B2 & F1 Service Manual
Contents
1. spuoaas uey uajs pjou pue usng uong usng uaaic snowed euinsai pue ayeaay 5 z uey usng uaaic DNSTA 8805 paads jo auunsai 128 9 Spuodas uey pjou pue usng uong usng pay qIOH dOlS wimp dois spuoaas uey uong usng pay 4015 Tomo 2 3 ui9js S e211129 3 Bridge Axle Control System Housby Mixer BRIDGE AXLE CONTROL SYSTEM The bridge axle control system is a 12V dc system controlled by the bridge axle controller located in the controller box on the floor of the cab The controller takes inputs from the control panel and creates outputs to the mixer Inputs There are 5 inputs into the bridge axle controller that are analyzed and converted to outputs 1 Bridge Axle Start This 12V dc input at P11 10 is created by pushing the orange START button on the control panel Bridge Axle Raise This 12V dc input at P11 2 is created by pushing the Raise Lower switch to RAISE Bridge Axle Lower This input is also at P11 2 however it creates a ground for the circuit It is created by pushing the Raise Lower switch to LOWER Chute Proxy Sensor This 12V dc input at P11 9 is created by having the chute in the fully lowered and centered position If the Chute is centered and lowered it is possible to ra2. ayy 484901 MejuauoN TOH HOXVHOSIG usng pay TIOH HWU1 33 spuo2as Z uey 310W apis Ya 5 pue pue YoWas 183204 TIOH HD4VHO PHP fluo saiueysaw sseifiap ur sa1e301 spuoaas z uey alow yams pjou pue uopng usng uaaic 0117 7 Ta peads abseyasip 8805 uni dos 0 ji saseai2ap 8805 wing spuoaas z uey pue apis uas 184301 FOUVHSIA SJuawaioul jews abueuasip saseasoul paads jews abueua ui saseaisap paads wng 5 z uey ssa apis uotis 48201 uejuauo SOXVHOSIG dois 8805 58588138 uini spuoaas z jj doys paads paads ji paads wng z uey pue apis Yay 18201 fuejuauop ISHI 5 jews abueuasip saseaiaap paeds wng sJuawaiaul jews abueua 8805 585 wng spuoaas z uey sse epis ya YSN quais 18201 uejuauop AOMVHO uidi z Ajeyeuurxoadde ur
3. hem 2 5 Housby Mixer Bridge Axle Controller Logic BRIDGE AXLE CONTROLLER LOGIC dn amod uodn juBi pay ayy 5 ysey 18 043u02 ayy uonisod 4015 aui ur 81 0 si aui jl dn 18 amp od uodn spiousjos BAS pue ZAS asies dn jja ayy uonisod eui ur 18 043u02 ay Inys si j dn uamod uodn piouajos LAS dn 1 18 04ju02 ayy u od 841 Ul 0 inus 5 amod 8914 safessaw ansoubeip 104 51481 anog Ive pejeniur si 5 eui eui puoaes ay opioud paddojs si ayp usep pue jo 1no si agnya ay s uaym 15 ysey pas ayy umow sr axe uaya spuoa8s 10 w vr g Spuo3as 51 104 uo ay pue punos jja ay pajeaoe se uogng LY WLS ay pue uonisod se quauis 484901 ay uBnouj se ay asies syo g spaaaxe jeubis siy 0 sjuBi dn YONI 8u uoneniur 1Mv1S Injssaaans e uodn spuoa
4. dum gt o hem E ui9js S e211129 3 Fuses Housby Mixer FUSES 1 5A BRIDGE AXLE 5 5A HOPPER 9 10A PENDANT 2 CHUTE PROX 6 5A CHUTE LOCK 10 OPEN 3 5A DRUM 7 15A OIL COOLER 11 20A WORK LIGHTS 4 CHUTE 8 5 HYD OILLEVEL 12 OPEN 1 5 9 2 6 10 3 7 11 4 8 12 CHUTE LOCK LOCK RELAY RELAY On B2 Mixers there are 10 Fuses and on F1 Mixers there are 8 Fuses The only difference between the mixers 15 the F1 s have fuse 1 and 2 open The fuses are located inside the Controller Cover on the floor of the Mixers A decal like the one pictured above is located under the lid of the controller directly above the fuses with a fuse number the size of the fuse and the circuit affected 2 10 Housby Mixer Reprogramming the Drum Counter REPROGRAMMING THE DRUM COUNTER 1 With the truck shut down and the key turned off remove the 4 Screws in the Control Panel Cover Connect a jumper wire from the program terminal to the common terminal Turn on power Press SELECT until dsPSEL appears on the display Set to Yes Press and hold SELECT to record Press SELECT until tot dP appears on the display Set to 0 0 Press and hold SELECT to record Press SELECT until SCLFAC appears on the display Set to 0035 Press and hold SELECT to record Press SELECT until rAtE Enb appears on the display
5. This output from P1 4 varies depending on the speed the controller wants the drum to turn at It gives no output when the drum is in charge ul9js S Je21129 3 Drum Control Schematic DRUM CONTROL SCHEMATIC 2 2 Housby Mixer Drum Controller Logic Housby Mixer DRUM CONTROLLER LOGIC e21199 3 paysnd pue dojs o sawoa Jaye paseaja aq j5nui yapms 8805 wrup OL safessaw arsoufieip 10 anoj sayjoujuod 6 uoisuedxa 104 jndinoindur auo 8u 8 ay pun ay se 31o awes eeu juepuad ayy 7 einjeaj udi juejsuoa ayeygip Ajuo jja anjiej sosuas paads yg juo saiueysaw pas 5 p Ajayewixoidde afseyasip sayeyou uina 2 yayms yana eu jo Bunus 5 1044403 eui yo YIPMS epis 2595510 10 84 Buigsng Bu aBieuasip ysey Ajainb po c Wy Z ur uaym Apeo s yim due ayy 2 spuoaas z uey apis juBu yopms pou pue pue spuoaas z uey aow 5 pue abueua duie
