwise (LH)
Charge Pump Rotation Identification
(Looking from “back” of Unit)
(CCW)

Ridges are aligned on body and pump section.

Clockwise (RH)
Charge Pump Rotation Identification
(Looking from “back” of Unit)
(CW)

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

PUMP VALVE PLATE FOR

CCW INPUT SHAFT
ROTATION (Lefthand)

Fixed Clearance

54 PV LH Plate
1. Eaton P/N 105103
2. McNeilus P/N 080.025

Ball Guide Units

54 PV LH Plate
1. Eaton P/N 102795
2. McNeilus P/N
080.02447

46 PV LH Plate
1. Eaton P/N 102627
2. McNeilus P/N
080.02442

PUMP VALVE PLATE FOR

CW INPUT SHAFT ROTATION
(Righthand)

Fixed Clearance

54 PV RH Plate
1. Eaton P/N 105102
2. McNeilus P/N
080.02525

Ball Guide Units

54 PV RH Plate
1. Eaton P/N 102744
2. McNeilus P/N
080.02446

46 PV RH Plate
1. Eaton P/N 02626
2. McNeilus P/N
080.02441

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

The broken shaft coupling end noted on this shaft

indicates a possible improper torquing of the mating
coupling retaining nut. This condition usually is the
result of the torque to turn the shaft being transmitted
through the key and shaft keyway rather than proper
shaft to coupling taper fit.

36 Broken Pump Shaft © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Hydrostatic Installation and Clean and Flush Procedures
Contamination (dirt, metal particles, etc.) in fluid of a
hydrostatic transmission is the primary cause of failure.
Before reinstalling a set of hydrostatic transmission
units, the system must be completely free of
contamination.Changing the filter element and fluid is
not enough to thoroughly clean the system. For this
reason, we have derived the following list of procedures
that, when followed step by-step, will help assure
system cleanliness; resulting in longer life for your
hydrostatic transmission components. Remember, it is
desirable that both the hydrostatic pump and motor be
replaced at the same time.
After Determining that the Hydrostatic Units Need to
be Replaced:
1. Drain all fluid from the system at the lowest point.
2. Remove the old hydrostatic pump and motor and
return it to McNeilus.
3. Remove the filter element and reservoir clean-out
door.
4. Check the suction hose for kinks, collapsed or
flaking liner, or any other obstructions. Check the
function of the shut-off if installed. Inspect all other
hose and fittings and replace as required.
5. Check the inside of the reservoir for contamination
(particles of steel or brass, sludge, dirt, etc.) and be
sure the pipe couplings from the reservoir to the
suction hose are not obstructed.
6. Flush all hoses, pipes, tubing, filter housings, and
reservoir with clean kerosene or solvent several
times.
7. Fill all lines, hoses, pipes, etc. with clean kerosene
or solvent and blow out with air pressure.
8. Reverse flush the oil cooler several times with clean
kerosene or solvent and blow out with air pressure.
9. Hand wipe the inside of the reservoir and filler
housing with clean, lint free towels.
10. Clean all hydrostatic pump and motor hose fittings
and replace “O” rings as required.
11. Replace filter elements, filter gaskets and reservoir
clean-out door gasket.
12. Check the filter vacuum gauge. The vacuum gauge
is normally located on the filter assembly.
Remember the importance of a good vacuum gauge
in the system. If this vacuum reading exceeds 10
inches, the result may be cavitation in the system.
Normally, this indicates a need for an oil filter
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
change. If the new filter doesn’t solve the problem,
check for restrictions and proper SAE 100R4 suction
line diameter. Many mixers had a primary filter
internally in the reservoir and a filter assembly
externally mounted in the system. It is our
experience that the internal filter in the tank may be
removed if a 10 micron filter assembly.with correct
by-pass system and capacity is used externally in
the suction line which goes from the reservoir to the
charge pump.
13. Keep all loose hose ends capped after flushing to
prevent contamination from entering the system.
14. Reinstall pump and motor units (on replacement
motors. apply a thin coat of MOLYBDENUM
DISULPHITE grease to the spline to prevent the
motor shaft from seizing to the gear box receptacle).
15. Fill reservoir, hydrostatic pump and motor cases.
hose, lines, etc. with new, clean pre-filtered fluid.
Make certain fluids meet specifications of the
equipment manufacturer or see a fluid
recommendation chart.
16. Be sure to fill the hydrostatic pump and motor cases
before start-up. Proceed with the start-up procedure.
17. Slotted pump yoke nut must be torqued to specs.
CAUTION: Failure to properly torque the slotted
pump yoke nut may result in a broken pump shaft.
REMEMBER, KEEP IT CLEAN!
This includes any oil drums, buckets, transfer pumps,
etc., used to clean and flush the system!
Although these steps will take considerable time to
complete, we at McNeilus feel that they are extremely
important to prevent unnecessary replacements which
result in expense and down time. Remember, we want
you to get the most from your equipment and our
hydrostatic transmission program.
OPERATION RECOMMENDATION
The engine must have at least 600 RPM at idle with a
load in the mixer drum control to rotate the drum at 1-1/2
to 2 revolutions. In cold weather, allow for warm up of
hydraulic oil before charging the mixer.
Hydrostatic Installation and Clean and Flush Procedures 37
Recommendations for Hydraulic Fluid Specifications

