B1 Service Manual
Contents
1. PNEUMATIC COMPONENT DETAILS Bridge Axle Reservoir If the truck needs added air storage capacity to supply the extra demands of the bridge axle air brakes a bridge axle reservoir is added to the truck chassis and tied into the truck s pneumatic system Not all the trucks will have this Many will simply connect to the existing air tank s The bridge axle reservoir supplies the water reservoir and the bridge axle brakes with compressed air TO INTERIOR OF DRUM RIGHT SIDE WATER WATER MANIFOLD TO SPRAY NOZZLE BRIDGE AXLE PRESSURE ON LADDER BRAKE CHAMBER ON OFF VALVE AR TO SPRAY NOZZLE A ON LOWER TRUCK d 5 REGULATOR RELAY WATER TANK VALNE VALVE PRESSURE N GAUGE 3 c AON _ _ WATER FLOW X DK oNorr VALVE d X7 WATERLINE N LLL 34 J DRAIN VALVE aN A i PRESSURE PROTECTION VALVE LEFT SIDE T00PSl BRIDGE AXLE BRAKE CHAMBER __ PILOT PRESSURE WATER RESERVOIR TRUCK RESERVOIR 1440 Cl RESERVOIR B FROM SERVICE BRAKES Volume Theory of Operation A2 9 c o c o 2 E e O c o E E e O This page intentionally left blank Housby Mixer Overview Chapter 3 Drum Subsystem OVERVIEW See Drum Circuits in the drum subsystem rotate the mixing drum in forward and Subsystem on reverse and at different speeds A counter circuit counts rotations and the page E 9 for water circuit provides water to thin the mix or to w2. passes to the PLC The PLC responds by increasing the current at terminal IO to the next step The current ranges from 4 to 24 milliamps If the switch is held in the INC position the PLC continues stepping up the current until full speed 24 milliamps is reached In the DEC position the 24 volt dc signal input I1 6 passes to the PLC It responds by stepping down the current at terminal IO If held in the DEC position the PLC steps down the current to 4 milliamps resulting in the pump swashplate moving to the zero angle stopping drum rotation The momentary 1 RPM switch is located on the control console in the cab When in the ON position a 24 volt dc signal input I0 1 passes to the PLC The PLC responds by monitoring the input signal I0 0 from 1 the pulse pickup unit PPU in the hydraulic motor and adjusting the output current at terminal IO As noted above the current at IO regulates the EDC which controls the swashplate which controls the rate of flow from the pump which controls the speed of the motor E D gt a Q 5 o E 2 S a The motor drives the drum through a gearbox 2 with a 111 1 gear ratio so the PLC adjusts the current at output IO to produce 111 rpm at the motor When the feedback from the PPU indicates that 111 motor rpm is reached the PLC applies current at approximately 24 volts dc output Q0 5 to the 1 RPM indicator bulb mounted behind the 1 RPM switch The PLC also uses inp
3. The lower outer corner lists the primary section The outer upper corner of the page of the lists the major topic covered on the page REFERENCE PUBLICATIONS Housby Publications The following Housby Publications are necessary for reference e Housby B 1 Mixer Operator s Manual e Housby B 1 Mixer Parts Manual e Housby B 1 Mixer Maintenance Manual Contact Housby to order these publications Vendor Publications The following vendor publications are optional reference materials included at the back of this binder e Sauer Sundstrand Series 90 pump and motor service manual e Sauer Sundstrand Series HPM 61 2 Transit Mixer Drive start up and maintenance information e Powermate Company hydraulic flow diagrams e Hydraforce information on solenoid valves directional valves flow con trols pressure controls and technical data e Eaton Model 70122 Pump parts and repair information e Pinnacle Engineering electrical trouble tree diagrams schematics and control system overview e Westport Axle Corporation tag axle service manual A1 8 Volume Theory of Operation Housby Mixer Warranty Considerations WARRANTY CONSIDERATIONS Housby Warranty Scott Please provide Vermeer s one year warranty is printed inside the front cover of the 520 what info you want Brick Press Operator s Manual The warranty requires that all service work given here about be conducted by an authorized Vermeer dealership or the warranty shall Ho