6. Troubleshooting 5 Housby Mixer B2 Pressure Compensated Pump Troubleshooting Symptom Cause Remedy A Noisy pump caused by cavitation 1 Oil too heavy 1 See oil recommendations 2 Suction strainer 2 Suction strainer plugged 2 Clean or 2 Clean or replace Suction line plugged too small or _ PNEU Clean line and check for proper too long size length and hose rating B Noisy pump caused by aeriation 1 Oil omm low nomm Fill reservoir 2 Air leaking into suction line 2 Tighten fittings 3 Foaming oil 3 See oil recommendations C Hydraulic system overheating 1 Oil supply low 1 Fill reservoir 2 Oil in system in too light 2 Drain reservoir and fill with proper viscosity oil See oil recommendations 3 Excessive internal pump leakage 3 Disconnect case remove drain line measure leakage volume while pressurizing hydraulic system Case drain flow should not exceed 2 5 GPM If excessive remove pump disassemble and repair 4 Aeration of oil 4 Tighten fittings D System not developing adequate pressure 1 Excessive internal leakage 1 Refer to C 3 2 Compensator spool stuck open 2 Disassemble compensator inspect for stuck spool clean or replace 3 Compensator spring weak or 3 Dissasemble compensator inspect broken for weak or broken spring Replace spring if necessary 4 Pump cavitation 4 Refer to causes and remedies for A 1 A
7. the system must be completly free of any contamination Changing the filter element is not enough to thoroughly clean the system For this reason it is necessary to flush out the system before replacing components of the hydrostatic transmission NOTE It is recommended that both the hydrostatic pump and motor be replaced at the same time NOTE When removing hydraulic lines keep the fittings and the lines plugged with clean plugs to prevent contamination After determining the hydrostatic units need to be replaced 1 Drain all fluid from the system at the lowest point 2 Remove old hydrostatic pump and motor 3 Remove the filter element and the hydraulic tank clean out cover 4 Check the suction hose for kinks collapsed or flaking liner or any other obstructions Inspect all other hoses and fittings and replace as required 5 Check the inside of the hydraulic tank for contamination particles of steel or brass sludge dirt etc and be sure the ports and fittings on the tank are not obstructed with foreign particles 6 Flush all hoses filter housings and hydraulic tank with clean kerosene or solvent several times and blow out with air pressure T Reverse flush the oil cooler several times with clean kerosene or solvent and blow out with air pressure 8 Hand wipe the inside of the hydraulic tank and filter housing with clean lint free towels 9 Clean all hydrostatic pump and motor hose fittings and replace o r
8. 2 and A 3 Continued on next page 4 2 Housby Mixer F1 Gear Pump Troubleshooting Symptom Case Remedy ___ B Noisy pump caused by aeriation 1 Oil too heavy 1 See ail recommendations 2 Suction strainer plugged 3 Suction line plugged too small or 3 Clean line and check for proper too long Size length and hose rating 1 Oil supply low 1 Fill reservoir 2 Air leaking into suction line 2 Tighten fittings 3 Foaming oil 3 See oil recommendations 1 Oil supply low 1 Fill reservoir 2 Oil in system in too light 2 Drain reservoir and fill with proper viscosity oil See oil recommendations 3 Relief set to low 3 Adjust tank relief to 1800 psi by placing a gauge in the high pressure line and bottoming out and holding the chute cylinder in the down 4 Aeration of oil 4 Tighten fittings 5 Bypass valve malfunctioning 5 Check electrical Install new valve 1 Excessive internal leakage 1 If there is no flow between the tank and the releif and pressure does not develop in the system Replace pump 2 Pump cavitation 2 Refer to causes and remedies for A 1 amp 2 and 3 Troubleshooting This Page Intentionally Left Blank Housby Mixer Drum Roller Adjustment Chapter5 Maintenance DRUM ROLLER ADJUSTMENT Drum Rollers have two critical adjustments to maintain for smooth contact between the 23 rollers and the roller track 4 1 Rollers mus