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

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

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

Chevron Hyd Oil AW 54 99 -22

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

38 Recommendations for Hydraulic Fluid Specifications © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
 MIXER OIL SPECS
ISO 100 OIL (Over 80 degrees ambient)

SUS at 100 Degrees F. 544

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

ISO 68 OIL (Less than 80 degrees ambient)

SUS at 100 Degrees F. 359

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

ADDITIVES RECOMMENDED

Anti-Wear
Anti-Foam
Anti-Rust
Anti-Corrosion
Anti-Oxidant
Emulsifier
Detergent (minimum amount)

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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Recommendations for Hydraulic Fluid Specifications 39
40 © 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Water Tank Measurement
Contact ______________________________________
Company Name _______________________________
Mailing Address _______________________________
City _________________________________________
State ___________________ Zip__________________
Special Notations ______________________________
____________________________________________
____________________________________________
____________________________________________
(SAMPLE of completed measurements)
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Date of Order _________________________________
Phone Number ________________________________
Shipping Address ______________________________
City _________________________________________
State ___________________ Zip__________________
Number of tanks wanted ______ Gallon capacity______
Extra parts needed (example: site gauge kit)
____________________________________________
____________________________________________
■ Steel ■ Aluminum
Water Tank Measurement 41
Rear Pedestal Specification Sheet

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

Contact_______________________________________ Date of Order _________________________________

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

PUSHER

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

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

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

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

Item Part No. Description Qty

1 520.106591 Chute Block Body Only 1
2 260.106592 Check Valve Cartridge 5 P.S.I. 1
3 260.106593 Relief Valve 2200 P.S.I. 1
4&8 260.106594A Normally Open Solenoid Valve with Coil (Up) 1
4 260.106588A Normally Open Valve Poppet Only 1
5&8 260.106595A Normally Closed Solenoid Valve with Coil (Down) 1
5 260.106587A Normally Closed Valve Poppet Only (Screened) 1
6 260.106596 Flow Control Valve (Chute Down Speed) 1
7 260.106597 Check Valve 200 P.S.I. 1
8 060.85774A 12-Volt Coil Only 2
9 040.106634 Orifice Plate .062 (Chute Up Speed) 1
10 040.85743 Plug SAE 4 1

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

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

Chute Lift Cylinder Note: Use only McNeilus Chute Lift Cylinders
2 1/2” x 16” with Internal Flo-Fuse.
200.107620

N.C. Valve Assy. (CEC)

w/12V. Coil
)( Pressure Compensated
Flow Control
260.106596
260.106595A

N.C. Cartridge Only

(CEC)
260.106587A Normally Closed
Solenoid Valve
12 V. Coil Only (CEC) Energize to lower
060.85774A

200 P.S.I. Check

260.106597

5 P.S.I. Check
260.106592

)( .062 Orifice
040.106634
N.O. Valve Assy (CEC)
w/ 12 V. Coil
260.106594A Normally Open
N.O. Cartridge Only Solenoid Valve
(CEC) Energize to raise
260.106588