4. for raising and lowering the chute and hopper and for unlatching the chute Other 12 volt dc outputs illuminate indicator lamp and worklights Volume Theory of Operation A2 1 A sjueuoduio 5 uouiuio5 Hydraulic Common Components Housby Mixer The Components See Common Components on page E 8 e the 12 to 24 volt converter and 2 amp fuse protecting the converter the programmable logic computer PLC e the three 2 amp fuses and the 15 amp circuit breaker protecting the PLC e the control switches on the control console rear panel and optional hand held remote panel that provide inputs to the PLC e the low hydraulic oil relay e the hydraulic oil level switch HYDRAULIC COMMON COMPONENTS Inputs Outputs To the Bridge Axle Subsystem To the Chute and Hopper Circuits The Components See Common Components on page E 8 A2 2 Torque from the truck s PTO gearbox rotates the pump Be aware that the ratio of engine input speed to the PTO out speed varies with truck manufacturer e Mack trucks are 1 23 engine to 1 PTO Trucks with Cummins engines are 1 15 engine to 1 PTO e Trucks with Caterpillar engines are 1 31 engine to 1 PTO Flow from the hydraulic common components is used to raise and lower the bridge axle and provide downforce to shift weight from the truck s drive wheels to the wheels of the bridge axle Flow is also used to overpower the spring loaded latch mechanism that holds the bridge axle
5. 3000 psi the PC will increase the angle of the swash plate to increase the flow from the pump Volume Theory of Operation Housby Mixer Hydraulic Component Details Schematic of Common Hydraulic Components ACCUMULATOR BRIDGE AXLE Y 1GALLON CYLINDER CYLt CYL2 LATCH 5X32 CYLINDER SPD T 25X35 1 5 ROD V Ia CBV1 CHUTE a el CLAMP CHUTE m m BEC zi CYLINDER CYLINDER LOGV1 cv2 par f 2 5X 14 20ROD HP I 3i i CYL4 1 PRV2 3 PREDV 1 cS A 600 PSI eie fos E CBV2 900 PSI ah T LM ERE a PREDV1 3000 PSI uu HYD PUMP PRESSURE RETURN 3000 PSI 1 61 CID 10 GPM GAUGE FILTER Volume Theory of Operation A2 7 2 c D c o 2 E e O c E E e O A sjueuoduio 5 uouiuio5 Hydraulic Component Details Housby Mixer Front Valve Assembly A1 Directional Control Valves Pressure Reducing Valve Drain Valve A2 8 These solenoid operated valves DCV1 and DCV2 open when the PLC energizes the solenoids DCV1 when open allows flow from the pump to extend the latch cylinder Show A1 valve assembly retract the hopper cylinder and extend the bridge axle cylinder to lower the bridge axle DCV2 when open sends flow to retract the
6. Housby Mixer How the Machine is Used Chapter1 General System Information How THE MACHINE IS USED The B 1 Mixer is used to mix and deliver concrete to job sites Most of the controls are electrically operated through the PLC Programmable Logic Controller inside the cab The driver operates these controls through switches in the cab or at the rear of the machine The drum is supported and rotated by a motor and gearbox at the front pedestal and supported by two rollers at the rear pedestal Gravity holds the drum in place but the drum can lift free of the rollers a small distance and drop back onto them Flat spots can develop on the rollers and drum as the result of a stationary drum bouncing as the truck travels To prevent this the driver always has the drum rotating when the truck is moving The drum is rotated at approximately 20 rpm while mixing then slowed to 1 rpm while enroute to and from the job site To discharge the concrete rotation is reversed and the drum is turned at whatever rate is needed to supply concrete down the chute to the contractor c o hao E A o w E o gt o c pm o To properly mix the concrete the driver rotates the drum a certain number to times A drum rotation counter on the control panel counts and displays the number of revolutions The flighting or fins welded into the drum roll and mix the material as the drum rotates To discharge the mix the driver r
7. If the filter becomes clogged with dirt Prototype flow through the filter will be restricted Mt eee EE and pressure upstream of the filter will EE nc rise Rather than allow excess pressure i to burst a hose or fitting a bypass valve is installed in the filter head that will open at 22 psi The optional pressure gauge 1 installed on the filter head provides a rough indication of the filter life remaining The indicated pressure will be low unless a large amount of flow is returning to tank such as when the bridge axle is being raised If return pressure at the filter approaches 22 psi the filter should be replaced If return pressure remains very low and does not increase visibly when the bridge axle is raised examine the filter head to ensure the bypass valve is not stuck in the open position Pressure Compensated Pump A2 6 The pressure compensated PC pump 1 is mounted on the rear of the hydrostatic pump 2 The PC pump is a variable displacement piston pump with a special spool valve that controls the displacement This spool valve is the pressure compensator PC The PC is constantly adjusting the angle of the swash plate the displacement control in reaction to the pressure at the outlet port of the pump The compensator attempts to maintain a constant pressure of 3000 psi If the pressure reaches 3000 psi it decreases the angle of the swash plate to zero to stop producing flow If the pressure falls below