9. Ib 7 6 m and up IMPORTANT Do NOT exceed the maximum Gross Vehicle Weight Rating GVWR Housby Mixer Hydraulic ComponentTroubleshooting 3 Raising the Bridge Axle When the bridge is raising solenoids SV2 and 5178 in the pressure reducing valve block are energized SV2 sends flow from the pressure reducing valve to the bridge axle valve port B and the rear function valve port B In the rear function valve flow is blocked by the sequencing valve which is set at 2100psi In the bridge axle valve flow passes through the check valve CV1 and the leaves through port R Flow travel through the counter balance valve into the rod side of the bridge axle cylinder As the cylinder retracts oil 15 forced from the cap end of the cylinder through the bridge axle valve and into the pressure reducing valve block Oil flows through the pressure reducing valve passes through SV8 and flows into the tank As the axle raises pressure on port B stays below 2100 psi due to the massive flow of oil When the axle reaches the raised position pressure builds causing the bridge lock to lock and the rear function valve s sequencing valve to open Once this valve opens all rear functions are restored F1 Mixers On F1 Mixers the Function Control Circuit is supplied with an Eaton Gear Pump This pump is a fixed displacement pump meaning it supplies oil at a fixed volume per revolution of the pump For this reason the hydraulics are slightly
10. Sensor Installation This Page Intentionally Left Blank Housby Mixer Hydraulic System How It Works Chapter1 Hydraulic System HYDRAULIC SYSTEM How IT WORKS The Hydraulic System on the Housby Mixers is comprised of two separate hydraulic systems The Closed Drum Circuit made up of an Eaton Hydrostatic Pump and Motor and a Function Control Circuit made up of either an Eaton Pressure Compensated Pump on B2 Mixers or an Eaton Gear Pump of F1 Mixers and the valves cylinders and components of the chute hopper and bridge axle controls E o 0 gt o 5 2 rI Drum Control The Drum Control Circuit 15 used to control the speed and direction of the drum The Circuit Eaton Hydrostatic pump is electrically controlled by the Electric Proportional Control EPC mounted on top of the hydrostatic pump The EPC controls the displacement of the pump The pump moves oil through a closed loop that includes a fixed displacement Hydrostatic Motor The motor responds to changes in the pumps flow by changing speed and direction directly proportional to the change in flow The motor is attached to a ZF gearbox on top of the front pedestal of the machine This gearbox links the motor to the drum For every 143 revolutions of the motor the gearbox turns the drum one revolution Function Control The Function Control Circuit 15 used to operate all other functions of the mixer such as Circuit chute and hopper controls and on B2 M
11. The controller takes 12V dc inputs from the control panel and the hand held remote and creates outputs accordingly Inputs dum gt o hem There 5 inputs into the controller that are analyzed and turned into outputs 1 Drum Start This 12V dc input at 21 10 is created by pushing the green drum START button in the cab or by flipping the drum RESUME switch on the remote 2 Drum Stop This 12V dc input at P1 9 is created by pushing the red drum STOP button in the cab or by flipping the drum PAUSE switch on the remote 3 Charge This 12V dc input at P1 5 is created by flipping the switch in the cab or on the remote to the CHARGE position 4 Discharge This 12V dc input at P1 2 is created by flipping the switch in the cab or on the remote to the DISCHARGE position 5 Speed Sensor This input sends pulses to the controller and to the drum counter depending on drum speed Outputs There are 3 outputs from the controller to the mixers drum system 1 Green Light This output from P1 6 sends a signal to the green light on the control panel in the cab It is on continuously in CHARGE it pulses slowly when in constant speed and it pulses quickly when in discharge The light is off if the no drum is stopped 2 Drum Forward This output from P1 3 varies depending on the speed the controller wants the drum to turn at It gives no output when the drum is in discharge 3 Drum Reverse
12. a pause as described above b The bridge is slow from pulling away from the rear pedestal and when it does go it is erratic Ifa low accumulator is suspected it will be necessary to lower the bridge and verify the pressure by installing a gauge on the inlet valve If accumulator still contains low pressure check for leakage with soapy water at the accumulator valve prior to recharging accumulator r av 27 N 247 247 247 247 247 247 247 247 27 47 47 WARNING Before beginning service on the accumulator the truck must be locked according to OSHA lockout tagout procedures with all pressure relieved from the bridge axle Accumulator must be entirely discharged if removing the accumulator inlet valve assembly