12 V. Coil Only (CEC)

060.85774A

Relief Valve
2200 P.S.I.
260.106593

T P

A Revisions made in 1991 with CEC weather resistant coils (rectangular,

rubber coated) and heavier valve assemblies. Previously used round metal Raise Pressure
sheated coils. The valve assemblies are interchangeable, the individual
pieces are not. Return Pressure

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

Chute Lift Cylinder Note: Use only McNeilus Chute Lift Cylinders
2 1/2” x 16” with Internal Flo-Fuse.
200.107620

)( Pressure Compensated
Flow Control
260.106596
N.C. Valve Assy.
w/12V. Coil
260.106595A Normally Closed
N.C. Cartridge Only
Solenoid Valve
260.106587A Energize to lower

12 V. Coil Only
060.85774A

200 P.S.I. Check

260.106597

5 P.S.I. Check
260.106592

)( .062 Orifice
040.106634
N.O. Valve Assy
w/ 12 V. Coil
260.106594A Normally Open
N.O. Cartridge Only
Solenoid Valve
260.106588 Energize to raise

12 V. Coil Only
060.85774A

Relief Valve
2200 P.S.I.
260.106593

T P

Lowering Pressure

Return Pressure

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

Chute Lift Cylinder Note: Use only McNeilus Chute Lift Cylinders
2 1/2” x 16” with Internal Flo-Fuse.
200.107620

)( Pressure Compensated
Flow Control
260.106596
N.C. Valve Assy.
w/12V. Coil
260.106595A Normally Closed
N.C. Cartridge Only
Solenoid Valve
260.106587A Energize to lower

12 V. Coil Only
060.85774A

200 P.S.I. Check

260.106597

5 P.S.I. Check
260.106592

)( .062 Orifice
040.106634
N.O. Valve Assy
w/ 12 V. Coil
260.106594A Normally Open
N.O. Cartridge Only Solenoid Valve
260.106588 Energize to raise