8. a given task Additional information may be available through HOUSBY Service Support resources Organization of Material Volumes A B C and D of this manual are divided into chapters for e Safety and General Information Chapter 1 e Common Components of the other subsystems Chapter 2 e Drum subsystem Chapter 3 e Bridge Axle subsystem Chapter 4 e Chute and Hopper circuits Chapter 5 c o i E A o w E o gt o c A o Chapters are added to cover ancillary items e Engine Speed Control Chapter 6 e Work Lights Chapter 7 Volume E is large format pages showing schematics functional diagrams and harness diagrams Currency of Material The instructions illustrations and specifications in this manual are based on the latest information available at the time of publication given machine may have product improvements and features not described in this manual Housby Mixer Group reserves the right to make changes at any time without notice or obligation Operating instructions are found in the Housby B 1 Mixer System Operator s Manual Lubrication and maintenance procedures are found in the Housby B 1 Mixer System Owner s Maintenance Manual Volume Theory of Operation A1 7 IV uoneun0Ju ui9 s S eJouot Reference Publications Housby Mixer Visual Cues to Locating Information The front page of each chapter holds a detailed table of contents for the chapter
9. ash down the chute after reference the pour Since the drum rotation circuit adds most of the heat to the hydraulic oil the oil cooler and it associated components are also grouped with the drum subsystem DRUM ROTATION CIRCUIT The rotation of the drum is hydraulically operated and electrically controlled The direction of drum rotation is determined by the direction that the oil flows through the closed loop The speed of rotation is determined by the rate of flow through the closed loop Both speed and direction are controlled by the swashplate of the pump The swashplate can move from 17 in one direction full speed in CHARGE through the zero angle drum stopped to 17 in the opposite direction full speed in DISCHARGE E 2 0 gt D Q 5 o E 2 e a The swashplate is controlled by the Electronic Displacement Control EDC The EDC is controlled by the PLC Electrical Controls Stop Resume Three momentary switches are wired in parallel to allow the operator to stop Rotation or resume drum rotation from three different places The STOP RESUME switches are located on the on the control console in the cab on the rear control panel near the ladder and on the optional hand held remote panel See Electrical In the RESUME position a discreet 24 volts dc signal input I2 0 passes to Schematic of 24 the PLC In response the PLC provides restores an analog output 4 to 24 Volt Inputs to PLC milliamps to termi
10. blank
11. bridge axle cylinder and to the sequence valve SEQV1 in valve assembly A3 The small knurled knobs at the ends of the valves are manual overrides If the valve will not operate electrically it can be moved out of its normal closed position by pushing in on the knob rotating it 180 and allowing it to pop up IMPORTANT Do not use this override for continuous operation Fix the electrical problem as soon as possible The interlocks that prevent damage to the bridge axle or chute are provided electrically Manually overriding the valve will also override the interlocks This pressure reducing valve 3 PREDV1 is manually adjusted by the truck driver to adjust the amount of downforce the bridge axle is putting against the pavement Adjusting the valve limits the amount of pressure in the lines downstream from the valve This solenoid operated valve DCV3 is energized by the PLC whenever DCV2 is energized It opens a path to tank for the oil from the cap end of the bridge axle cylinder when DCV2 sends oil to the rod end of the cylinder to retract it Volume Theory of Operation Housby Mixer Pressure Gauge Pneumatic Component Details This pressure gauge is mounted in the cab It displays the pressure present at the cap end of the bridge axle cylinder The driver watches this gauge as he adjusts the pressure reducing valve PRedV1 to provide the proper amount of bridge axle down force for the size of the load in the drum
12. everses the direction of the drum rotation The flighting is shaped to auger the mix up and out of the drum opening when the drum rolls in reverse The driver raises the bridge axle for all activities except travelling on paved roads When loaded with five or more yards of concrete the bridge axle is lowered on paved roads to spread the weight dramatically reducing road wear and allowing heavier legal payloads The wheels of the bridge axle caster to allow easier steering Since they would hinder steering in reverse the bridge axle automatically raises when the driver shifts the truck into reverse When loaded the driver physically adjusts a knob controlling a pressure reducing valve to set the downforce of the bridge axle for the weight of the load Continued on next page Volume Theory of Operation A1 1 IV uoneuno0Ju Wa SAS JeJouot System Overview Housby Mixer At the top rear of the drum a hopper can be lowered to direct dry materials into the drum when loading The hopper is raised to allow a larger exit opening when the concrete is discharged at the job site The hopper automatically lowers whenever the bridge axle is lowered or when the truck is shifted into reverse gear At the site the driver can hydraulically raise and lower the chute and physically move it from side to side provided the bridge axle is fully raised The strength and quality of finished concrete depends heavily on how wet the mix is when it