Removing the accumulator inlet valve assembly with pressure in the accumulator may cause personal injury Cylinder rod must be extended Bridge down before accumulator is charged Do not stand behind cylinder when charging the accumulator 247 247 47 47 47 247 247 247 247 47 247 Housby Mixer Accumulator Charge and Pressure Check Instructions ACCUMULATOR CHARGE AND PRESSURE CHECK INSTRUCTIONS r av 47 47 247 247 247 247 247 247 247 27 27 247 WARNING Before beginning service on the accumulator the truck must be locked according to OSHA lockout tagout procedures with all pressure relieved from the bridge axle Accumulator must be entirely discharged if removing the accumulator inlet valve
13. assembly Removing the accumulator inlet valve assembly with pressure in the accumulator may cause personal injury Cylinder rod must be extended Bridge down and all hydraulic pressure relieved before accumulator is charged Do not stand behind cylinder when charging the accumulator av 247 47 47 47 AD 247 AD 247 247 27 47 247 1 Purge air from the charge kit by allowing a slight flow of nitrogen to escape while attaching the charge kit to the charge stem IMPORTANT Use only dry nitrogen to charge accumulator 2 Once the charge kit is connected to the charge stem loosen the top nut slightly while holding the bottom nut in place The nut should only be loosened enough to get a pressure reading on the gauge of the charge kit If the accumulator s charge pressure is less than 1800 psi nitrogen should be added If pressure is 1800 psi skip step 3 3 Ifthe accumulator is low on charge slowly open the valve on the charge bottle When the pressure reaches 1800psi shut off the valve 4 Tighten top accumulator valve nut to 50 70 in Ibs of torque the bottom nut should be torqued to 100 110 in Ibs IMPORTANT The accumulator charge stem uses tapered seats and requires 50 70 in Ibs to seal properly Over tightening of the bottom nut can cause damage to the o ring 5 Remove charge kit and spray soapy water on valve stem to make sure no air is leaking NOTE Housby recommends that accumulator charge pressure be checked ever
14. by driver Downforce of wheels against paving n2 pein ares 12 5 in piston area 20 86 78 15 E 0 gt o 2 rI 15 Hydraulic System How It Works Housby Mixer The area of the rod side of the piston in the Bridge Axle Cylinder is 12 5 in The fixed pressure reducing valve keeps the pressure on the rod side at 600 psi when the wheels are lowered At 600 psi the rod side of the piston exerts 7500 lbs of force in the retract direction This force must be subtracted from the force produced on the cap end side of the piston which is the pressure set by the driver in the Pressure Reducing Valve times the area of cap end 19 6 in This table shows the recommend pressure settings according to load and the resulting downforce on the bridge axle wheels For mix weighing between 3600 and 4800 Ib yd 2250 2500 Kg m PressureSetting Cap Side Force Downforce Concrete Mix Load PREDVI psi X 19 6 in minus 7500 165 times 0 266 0 yd leave bridge axle up 0 02 3 m 4 800 psi 15 680 Ib 8180 Ib 2175 Ib 3 1 m 5 yd 900 psi 17 640 Ib 10 140 Ib 2697 Ib 3 8 m 6 yd 1400 psi 27 440 Ib 19 940 Ib 5304 Ib 4 6 m 7 yd 1600 psi 31 360 Ib 23 860 Ib 6346 Ib 5 4 m 8 yd 1800 psi 35 280 Ib 27 780 Ib 7389 Ib 6 1 m 9 yd 2300 psi 45 080 Ib 37 580 Ib 9996 Ib 6 9 m 10 yd and up 2400 psi 47 040 Ib 39 540 Ib 10 517
15. different on an F1 Mixer When no hydrualic functions are being used chute and hopper functions the oil is pumped directly back to the hydraulic reservoir When oil 1s needed for the functions the bypass valve on the rear function valve blocks flow to the tank and directs flow to the appropriate function valve If the bypass valve fails or becomes clogged there is an 1800 psi pressure releif valve on the tank to prevent damage to the gear pump HYDRAULIC COMPONENTTROUBLESHOOTING AND REPAIR For information on troubleshooting the hydrostatic pump hydrostatic motor or hydrualic pump systems refer to the respective Eaton service and repair manuals at the back of the Housby Service Manual For troubleshooting information regarding single or multiple functions of the mixer refer to chapter 4 Troubleshooting E 0 gt o 5 2 rI Housby Mixer B2 Hydraulic Schematic B2 HYDRAULIC SCHEMATIC ISd uana W3NIVHIS OF W3NIVHIS A wuni3y lt 7 S 7NOLLORSS lt 7 GOL k Y 5 0022 1 0092 Y N uum Mv pul 01969 18 0008 aio 821 GIO ONGAH Hydraulic System 3ATVA ONIONGSY Saud gt q J3AIVA3IXV d9 dldd 026 09 OVL 008 9 0 96 YAGNITAD HOLV1 3AT1VA NOLLOND tS wb LE