12 V. Coil Only
060.85774A

Relief Valve
2200 P.S.I.
260.106593

T P

Hold Pressure

Return Pressure

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

Symptom Cause Remedy

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

2. Normally closed solenoid valve 1. Install new valve

stuck open or leaks 2. Correct electrical

Chute drifts up during 5 PSI check leak Replace valve

transport

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

2. Normally closed valve stuck open 1. Replace valve

2. Check electrical

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

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

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

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

**

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

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

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

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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Maintenance Periodic Inspection 49
Maintenance Periodic Inspection
DAILY INSPECTIONS
1. Hydraulic hoses, fittings, and pipe must be
inspected on a daily basis for leaks, cuts, abrasions,
damage, aging, improper clearance, and along the
frame for hidden damage. If you find hoses with any
such adverse conditions or damage, they must be
replaced before the mixer is returned to service! In
any event, all hydraulic hoses must be replaced
every two years. Failure to properly inspect and
maintain your mixer may result in serious personal
injury.
2. Visual roller track and roller alignment check. Check
for “snapping” or “popping” noises while drum is
turning.
3. Check oil level in hydraulic reservoir. Add oil if
below sight gauge level with all cylinders retracted.
Use correct oil.
4. Start engine and warm up hydraulic system with
truck engine at approximately 1,200 RPM and mixer
drum turning at approximately 2 RPM. Warm up
time minimum is 5 minutes.
5. Check vacuum gauge on oil filter. Replace element
if the reading exceeds 10 inches of vacuum after oil
has reached operating temperature.
6. Check for and correct any external oil or air leaks.
NOTE: Do not tighten or loosen any connections
while system is under pressure.
7. Lubricate pump drive shaft universal joints.
8. Lubricate roller bearings.
9. Lubricate and inspect rear cable control box.
10. Lubricate chute pivot system and inspect chutes and
chute hardware for wear or damage.
WEEKLY INSPECTIONS
1. Check pump drive shaft cap screws for proper
tightness.
2. Lubricate complete mixer per lube chart supplied with
mixer.
3. Draw sample of oil from reservoir and check for
presence of water. If water is present, the oil may
be milky in appearance. Milky oil should be drained
from the system and replaced and the source of the
water entry found and corrected.
50 Maintenance Periodic Inspection
4. Check filler cap and neck on oil reservoir for leaks.
Check oil reservoir mounts. Make any necessary
repairs immediately.
5. Check and record drum RPM while loading mixer
with concrete and truck engine running at top
governed RPM. If drum revolution is 2 RPM less
than that recorded at previous check, see manual
for component check out.
6. Check inside of drum for concrete build up and
clean as required.
7. Check mounting bolts for proper tightness.
8. Check ZF transmission drive plate bolts. Torque to
170 lb ft.
9. Check ZF transmission hold down bolts. Torque to
420 lb. ft.
10. Inspect debouncer for proper clearance.
11. Inspect roller track for cracks, flat areas. Correct as
necessary.
SIX MONTH INSPECTION
1. Change hydraulic oil and install new hydraulic oil
filter(s). Remove filters and check for metal
particles. Replace filter(s) with correct part number
filter. Use the correct hydraulic oil as per McNeilus
specs. Check with McNeilus before using any
alternate hydraulic oil or filters. Multiple Viscosity
oils and Automatic Transmission Fluid (ATF) cannot
be used in the hydraulic system.
2. Lubricate control cables using the McNeilus Cable
Lube Kit.
3. On Bridgemaster systems check the indicator gauge
on the high pressure filter when the system is warm
and the Bridgemaster Trailer is actually moving
down (if the trailer is not moving, the indicator will
not read).
4. Service the ZF transmission. The lubricant should
be drained while the ZF drive is hot. 85w-140 with a
GL5 spec is the proper lubricant. Do not overfill the
drive. Proper oil level is to the bottom of the sight
glass.
5. Inspect mixer main hold down bolts and springs.
Replace or adjust as required.
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Roller Adjustments

Drum Roller: Roller Alignment:

Each drum roller is equipped with two tapered roller
bearings. Seals are provided to exclude water and dirt. If
it becomes necessary to replace the bearings, the
assembly must be thoroughly cleaned before installing
the new bearings. Pack the bearings with the
recommended lubricant. (See lube chart).
Drum rollers must run parallel (in line) with roller track.
Rollers are to be set by using a minimum 12” long
straight edge, with one knife edge. Working from both
sides of rear face of roller, straight edge is to match with
chamfer on roller track (see below).

To take up bearings, tighten nut until roller cannot be

turned by hand, then back off until roller turns with slight
drag.

Face contact of track and roller is to be flat, no light

showing through contact under rated load.

Unloaded Drum Roller Alignment:

Maintain a space of .012” to .015” by shimming under

either side of roller bracket (see right).

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Roller Adjustments 51
Universal Drive Shaft
After the universal drive shaft has been assembled to
the engine and pump, be sure that the following
conditions exist:
a. The drive shaft joint are in phase (See Below)
b. The slip joint spline has ample engagement and that
at least 3/8” of clearance exists between the end of
the male spine and the bottom of the female spline.
(See Below)
Misaligned
52 Universal Drive Shaft
CAUTION: If the yoke (00700) nut is not properly
torqued to 175 ft. lbs., drive shaft failure may occur. In
most universal drive shaft installations, a slight
misalignment between driving and driven members is
desirable but in no instance should the angle of the
universal drive shaft between joints and the shaft
centerline of the driving or driven member exceed 6°.
(See Pump and Universal Alignment)
Aligned
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
Pump and Universal Alignment