13. f Operation Housby Mixer Subsystems Overview SUBSYSTEMS OVERVIEW Hopper and Chute Circuits These rotate the hopper to the charging and discharging positions and raise and lower the chute and lock unlock the chute pivot to allow it to swing right and left Drum Subsystem This rotates the drum at variable speeds in charge direction to mix materials and in discharge direction to force the mix out of the drum and into the chute When not mixing or discharging a 1 RPM setting turns the drum slowly to prevent the concrete from hardening or prevent the truck s bouncing from pounding flat spots in the drum The drum subsystem also includes the water tank used to add water to the mix Bridge Axle Subsystem This raises and lowers the bridge axle and provides proper downforce on the bridge axle to spread vehicle and load weight while in transit on hard surfaced roads Common Components In addition to these three subsystems the system also includes components common to two or more subsystems The system is divided this way to allow easier discussion and troubleshooting of the system Volume Theory of Operation A1 3 c o E A o w E o gt o o IV uoneuno0Ju Wa SAS eJouot Block Diagrams Housby Mixer BLock DIAGRAMS Structural Block Diagram The material is grouped and presented in the manuals according to the structural block diagram Housby B1 Mixer System C
14. he air pressure gauge 3 Pressure Protection Air pressure in the water tank can be Valve increased by heating due to sunlight or other sources The pressure protection valve 4 is a poppet set to vent ME E pressure to atmosphere if pressure rises above 100 psi me Volume Theory of Operation A3 9 cv uiojs sqng wnig Water Circuit Housby Mixer Water to Hoses or Drum Water Tank Water Flow ON OFF Valve Flow to Drum Flow to Wash Down Hoses Water System Drain Valves A3 10 A simple flap covers the water inlet 1 on the water tank To fill the pressure is bled from the tank with the three way valve then a hose is pushed into the inlet past the flap When the desired water level is indicated on the sight gauge the hose is withdrawn the Water Flow ON OFF valve is closed and the Water Pressure ON OFF valve is moved to the ON position to charge the water tank with air pressure The air pressure holds the flap closed A water line leads from the bottom of the tank through the top of the tank to a Water Flow ON OFF valve 2 The valve enables or stops flow to the water manifold At the water manifold 4 is a spring loaded Water Injection valve 3 that ports water to the interior of the drum when increased slump is desired Pull the handle to add water release it to stop i Two on off valves 5 allow flow to the upper and lower wash down hoses The hoses are usually equipped
15. hrough clearances of the moving parts also contributes to case flow The motor case overflow port is located on the top of the motor case Hoses lead the overflow to the oil cooler Heat from the oil is drawn off by air passing through the fins of the oil cooler 1 The cooled oil is drained away to the tank where further cooling occurs Volume Theory of Operation A3 7 E 0 gt a Q 5 o E 2 e a cv waysAsqns winig Cooling Circuit Housby Mixer Oil Cooling Controls and Indicators Fan Auto Manual Oil Cooler Relay 160 F Temperature Switch Hot Hydraulic Oil Indicator Bulb Test Diode A3 8 Two switches wired in parallel control the oil cooler fan the Fan AUTO MANUAL switch and the 160 Temperature switch The Fan AUTO MANUAL switch is located on the control console in the cab When in the AUTO position the switch is open When in the MANUAL position the switch is closed applying 12 volts de from the key switch to the coil of the oil cooler fan relay and to the Oil Cooler Fan indicator bulb mounted behind the AUTO MANUAL switch When the coil of the Oil Cooler relay is energized the contacts close and applies12 volts dc from the 15 amp circuit breaker to the motor of the oil cooler fan Located at the inlet of the oil cooler are two temperature switches One closes at 160 F the other at 180 F When the 160 switch closes it applies 12 volts dc from the key switch to the c