16. Chamfer 2 Rollers must run flat on the Roller Track under rated load N p Refer to and follow the owner s manuals procedure for Mixer Drum Lockout before Straight age qe beginning When truck is unloaded adjust rollers using shims H10881 until the back edge of the rollers become the contact points There should be a small amount of light 012 015 showing through the Straight Edge front edge of the roller track fig 2 This allows the rollers to run flat on the roller track when the truck is loaded Roller Track Figure 3 5 1 Maintenance Bridge Axle Accumulator Charge Quick Check Housby Mixer BRIDGE AXLE ACCUMULATOR CHARGE QUICK CHECK 1 Chock both sides of the front wheels of the truck and lower the bridge axle 2 Pressurize the system to 2000 psi 3 Raise the bridge slightly off the ground and stop the bridge Once again lower the axle while watching the pressure gauge The gauge will quickly rise once the wheels contact the ground If one watches closely the gauge will hesitate for a moment and then continue to climb up to 2000 psi Take note of the point the pressure hesitates 4 Repeat above procedure and note the hesitation point they should be about the same NOTE The point at which the needle hesitates is the accumulator pressure It should be 1750 1850 psi You should suspect low accumulator charge if a You do not see
17. Set to Yes Press and hold SELECT to record Press SELECT until rAtE dP appears on the display Set to 0 0 Press and hold SELECT to record Press SELECT until rAtE dSP appears on the display Set to 60 Press and hold SELECT to record Press SELECT until rAtE INP appears on the display Setto 2886 Press and hold SELECT to record E dum gt o hem This Page Intentionally Left Blank Housby Mixer B2 Pneumatic Diagram Chapter 3 Water and Pneumatic Systems B2 PNEUMATIC DIAGRAM F1 PNEUMATIC DIAGRAM 3 1 Water and Pneumatic Systems suiajs g oneuinaug Water Circuit Diagram WATER CiRCUIT DIAGRAM Compressed Air Water Water Manifold Air Pressure Gauge Air Pressure 3 Way Valve Regulator Water Tank On Off On Off Air Valve Valve Water Truck Air Line Clean Out Reservoir Housby Mixer Upper Spray Nozzle Nozzle to Drum Interior Lower Spray Nozzle Housby Mixer Chapter 4 Troubleshooting System will not build pressure Bridge Axle will not change direction Excessive fluttering of pressure gauge during transport Bridge axle drifts down when held in mid position Chute drifts down while in hold Chute will not raise or Chute will not unlock or Hopper will not raise Chute will not lower Continued on next page High pressure releif valve stuck Replace high pressure relief open Pre
18. This Page Intentionally Left Blank Table of Contents TABLE OF CONTENTS Chapter 1 Hydraulic System Drum Control Circuit Function Control Circuit B2 Function Control Circuit F1 Hydraulic Schematic B2 Hydraulic Schematic F1 Chapter 2 Electrical System Drum Control System Drum Control Schematic Drum Controller Logic Bridge Axle Control System Bridge Axle Control Schematic Bridge Axle Controller Logic Auxillary Control System Fuses Reprogramming the Drum Counter Chapter 3 Water and Pnuematic Systems Pnuematic Diagrams Water Circuit Diagram Chapter 4 Troubleshooting General Troubleshooting Pressure Compensated Pump Troubleshooting Gear Pump Troubleshooting Housby Mixer 2 1 2 2 2 3 2 5 2 6 2 7 2 0 2 1 3 1 3 2 4 1 4 2 4 3 Housby Mixer Table of Contents Chapter 5 Maintenance Drum Roller Adujstment 5 1 Bridge Axle Accumulator Quick Check 5 2 Bridge Axle Accumulator Charge Instructions 5 3 Emergency Jumper Procedures 5 4 Hydraulic Clean Flush Procedures 5 5 High Pressure Filter 5 6 Eaton Hydraulic Service Manuals 1 Eaton Troubleshooting Guide for Heavy Duty Hydrostatic Transmissions used on Concrete Mixers Eaton Hydrostatic Variable Pump Repair Eaton Electronic Proporional Control Eaton Hydrostatic Motor Repair Eaton Pressure Compenstated Pump Repair Eaton Gear Pump Repair Eaton Constant Speed Control Installation ue Doce ae wedge Eaton Speed
19. XS L MAGNITAO H3ddOH 1 gt y 1 E 1 ds D r Do 1 Wd9 v JNIA 81 ONIONANDAS r i VAS GOM Z 291 X O S MAGNITAO 1417 310H9 SAS J SLXOE YAGNIMNAOD dWY19 ALNHO ulo9js S E o o o 5 i 2 I isd ned LEX SL MANIVELS A AMANIVELS NOILONS gt NOLLONS lt IGI i W3ONITAO Y3ddOH Ze N Pd 1 1 ISd US lun t dS 1 N 0022 a l Y n 2 alo 99 TN nasi KY WS po alo ISa 9 alo eZ 1 Nn XV GIO 98 9 NNSA Sod ELLA 587008 1 b v 29 GOH c SCSLXO SHJONITAO 13111 SAS 0 SLiLXO W3ONITAO TO 310HO F1 HYDRAULIC SCHEMATIC Housby Mixer This Page Intentionally Left Blank Housby Mixer Electrical Components Chapter2 Electrical System ELECTRICAL COMPONENTS The Housby Mixers have 3 separate electrical controlling systems on the B2 Mixers and 2 on the F1 Mixers The systems for drum control and auxillary controls are the same on the B2 and F1 Mixers and in addition the B2 has a bridge axle control system Drum Control System The drum system is a 12V dc system controlled by a drum controller located in the controller box on the floor of the cab