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Pump and Universal Alignment 53
ZF Drum Drives
ZF was founded in 1915 by Count Zeppelin (the airship
Zeppelin) and is the world’s leading manufacturer of
transmission systems including axles and steering.
McNeilus Companies has used ZF’s Drum Drive since
the 1970’s. Since that time several models of the ZF
have been developed and put into production. Over the
years the torque rating of the ZF has continually
increased to meet the demands of larger capacity mixer
drums and lower slump concrete.
The ZF drive is a double planetary reduction drive. The
input rpm (where the motor is mounted) is reduced to the
output rpm (the flange that bolts to the drum) by the ratio
of the drive. As an example, if the ratio is 144:1, the
flange rotates once for every 144 turns of the motor.
This reduction is accomplished through planetary gears
which rotate around a sun gear. There are two sets of
planetary gears which accomplish the reduction.
Planetary gears are very efficient and cool running. The
drive is around 96% efficient meaning only 4% of the
input energy is used by the drive. This compares to 80%
efficiency for many of the straight gear reduction drives.
Servicing the ZF drive is critical to the overall lifetime of
the drive. The proper lubricant for the drive is 85W-140;
the same lubricant commonly used in differentials. The
spec of the lubricant is GL-5. This lubricant is available
from nearly any oil distributor.
It is important that the ZF be serviced after the first 100
hours in service. The drive should be drained while the
lubricant is warm. This 100 hour period is considered the
“clean up” lubricant change for the drive. Any
contamination which washes from the new castings,
bearings, gear wear-in, etc. can be drained at this time.
After the initial service the drive should be serviced every
six months or 1,000 hours; whichever comes first.
Remember that the drive has a positive pressure within
the case. The drive design allows a minimum amount of
internal pressure to develop as the lubricant and drive
warm up. This positive internal pressure helps prevent
contamination from entering the internal drive
components. This internal pressure also means that
caution must be used when removing any fill plugs from
the drive while the drive is warm. Safety glasses must be
worn while servicing the ZF drive. Even though the
internal pressure is minimal, the fill plug may want to
blow from its port and spray lubricant from the port.
Loosening the four hydrostatic motor mount bolts and
then loosening the hydrostatic motor will normally relieve
any pressure in the ZF drive. Any excess pressure
developed in the drive is normally relieved by the output
flange seal.
The hydrostatic motor is bolted to the input of the drive.
54 ZF Drum Drive
The hydrostatic motor has a shaft seal which prevents
the hydraulic fluid in the motor from leaking around the
motor shaft under pressure. If this motor shaft seal
leaks, hydraulic oil and pressure can transfer from the
motor case to the ZF drive case. There is also an input
seal in the ZF input cavity around the splined receptacle.
This ZF seal is “nicked” at the factory in the 9:00 or 3:00
o’clock position. The nick allows the ZF lubricant to leak
from the drive and lubricate the spline on the motor shaft
and ZF splined receptacle. Without this lubrication, the
motor spline and ZF receptacle will wear prematurely.
Because this seal is “nicked”, there will normally be 85W-
140 lubricant in this cavity. The hydraulic fluid in the
motor case is quite “thin” compared to the ZF lubricant.
Also the ZF lubricant has its own strong odor. If there is
hydraulic fluid in this cavity, the motor seal is leaking.
Anytime the drive is overfilled - either from servicing the
drive or from a leaky hydrostatic motor seal - the excess
lubricant will exit the drive around the output flange seal
and show up on the drum head. This seal is a heavy
rubber lip seal which is quite strong. It is our experience
that a leaky ZF output seal is generally an indication of a
faulty motor seal or overfilled drive rather than a faulty ZF
output seal. The seal cavity also holds a quantity of
lubricant and may take two or three weeks for the
lubricant around the seal cavity to dry up. Changing the
seal is a difficult job which requires a 60 ton press. The
seal is one of the last items to come out of the drive
when it is completely disassembled. Never assume this
heavy rubber lip seal is faulty. It normally only leaks only
when the drive is overfilled. A ZF Repair Manual is
available from McNeilus if you are planning on working
on the drive.
When changing the ZF drive it is important to retain the
flange in its normal centered position that it is in when the
drive is mounted on the mixer. Allowing the weight of the
output flange to put its weight on the output seal may
damage the seal; especially if it’s left in that position for
any length of time. For this reason a bracket with a 90∫
bend should be fabricated. One end of the bracket
should be bolted to the flat on top of the drive and the
other to the flange. This bracket is especially important
when storing a ZF drive for any length of time.
There are flange bolts around the output flange which
secure the drive flange to the mixer drum socket. The
flange bolts should be torqued to 170 lb. ft and checked
on a weekly basis. There are threaded holes in the ZF
flange which are unused. When removing the ZF flange
from the drum socket, bolts can be threaded into these
extra threaded flange holes around the flange and
pressure applied from the flange to the drum socket by
tightening the bolts. This will help separate the ZF
flange from the drum socket. The bolts work like a
© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved
ZF Drum Drives
puller to help separate the flange from the drum socket.
Heat may have to be applied to the flange and drum
socket area to separate the flange from the drum socket.

