395 Anderson Blvd - Clarksdale, MS 38614 - 1-800-843-5241

Automatic Bridge Controller
Troubleshooting Your Machine

SYMPTOMS
WHAT TO CHECK
HOW TO CORRECT
Tamper stays up, bridge moves normally
  1. Cables: check cable connectors on the back of the box for loose connections.
  2. Tamper sensor: observe the indicator lights on the control panel, the "PRESSURE" and "BOTTOM" lights should both be OFF when the tamper is not at its bottom position
  3. Use your hands to move the sliding rod up and down, it should have springing reactions both ways, and the rod should be normally centered (top end and bottom end are about the same length
  1. Secure all connections
  2. If "PRESSURE" light stays on at a pressure lower than 1800 PSI (see pressure gauge), adjust or replace pressure switch. If "BOTTOM" light stays on, check for physical damage on the sliding bar of tamper sensor.
  3. If sliding rod is bent, straighten it (you have to disassemble the sensor unit in order to do this). If the sensor inside appears to be damaged, replace it with a new one.
    CAUTION: DO NOT UNSCREW THE PRESSURE SWITCH WHILE TRACTOR IS RUNNING
Bridge hits the end of the Builder and does not stop, and does not return
  1. Turn off the controller and manually move the bridge away from the end. Turn off the tractor engine. With the tractor turned off, turn the controller on again and ask someone to swing the pendulum (located at the side of the bridge) to the direction it should go when it hits the end-detector bar. Observe the "BACK" light on the control panel, it should be ON when the sensor senses the pendulum position.
  2. Visual check for broken sensor or sensor cable.
  1. If the indicator does not light when the pendulum is swung to the sensing point, the pendulum might need to be tightened to reduce the clearance between the pendulum magnet and the sensor. Check cable connections to the sensor, make sure it is securely connected to the main cable (the 50-foot cable)
  2. Replace broken/damaged sensor.
Bridge moves five steps in one direction then starts to move in reverse.
  1. Check the tractor speed, it should not be over 1400 RPM. The pendulum can swing wildly when the tractor is running too fast.
  1. Slow down the tractor. If slowing down the tractor does not help, stop the tractor and tighten the pendulum's retaining nut a little so that it swings smooth and less wildly at a tractor speed of 1300 to 1400 RPM.
No Beep, No Light
  1. Check the fuse. The fuse is located on the back panel of controller box.
  2. Check battery cable and connection
  3. Defective Controller Box
  1. Replace burned out fuse with a new 1.5A slow-blow fuse. DO NOT USE FUSE THAT IS LARGER THAN 1.5A
  2. Repair any damaged wore or corroded clip. Make surer the RED clip is connected to the POSITIVE terminal of a 12-volt battery and the BLACK clip is connected to the NEGATIVE terminal of the battery or the chassis of the tractor. Turn the switch to RUN position.
  3. Replace controller box
The system beeps but bridge or tamper is not moving
  1. Hydraulic Fluid: check the level of hydraulic fluid in the tank
  2. Hoses: check for broken or damaged hoses
  3. Connections: check for a loose connection of cables between the hydraulic valves and the controller box. Check for damaged or missing cables.
  4. Hydraulic Valve: turn off the controller and operate the hydraulic valves manually a few times to make sure that the valves are mechanically functional.
  1. Add hydraulic fluid
  2. Replace damaged hoses
  3. Secure all connections. Replace damaged/missing valve cable.
  4. If the valve operates manually but not automatically, replace the valve cable or replace the valve's solenoid. If the valve does not operate manually, replace the entire valve.
Tamper goes down and does not seem to sense the bottom or the pressure
  1. Connections: check for loose connections on the back panel of the controller box.
  2. Tamper Sensor: check for any visual damage on the tamper sensor and the main (50 feet) cables, check for any physical damage on the tamper sensor unit (bent rod, etc.)
  3. With the tractor running, manually move the tamper down and hold it there for a few seconds until the pressure gage reads 1800 PSI or more. The "PRESSURE" light on the controller should light.
  4. Turn off the tractor and mode the tamper down. Ask someone to pull the tamper sensor's rod down while you observe the "BOTTOM" light on the controller box. The light should turn on when the rod reaches the sensing point.
  1. Secure all connections on the controller box and on the bridge by tightening them with your fingers.
  2. Replaced damaged sensors or damaged cables.
  3. If the "PRESSURE" light does not light at 1800 PSI or above, adjust the pressure switch accordingly. Replace malfunction pressure switch.
  4. If the "BOTTOM" light stays on all the time, disconnect the sensor from the bridge and see if the light goes off. If it does replace the sensor. If the "BOTTOM" light never turns on eventhough the rod is at its sensing position, tighten the connectors on the bridge and the connector of the 50-foot cable behind the controller box. If this does not correct the problem, the 50-foot cable may have been damaged or the sensor is damaged. Replace damaged sensor and damaged cable.
Nothing works right, the controller beeps nonstop
  1. TOO HOT or TOO COLD: The controller will not work properly at a temperature above 120 degrees or below 32 degrees Fahrenheit.
  2. Intermittent power connection
  3. Defective controller box
  1. If the temperature is too cold, operate the module builder manually for a while until the hydraulic fluid gets warm enough that the heat generated in the hydraulic lines warms up the controller box. If the temperature (of the hydraulic fluid) is too hot, stop the tractor and wait for it cool down until the temperature is suitable.
  2. Secure power connections to the tractor's power source and secure the power connector behind the controller box.
  3. Replace defective controller box.
Controller power light is on, but no beep and no movement on the tamper or the bridge
  1. Make sure there is a 12-volt going to the controller. Some tractors use two 6-volt batteries instead of one 12-volt battery.
  2. Bad controller
  1. Connect the battery cable to the 12-volt source of the battery. BLACK clip goes to the chassis, RED clip goes to the PLUS terminal of the battery of alternator.
  2. Replace bad controller

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