20. as 40 punos jja jo 4681 au uo woy v Z uoiouny 2 84 810080 uonisod pasoja ayy eq snw pajajua2 pue umop ajnua Burjeao yoyms yuunoid ON v L CO oo 8 YIWAS HJAAOT3SIv uonisod Aq se ajxe abpug sajeAnov uey yapas uong INXVIS puewwos Mv S uodn afpug samo 01 Apeas si 5 5 uonisod uop uas YAMOT puewwos Mv S uodn asies Apeai 5 wajsds quais AISIA uong pegs njsa2ans Jaye Jas G Ajuo 0015 uonisod yopa yapas 18202 dOIS 1115702173 36 ONTO pauo 2 Electrical System Housby Mixer Auxillary Control System AUXILLARY CONTROL SYSTEM All other fuctions of the mixer such as chute controls hopper controls work lights and cooling fan are controlled manually without a control module Chute RAISE LOWER The chute RAISE LOWER momentary switches in the cab and on the remote are wired in parallel with each other and activate solenoids SV4 and SV3 respectively E dum gt o hem Chute LOCK UNLOCK The chute LOCK UNLOCK momentary switches in the cab and on the remote are wired in parallel and use a pair of relays to hold the power to sol
21. aution in removing motor as to not damage the hydraulic hoses 3 Operating Machine Remove the 2 high pressure hoses from port A and B and the case drain hose from the hydraulic motor and place plugs on the ends of the hoses and in the fittings of the motor 4 Operating Machine Remove the hyraulic motor from the disabled machine and attach it to the disabled machine s gearbox 5 Operating Machine Remove the 2 high pressure hoses from port A and B and the case drain hose from the hydraulic pump and place plugs on the ends of the hoses and in the fittings of the pump Disconnect the wires for the speed sensor on the motor 6 Operating Machine Attach the hoses from the jumper kit H10434 to the pump and the motor of the operating machine to their respective ports Be sure to bleed out any air trapped in the hoses motor or pump before tightening hoses 7 Operating Machine Check the oil and add if necessary 8 The disabled machine s drum may now be operated using the controls of the operating machine and the drum lock bolts may be removed from the drum of the disabled machine 9 Once finished unloading the disabled machine reverse the process to remove and reinstall the motor to the operational machine 5 4 Housby Mixer Hydraulic Clean Flush Procedures HYDRAULIC CLEAN FLUSH PROCEDURES Oil contamination is the primary cause of hydrostatic transmission failure Before installing any new hydrostatic elements pump or motor
22. enoid SV5 and to the Chute Unlocked light when the chute is unlocked When the chute is locked there is no power and the spring in the cylinder holds the chute locked ui9js S Je21129 3 Housby Mixer Hopper RAISE LOWER The hopper RAISE LOWER switch sends power to solenoid SV7 and the hopper raised light when the switch is in the RAISE position When the hopper is in the LOWER position there are no signals sent out Cooler Fan AUTO ON The cooler fan is operated by a the AUTO ON switch in the cab When in ON mode the fan runs continuosly and the light in the switch illuminates When the switch is in AUTO mode the fan runs when only when oil temperature is above 160 degrees When the temperature reaches 210 degrees the OIL TEMP light in the cab illuminates and if the 160 degree temperature sensor has failed the fan begins to run The fan will continue to run until oil temperature has fallen below 160 degrees OIL LEVEL The OIL LEVEL indicator illuminates when the switch float in the oil tank closes due to low oil Housby Mixer Work Lights ON OFF Optional The work lights are operated by a switch on the control panel When in ON the lights and the light in the switch illuminate When in OFF the lights extinguish Tail Lights The tail clearance brake and back up lights are operated through the truck s electrical system They are connected to the truck s wiring harness near the rear of the truck E