16. in its fully raised position Flow from the hydraulic common components is used to raise and lower the hopper to overcome the spring loaded chute lock and to raise and lower the chute e the hydraulic oil tank or reservoir return filter and its pressure gauge e the Eaton model 70122 pressure compensated pump serving the bridge axle hopper and chute circuits the front valve assembly A1 Volume Theory of Operation Housby Mixer Pneumatic Common Components PNEUMATIC COMMON COMPONENTS Inputs The truck s air compressor provides compressed air to the air reservoir Outputs To Drum Subsystem Air pressure from the reservoir is used to push water to the manifold used for adding water to the drum or operating the wash down hoses To Bridge Axle Air pressure from the reservoir is used to operate the air brakes on the Subsystem wheels on the bridge axle The Components See Common e the bridge axle reservoir Components on page E 8 Volume Theory of Operation A2 3 2 c D c o 2 E e O c o E E e O A sjueuoduio 5 uouiuio5 Electrical Component Details Housby Mixer ELECTRICAL COMPONENT DETAILS PLC A2 4 The programmable logic control PLC controls all the solenoids that operate the hydraulic valves and it operates the electric displacement control EDC that controls the speed of the mixer drum The PLC is located inside the control console inside the cab The PLC responds to 24 volt
17. input signals from the switches on the control panels and produces e 12 volt outputs to operate solenoid valves the Charge Discharge relay and illuminate indicator bulbs on the console control panel e 24 volt outputs to illuminate indicator bulbs located in switches on the console control panel e variable voltage outputs to the EDC to control the speed of the mixer drum The PLC is separated into different modules a primary module 1 where the logic occurs a 24 volt input output module 2 a 12 volt input output module 3 and an analog output module 4 The modules are separately protected by e primary module a 2 amp fuse between the converter and the PLC e 24 volt input module a 2 amp fuse between the converter and the switches e 24 volt output module a 2 amp fuse between the converter and the PLC e 12 volt output module a 15 amp circuit breaker between the key switch and the PLC Small LEDs light emitting diodes 5 on the modules illuminate when different inputs and outputs are received and sent The inputs and outputs are labeled on the modules and shown on the electrical schematics Volume Theory of Operation Housby Mixer Hydraulic Component Details Converter 12 to 24 Volt The PLC uses 24 volts the truck electrical system supplies 12 volts soa converter is installed to power the PLC The converter s power comes directly from the truck s ignition key with a 2 amp fuse between the ke
18. is poured The wetness or slump is measured by a slump meter actually a pressure gauge The slump meter is optional It measures the amount of resistance to drum rotation caused by the mix riding up the drum walls on the flighting A wet mix pours off of the flighting while a drier mix clings to the flighting longer as it is carried up the drum wall The slump meter has moveable markers attached to the exterior of the gauge face which can be positioned to indicated slumps of 1 inch 2 inches 3 inches etc If the mix is too dry the driver can add water from the water tank directly to the drum After completing the pour the driver can use a water hose one at ground level and another at the top of the ladder to wash wet concrete off of the truck before it hardens Usually the remaining water is added to the empty drum to slosh out the drum interior as the truck travels back to the plant SYSTEM OVERVIEW A1 2 The Housby B1 Mixer system is designed to e operate the hopper used for loading dry materials in to the drum e rotate the drum to mix dry materials with water and to discharge the concrete supply additional water to the mix if needed and supply pressurized water for after pour wash down raise and lower the chute used to deliver discharged concrete to the forms raise lower and provide proper downforce to the bridge axle to allow the truck to legally transport greater loads Volume Theory o