Normal maintenance of the ZF drive includes checking

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

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

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

Please call your McNeilus branch or McNeilus Truck and

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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved ZF Drum Drive 55
Fluid Power Equivalents
EXACT EQUIVALENTS: APPROXIMATE EQUIVALENTS

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

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

1 Micro-Meter = 1 Millionth of a meter

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

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Common Abbreviations 57
Index
10 Micron Filter Assembly, ............7, 37
A- B-C
Accumulator Charge Kit, ....................5
adapters, ......................................2, 17
air chute lock, ......................................3
air leaks, ............................................50
ANSI, ............................................3, 57
Automatic Transmission Fluid, ......9, 50
blocking devices, ................................1
Bridgemaster, ..........4-6, 10, 12, 50, 57
Broken Pump Shaft, ....................36-37
Charge Pump, ................10-15, 17-19,
..........................................25-29, 34, 37
Charge Pump Rotation, ....................34
Charge Relief Valve, ..............25-27, 29
Check Valve, ..............................24, 44
contamination, ............9, 19, 21, 37, 54
D-E-F
debouncer, ........................................50
Diagram Action Steps, ................28-29
electrical, ....................................3-4, 48
extension chutes, ................................3
External Oil Cooler Bypass, ........26-28
fault-logic charts, ..............................23
Fender, ..............................................43
G-H-I
high pressure, ..............2, 9-11, 13, 15,
..............................20-21, 26-29, 50, 57
Hydraulic Down Pressure, ..................5
hydraulic fluid, ..........1, 9-11, 14, 38-39,
..........................................................54
Hydraulic Fluid Specifications, ....38-39,
..........................................................59
Hydraulic hoses, ........................1-2, 50
hydraulic pipe, ....................................2
Hydrostatic Installation, ....................37
Hydrostatic Pump, ................4, 6, 9-14,
....................................18-19, 30-31, 37
Open Center Chute Valve Assembly,
......................................................45-47
P-Q-R
Periodic Inspection, ....................49-50
power limiters, ............................20, 28
proper protective clothing, ..................4
Pump and Universal Alignment, ..52-53
Raise Position, ..................................46
Rear Pedestal, ..................................42
Roller Adjustments, ..........................51
Roller Alignment, ........................50-51
roller track, ..................................50-51
S-T-U
SAE J1065, ..................................2, 11
Safety, ........................................1-7, 54
tapered roller bearings, ....................51
trailer, ........................................4-6, 50
transmission, ................3, 9, 37, 50, 54
Troubleshooting, ..........2, 17-21, 24-27,
..........................................................48
Tuck-A-Weigh, ................................4-6
universal drive shaft, ........................52
V-W-X-Y-Z
vacuum gauge, ........11, 15, 17, 37, 50
Vacuum Hose, ..................................28
Valve Plate Rotation, ........................35
Water Tank Measurement, ..............41
ZF Drum Drives, ..........................54-55
ZF transmission, ..............................50

J-K-L

kit, ............2, 5, 7, 12-14, 17-18, 41, 50

Lock out, ..................................1, 3, 57
Lower Position, ................................47

M-N-O

Main, ................................3, 20, 50, 57

McNeilus Cable Lube Kit, ..................50
mixer drum, ................3, 24, 37, 50, 54
Molybdenum Disulphite, ....................37
o-ring, ..............5, 12-13, 18, 28-29, 57
oil, ....................1-2, 9-10, 17-21, 26-28,
........................37-39, 49-50, 54, 56-57
Oil Level, ................................26-28, 50
Open Center Chute Block, ................44

© 3/98 McNeilus Truck and Manufacturing Co. All Rights Reserved Index 59
Notes
Notes
Notes
Notes
 McNeilus Truck and Manufacturing Co.
CORPORATE HEADQUARTERS
P.O. Box 70, County Road 34E, Dodge Center, MN 55927
Phone: 507-374-6321 • FAX: 507-374-6306

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