23. he flow from the rod end enters the bridge axle valve at port R Pressure builds shifting the sequencing valve SEQ1 allowing flow from the rod end to the cap end This regenerative loop allows the cylinder to extend quickly but with relatively little force NOTE The pressure on both sides of the cylinder is equal but the cap end size has more surface area causing the cylinder to extend Housby Mixer Hydraulic System How It Works 2 Applying down force As the wheels touch the ground pressure builds to the current setting on the pressure reducing valve When the pressure exceeds 600 psi the setting of the fixed reducing valve the check valve CV2 closes This ends the regenerative loop and allows the pressure of the pressure reducing valve to be exerted on the cylinder Once this pressure 1s built up cylinder movement stops causing the pressure relief valve PRV2 to close The rod end of the cylinder continues to have 600 psi from the fixed pressure reducing valve which opposes the pressure of the cap end of the cylinder exerting 7500 Ibs of force in the raised direction Opposing the 7500 Ibs of force is the pressure from the cap end of the cylinder 19 6 in x current pressure setting The downforce at the wheels results from force applied to a lever The ratio of the two arms of the lever result in a force multiplier of 0 266 20 86 divided by 78 15 Cylinder Rod force x 20 86 78 15 Downforce Hn psi as set
24. ings as necessary 10 Replace filter elements filter gaskets and hydraulic tank clean out cover gasket 11 Reinstall pump and motor units 12 Fill reservoir hydrstatic motor and pump cases hoses etc with clean pre filtered oil Make certain that the oil meets the fluid recommendations of the equipment manufacturer 13 Proceed with start up procedure NOTE Although these procedures will take considerable time to complete we at Housby feel that they are extremely important to prevent unnecessary replacements or the hydrostatic components Maintenance High Pressure Filter Housby Mixer HIGH PRESSURE FILTER 5 6 Bypass Indicator The high pressure filter installed on the hydraulic system of the Housby mixer contains a bypass valve to protect the filter element from collapsing On the top of the filter is a bypass indicator It is green in normal operating conditions and turns to red when in bypass filter plugged The only time there is flow through the filter is when a function is being used hopper chute or bridge axle If during the operation of these functions the indicator shows red the oil is bypassing the filter and your system may become contaminated causing a malfunction of valves or the hydrualic pump When the filter is running in bypass be sure to replace the filter as soon as possible
25. ise and lower the bridge axle by using the bypass switch on the bottom of the control panel The bypass sends 12V dc to the controller as if the sensor was giving the signal 497 47 47 47 497 NOS 47 WARNING Do not use the Chute Override Switch Unless you are certain that the bridge axle and the chute will not collide Serious Damage to the machine may occur If the sensor is not working replace it as soon as possible to avoid damage to the mixer EF 497 47 E 47 V 47 5 Truck Reverse Signal This 12V dc input is created when the truck is shigfted into reverse Outputs 1 Bridge Axle Raise This 12V dc output sends power from P11 3 to solenoid SV2 and SV8 to raise the bridge axle Bridge Axle Lower This 12V dc output sends power from P11 4 to solenoid SV1 to lower the bridge axle Rear Horn this 12V dc output sends power from P11 5 to the warning horn when the bridge axle is in motion Chute Position and Mid Stroke Light This 12V dc output sends a signal to the light depending upon the inputs The light is on during axle movement The light slowly flashes when the bridge is stopped in the middle of its path and the light flashes quickly if the chute is not in its fully lowered and centered position Housby Mixer Bridge Axle Control Schematic BRIDGE AXLE CONTROL SCHEMATIC E dum gt o
26. ixers bridge axle controls B2 Mixers On B2 Mixers the Function Control Circuit is supplied with an Eaton Pressure Compensated Pump This pump attempts to keep oil supplied to the system at 2500psi at all times When there is no flow requirements pressure at 2500psi the pump stops pumping oil until the pressure drops because of the flow requirements from a function being used It then responds by pumping oil to the system until pressure once again reaches 2500 psi 1 1 15 Hydraulic System How It Works Housby Mixer The bridge axle has three separate phases in its operation which will be discussed in order to understand how it operates 1 Lowering the bridge axle When the axle is lowering solenoid 5171 is energized allowing flow to the pressure reducing valve When 5171 is energized pressurized oil also travels to the bridge lock cylinder releasing the lock Oil leaves the pressure reducing valve block at the pressure set by the driver and enters port A of the bridge axle valve Within the bridge axle valve pressure is reduced by a fixed reducing valve to 600 psi or the setting of the pressure reducing valve whichever is less Flow moves through the bridge axle valve and leaves through port C flowing to the cap end of the bridge axle cylinder When the cap end of the cylinder becomes pressurized the counter balance valve on the rod end side opens allowing flow out of the rod end of the cylinder T