19. lump Meter A3 6 Housby Mixer The optional slump meter 1 is simply a pressure gauge that measures the resistance to pump flow caused by the work being done When the concrete is relatively dry more material is lifted by the flighting in the drum and carried higher The pressure indicated for each slump will vary with the amount of concrete in the drum The driver consults a chart to determine how much water to add to get the desired slump The slump meter is plumbed into the side of the loop that is under high pressure when the drum is rotated in the CHARGE direction Dry less slump Volume Theory of Operation Housby Mixer Cooling Circuit COOLING CIRCUIT Case Drains Oil Cooler When the charge pressure reaches 350 psi additional flow from the charge pump passes through the charge relief valve and into the pump case In addition any leakage through the internal clearances in the pump also enters the case The oil in the case is used to lubricate the rotating group of the pump As additional oil fills the pump case the overflow travels via the case drain line to a case drain port in the bottom of the motor The motor case gets additional oil from the hot oil shuttle valve sometimes called a loop flushing shuttle valve The hot oil shuttle drains a portion of the oil from the low pressure side of the loop to allow the charge pressure to cycle cool oil from the tank into the loop As with the pump leakage t
20. nal IO representing the last speed control output to the on page E 3 See EDC coils via the Charge Discharge relay The PLC also applies current at Electrical approximately 24 volts dc to the Drum Run indicator bulb mounted behind Schematic of PLC the STOP RESUME switch Outputs on page E 4 In the STOP position a discreet 24 volt dc signal input I 1 7 passes to the PLC The PLC responds by terminating the analog signal at terminal IO Volume Theory of Operation A3 1 cv waysAsqns winig Drum Rotation Circuit Rotation Direction See Electrical Schematic of 24 Volt Inputs to PLC on page E 3 See Electrical Schematic of PLC Outputs on page E 4 A3 2 Housby Mixer Three momentary switches are wired in parallel to allow the operator to reverse the direction of drum rotation from three different places The CHARGE DISCHARGE switches are located on the on the control console in the cab on the rear control panel near the ladder and on the optional hand held remote panel In the DISCHARGE position a 24 volt de signal input I1 4 passes to the PLC The PLC responds by passes a 12 volt dc signal output Q2 2 to the Charge Discharge relay In the CHARGE position a 24 volt dc signal input 11 3 passes to the PLC The PLC responds by terminating the current 12 volt dc signal output Q2 2 to the coil of the Charge Discharge relay The Charge Discharge relay is actually two relays CR1A and CR1B working in tandem The c
21. oil of the oil cooler fan relay and to the Oil Cooler Fan indicator bulb mounted behind the AUTO MANUAL switch When the 180 F temperature switch closes it applies 12 volts dc from the key switch to the Hot Hydraulic Oil Indicator bulb located on the control console in the cab If the STOP RESUME switch is held in the STOP position input I 1 7 and the 1 RPM switch is simultaneously held in the OFF position input I 0 2 the PLC responds by sending 12 volts dc to the all indicator bulbs on the console The bulb test diode prevents the bulb test current from energizing the coil of the Oil Cooler Relay Volume Theory of Operation Housby Mixer Water Circuit WATER CIRCUIT Air Pressure to Water Tank Air pressure pushes the water through the water lines Pressure Regulation Air pressure from the truck s pneumatic system passes through a regulator valve 1 which limits the air pressure used for the water system to 80 psi above ambient air pressure The regulator setting is adjustable Water Pressure On The two position water pressure ON Off OFF valve 2 controls whether the air pressure is allowed to charge the water tank In the ON position the 80 psi air flows to the water tank In the OFF position the 80 psi air flow is shut off and the air pressure in the water tank is ported to atmosphere E D gt a Q 5 o E 2 a Pressure Gauge The pressure of air in the tank is displayed on t
22. oils of both are energized or de energized at the same time When energized they position the contacts to route the current at terminal IO across the coil of the EDC 1 so it causes the pump to rotate the drum in the Discharge direction When the coils of CR1A and CR1B are not energized the contacts of the spring back reversing the polarity of the EDC coil and thus the direction of drum rotation If the operator turns the CHARGE DISCHARGE switch from one direction to the other the logic in the PLC recognizes that the drum is currently turning at a certain speed It steps down the current at terminal IO to 4 milliamps then either sends or stops output Q2 2 to reverse drum direction then steps up the current to the same level as used for the previous drum speed Volume Theory of Operation Housby Mixer Speed Control Increase Decrease See Electrical Schematic of 24 Volt Inputs to PLC on page E 3 See Electrical Schematic of PLC Outputs on page E 4 Speed Control One RPM Drum Rotation Counter Volume Theory of Operation Drum Rotation Circuit Three momentary switches are wired in parallel to allow the operator to increase or decrease the speed of drum rotation from three different places The INC DEC switches are located on the on the control console in the cab on the rear control panel near the ladder and on the optional hand held remote panel In the INC position a 24 volt dc signal input 11 5