27. ssure compensated pump Dead head test gauge in high malfunctioning B2 pressure filter Reading should be 2500 psi Refer to PC pump troubleshooting Gear pump malfunctioning F1 Check pressure reading should be 1800 psi while powering a cylinder at the end of its stroke Refer to gear pump troubleshooting Tank releif valve stuck open F1 Replace or adjust releif valve Solenoid valves malfunctioning Use respective override Check electrical system Replace valve as soon as possible Pilot controlled check valve inthe for plugged orifice or install Bridge Valve not shifting new valve Accumulator charge low Check and recharge accumulator Check valve leaking Clean or replace check valve in rod end of control block Counter balance valve leaking Replace counter balance cartridge in rod end of control block Pilot operated check leaking Install new valve Down solenoid valve stuck in Check electrical Solenoid should not energized position be energized Replace valve Solenoid does not operate properly Check electrical Install new valve B2 rear function sequencing valve Replace valve not operating properly F1 Bypass solenoid does not Check electrical Install new valve operate properly Solenoid does not operate properly Check electrical Install new valve Counter balance valve malfunctioning not operating properl Check electrical Install new valve operate properly 4 1
28. t run parallel to the Lo 2 Roller Track and each other LOT Refer to and follow the owner s manuals procedure for Mixer Drum Lockout before beginning In order to align rollers and the roller track a line is needed on the roller track close to the back edge This is done with the drum spinning at a slow WARNING speed using a marking instrument held in A a constant position with a magnetic dial e indicator base or similar fixture With the drum locked set up the marking Drum roller can device on the roller track Only after the hand device is in place should the lockout procedure be reversed Do not place hands on the roller track while scribing the line The scribed line will be used to align the rollers not the rear face of the roller 012 015 track After a line has been scribed lock out the truck as specified in the owner s manual Align the back face of the drum rollers d yo ff A 74 a Jg N Drum Roller with the scribed line fig 2 using a straight edge flat on the back face of the a rollers in both directions fig 3 The final 5 step is verifying that the rollers are Figure 2 Unloaded parallel with each other using a straight edge across the back face of both rollers Figure 1 Scribed Line Roller Track
29. y 60 90 days or sooner if low pressure is suspected 5 3 Maintenance Emergency Jumper Procedure Housby Mixer EMERGENCY JUMPER PROCEDURE Purpose To operate or discharge a load from a disabled machine by the use of the hydraulic system and controls of an operating machine 47 47 47 47 47 47 47 47 48 47 gt CAUTION Be sure the hydraulic system as well as the truck components have cooled sufficiently before disconnecting hydraulic fittings Do not disconnect the hydraulic motor from the gearbox until hydraulic pressures have been relieved Use extreme caution when removing hydrostatic hoses Cleanliness in very important Dirt concrete lint or other contaminates can cause severe damage to hydrostatic transmission V 47 487 47 47 47 47 47 47 48 48 47 gt Procedure 1 Follow the mixer lock out procedures lock out both machines before starting any of the procedures making certain to place the drum roller lock bolts in both machines to prevent the drum from rotating Failure to place the locking bolts in the rollers can result in serious injury from the drum freewheeling 2 Disabled Machine Remove the hydraulic motor from the gearbox It is not necessary to remove the hoses however the speed sensor wire may need to be unplugged to prevent damage to the wires Place motor out of the way of the gearbox to allow for installation of the motor from the operating machine Use c
Download Pdf Manuals
Related Search