23. ommon Components Hydraulic Electric Ch 2 4 Chute amp Hopper Circuits h5 C Drum Subsystem Bridge Axle Subsystem Ch 3 Ch 4 Functional Block Diagrams Each of the subsystems and the common components chapter has a functional block diagram found on pages XX through XX Functional block diagrams help explain the system and illustrate logical interdependencies of inputs to outputs of the subsystem These assist the technician when making decisions about how to troubleshoot the system A1 4 Volume Theory of Operation Housby Mixer Housby B1 Mixer System Service HousBv B1 MIXER SYSTEM SERVICE This manual is designed to help the technician repair a faulty system and return it to service as quickly as possible The manual is divided into five main sections e Volume A Theory of Operation e Volume B Performance Checks e Volume C Troubleshooting e Volume D Repair e Volume E Schematics and Diagrams 11 x 17 format A glossary of abbreviations and terms and an index are provided at the back of the Repair volume NOTE This manual does not cover the truck chassis engine or items related to the chassis or engine Consult the appropriate manuals from the chassis and engine manufacturer when necessary c o E A o w E o gt o c A c o Volume Theory of Operation A1 5 IV uoneun0Ju Wa SAS JeJouoc Housby B1 Mixer System Service Hou
24. sby Mixer Service Process Flow Chart The tasks involved in returning a malfunctioning system to service are to e localize the reported problem isolate faulty components from functioning components repair the faulty components e verify that the repairs solved the problem As this flow chart indicates this volume Volume A Theory of Operation is not critical to the repair process The intent of this volume is to familiarize you with the machine and its subsystems LOCALIZE ISOLATE REPAIR VERIFY Trouble shoot faulty Problem subsystem found Only 1 subsystem fails PC Problem not found Repair Return ise Checks for all as Checks for system to subsystems directed repaired service subsystem Fail PC More than 1 subsystem fails PC shoot Common Components Volume B Volume C Volume D Volume B Performance Checks Troubleshooting Repair Performance Checks A1 6 Volume Theory of Operation Housby Mixer About This Manual ABOUT THIS MANUAL NOTE This manual provides information and service procedures based upon machine knowledge and configuration at the time the manual was written Due to ongoing efforts to continuously improve the equipment there may be changes on the machine not reflected in this manual Procedures given in this manual provide one method for completing
25. until the pressure in the low side of the loop builds to 350 psi Above 350 psi the charge relief valve opens and the flow drains to the pump case and is drained away to the cooler and the tank The charge pump is integral to the hydrostatic pump 1 The PC pump 3 is mounted in tandem with the hydrostatic pump A3 4 Volume Theory of Operation Housby Mixer Hydrostatic Pump For different truck engines different PTOs are used Pump input shaft speed is engine RPM times 1 23 for Mack 1 15 for Cummins 1 31 for Caterpillar Motor and Gearbox Drum Rotation Circuit The amount of flow produced by the pump is dependent on the speed the pump is turning PTO gearbox output speed and the angle of the swashplate At full displacement 17 on the swashplate the pump produces 4 57 cubic inches of flow per revolution The swashplate angle is controlled by the EDC The motor 1 has a fixed displacement For each 4 57 cubic inches of flow pushed through the motor the motor makes one full revolution NOTE The displacements given here are theoretical Actually a piston pump and a piston motor are each about 97 effective when new and wear reduces the efficiency further The motor is mounted on the gearbox 2 For each 111 revolutions of the motor the gearbox makes one revolution Volume Theory of Operation A3 5 E 0 gt a Q 5 o E 2 S a cv uiojs sqng wnig Drum Rotation Circuit S
26. usby warranties become void c o E A o w E o gt o c A o Volume Theory of Operation A1 9 This page intentionally left blank Housby Mixer Definition of Common Components Chapter 2 Common Components DEFINITION OF COMMON COMPONENTS A common component is one that has a general function not specific to any one given subsystem or circuit As an example a circuit breaker that supplies current to several subsystems and or circuits would be considered a common component Also a flow control valve providing flow to enable more than one hydraulic function would be considered a common component ELECTRICAL COMMON COMPONENTS Inputs The key switch supplies 12 volts dc to the electrical common components See diagram on page A2 4 Outputs To Drum Subsystem A 12 volt dc output energizes a relay that switches the polarity of a variable voltage signal to the EDC controlling the hydrostatic pump that rotates the drum reversing the polarity reverse the direction of drum rotation A variable voltage output to the EDC controls the speed of drum rotation 2 c D c o 2 E e O c o E E e O To Bridge Axle The 12 volt dc outputs power solenoids that operate hydraulic directional Subsystem control valves used for raising and lowering the bridge axle To Chute and The 12 volt dc outputs power solenoids that operate hydraulic directional Hopper Circuits control valves used
27. ut from the PPU see above to determine when the motor has completed 111 revolutions one drum revolution The PLC then applies a 12 volt dc signal output Q2 3 to the coil of the drum counter relay When the relay energizes it contacts the two terminals of the drum counter which increments the drum counter LCD readout The drum counter has its own internal battery A button on the drum counter allows the driver to reset it to zero A3 3 cv uiojs sqng wnig Drum Rotation Circuit Housby Mixer Hydrostatic Loop The hydrostatic loop that rotates the gearbox and drum is comprised of a Series 90 Sauer Sundstrand pump and motor The motor includes a hot oil shuttle to drain a small amount of oil from the closed loop and the pump includes a gerotor type charge pump to replenish the loop with cool oil from the tank Suction Filter and The charge pump draws cool oil Vacuum Gauge through the suction filter 1 which filter removes dirt and other particles from the oil A vacuum gauge 2 at the suction filter measures the amount of suction needed to pull oil through the filter Replace the filter see page XX if the gauge indicates more that 5 Hg RF when the oil is warmer than 120 F or more than 10 Hg for oil colder than 120 F Charge Pump and The flow from the charge pump 2 Charge Relief enters low pressure side of the closed loop through one of two check valves The charge pump continuously adds oil to the loop
28. with spray nozzles e Water tank drain valve beneath tank e Water line drain valve 6 e Sight gauge drain valve 7 Volume Theory of Operation Housby Mixer Water Circuit Drum Counter Circuit Drum Counter Relay p Contacts Drum Counter Part of Common Components Hot Oil Indicator Circuit Part of g Common Components o D gt PLC Q2 1 for bulb test E E 3 A a From Key Switch 12v DC 180 Y Hot Hydraulic Temperature Oil Indicator Switch Volume Theory of Operation A3 11 cv waysAsqns winig Water Circuit Oil Cooler Fan Circuit Housby Mixer Part of Common Components 2 0 for bulb test Oil Cooler PLC en gt Fan Indicator Diode Oil Cooler Fan Relay 15 Amp Oil Cooler Circuit Breaker Contacts I Fan 160 Temperature Switch From Key Switch 12v DC l A3 12 Manual Auto Switch Volume Theory of Operation Housby Mixer Water Circuit Water Circuit Upper Spray Compressed Air Nozzle Water Nozzle to Water Manifold Drum Interior Lower Spray Air Pressure Nozzle Gauge Plumbing Drain Valve 80 psi Air Pressure 3 Way Valve Regulator Water Tank Tank Drain Valve Air Reservoir A3 13 Volume Theory of Operation E 2 0 gt D Q 5 o E 2 e a This page intentionally left
29. y and the converter to protect the converter Hydraulic Oil Level Switch and Low Oil Relay The level of the oil in the hydraulic reservoir is monitored by a float switch If the level falls below an acceptable level the contacts of the switch connect and ground the solenoid of the Low Oil relay energizing the relay s coil with 12 volts from the key switch The Low Oil relay when energized closes contacts allowing 24 volts from the converter to reach node I 2 7 of the PLC 24 volt input module The length of time that I 2 7 continues is used to differentiate low oil from sloshing oil If the signal continues for longer than several seconds the PLC sends a 12 volt output through node Q 2 4 which lights the Low Oil indicator on the control console in the cab HYDRAULIC COMPONENT DETAILS Tank c o c o 2 E e O c o E E e O The tank or reservoir 1 stores the oil and allows contaminants to settle out of suspension and entrained air to escape It also helps cool the oil The tank holds 27 gallons Volume Theory of Operation A2 5 A sjueuodujo 5 uouiuio5 Hydraulic Component Details Housby Mixer Return Filter and Filter Pressure Gauge Oil returning to the tank from the cylinders passes through the return filter The filter catches dirt and contaminants that may ingress through the rod seals of the cylinders The filter R is mounted inside the tank attached to eue the top of the tank
Download Pdf Manuals
Related Search