Page 1 ™ / S ™ IGHT UPER & F ™ EATHERWEIGHT AINTENANCE ANUAL...
Page 3 ™ / S ™ IGHT UPER & F ™ EATHERWEIGHT AINTENANCE MANUAL...
Page 4 Liability Labrie Enviroquip Group assumes no liability for any incidental, consequential, or other liability that might result from the use of the information contained in this document. All risks and damages, incidental or otherwise, arising from the use or misuse of the information contained herein are entirely the responsibility of the user.
Page 7: Table Of Contents
Table of Contents Liability ..................ii Table of Contents ................. v Introduction ................1 About This Manual ................................... 1 Topics not Included in this Manual ............................. 1 About the Illustrations in this Manual ..........................1 Schematics ....................................1 Warranty Registration Form ................................2 Introducing the W ™...
Page 8 vi Table of Contents Grease ......................................31 Hydraulic Oil ..................................... 31 Engine Oil ....................................32 Transmission Oil ..................................32 Centralized Grease Block ................................33 Lubricating Packer Rails ................................35 Preventive Maintenance ............37 Operating and Maintenance Records ............................. 37 ™ Preventive Maintenance Chart ..........................38 ITTKE Electrical System ...............
Page 9 Table of Contents vii Installing a Yoke-Locking Bolt ............................96 Priming a New Pump ................................97 Hydraulic Tank ....................................98 Inspecting the Hydraulic Tank ............................99 Emptying the Hydraulic Tank ............................100 Cleaning the Strainer ................................101 Return Line Filter ..................................102 Return Line Filter Element ..............................
Page 10 viii Table of Contents...
Page 11: Introduction
Introduction About This Manual This manual contains information regarding the correct maintenance of your W ™ garbage truck. ITTKE Maintenance personnel should read and understand this information before doing repairs and maintenance on the vehicle. For information on how to safely and efficiently operate the W ™, please refer to the ITTKE...
Page 12: Warranty Registration Form
2 Introduction For electrical schematics, refer to the schematics provided with your W ™ unit; ITTKE For pneumatic and hydraulic schematics, refer to the schematics provided with your W ™ unit. ITTKE : A number of system schematics are included in this manual. Warranty Registration Form Do not forget to complete the owner registration form and to send it to Labrie Enviroquip Group.
Page 13: Service And Maintenance On The Wittke
Introduction 3 Figure 1-1 Monitor : Maintenance personnel as well as in-the-field technicians who encounter any problems with the multiplexed system should refer to the Multiplex Diagnostic Manual (part# 153144_01) for troubleshooting information and guidelines. Service and Maintenance on the W ™...
Page 14: Wittke ™ Basic Maintenance
4 Introduction Figure 1-2 Lube chart Initial lubrication carried out by Labrie Enviroquip Group is sufficient for production and transport purposes ONLY. With your safety in mind, we would like to remind you that ONLY QUALIFIED PERSONNEL should service the hydraulic, electrical, and pneumatic systems of your W ™...
Page 15 Introduction 5 When greasing it is important to understand that providing the proper amount of grease is a delicate balance between over greasing, which can result in seal damage as well as wasted lubricant. Only pump enough grease until the air purges from the joint. Commonly, a “popping” sound can be heard as the old grease begins to evacuate the seal.
Page 16 6 Introduction 6) Proximity and Limit Switches Proximity and limit switches are used to limit travel of moving parts and/or to ensure conditions are safe for operation. If these switches are not adjusted properly, damage to the equipment may occur as well as poor or dangerous functionality.
Page 17: Our Office Addresses And Phone Numbers
Introduction 7 Our Office Addresses and Phone Numbers In the U.S. Address: 1198 Shattuck Industrial Blvd. LaFayette, GA 30728 Toll Free: 1-800-231-2771 Telephone: 1-706-591-8764 General Fax: 1-706-639-9275 Oshkosh General Fax: 1-706-591-8766 Parts and warranty: During business hours, 8:00 AM to 6:00 PM Eastern Standard Time Technical Support Service: Available 24 hours In Canada Address:...
Page 18 8 Introduction...
Page 19: Safety
Safety Safety is always of prime importance when servicing any type of equipment. All maintenance personnel working on the W ™ front-loader garbage truck ITTKE must be aware of the safety practices and features detailed in this chapter. Conventions Danger! Indicates a hazardous situation which, if not avoided, will result in serious injury or death.
Page 20: Responsibilities
10 Safety Danger! Never get in the hopper area when the engine is running. Only authorized personnel may do so following a lockout/tagout procedure (see Locking Out and Tagging Out the Vehicle on page 21). Responsibilities Safety is everybody’s responsibility. Both the employer and the employees must play their part to ensure their work environment is safe for everyone.
Page 21: Things To Do
Safety 11  To immediately report any damage or malfunction of the vehicle to the employer or supervisor. Damaged vehicle or equipment should be repaired before putting it back into operation. MPORTANT Things to Do  Make sure that the working area is clear of any people or possible obstructions. Be extremely cautious in areas where small children may be present.
Page 22: General Precautions
12 Safety General Precautions Danger! Operators/maintenance personnel must adhere to the following precautions at all times. Failure to do so may result in vehicle and/or property damage, personal injury, or even death.  Only qualified employees should be assigned to operate and service this vehicle. ...
Page 23: Fire
Safety 13  Never, under any circumstances (maintenance or otherwise), stand underneath a loaded body. Warning! Do not operate the lifting arms until you have been fully trained, and have read and understood both the Operator’s Manual and the Maintenance Manual supplied with this unit.
Page 24: Safety Kits
14 Safety ™ vehicles are equipped with a 5-lb fire extinguisher, which is located inside the cab. A 20-lb ITTKE fire extinguisher may also be installed as an option. Each fire extinguisher must be checked regularly by qualified personnel. Figure 2-1 5-lb fire extinguisher (left) and 20-lb fire extinguisher (right) Safety Kits A first aid kit and a flare kit are provided with the truck.
Page 25: Service Hoist Safety Props (Optional)
Safety 15 Service Hoist Safety Props (optional) The service hoist safety props must be set when any work is performed under a lifted body. This feature comes with the service hoist option. Safety props ensure that heavy body parts will not move inadvertently. Warning! Always unload the body before setting the hoist safety props.
Page 26 16 Safety Figure 2-3 Body latch assembly Bolt Spring Locknut Frame rail Raise the body until both safety props can be moved into position. The body can be raised by pushing the hoist joystick forward (see Figure 2-4) and holding it until the body reaches the desired height.
Page 27 Safety 17 Figure 2-5 Prop latch Release the other safety prop by pulling its latch towards you (see Figure 2-5), and position it adequately (see Figure 2-2). The safety prop must take place around the cylinder rod. Lower the body until both safety props rest on the cylinder casings. The body can be lowered by pulling back the hoist joystick (see Figure 2-4) and holding it until the props come into position on the cylinder casings.
Page 28: Tailgate Safety Prop
18 Safety Tailgate Safety Prop The tailgate safety prop is used to support and keep the tailgate open during inspection or maintenance procedures. It is mandatory to set the safety prop every time the tailgate is open for such purposes. Make sure that the body is empty before installing the safety props.
Page 29 Safety 19 Pull the safety prop upward and set it down (see Figure 2-7). Danger! Stand clear of the tailgate path while setting the safety prop. Figure 2-7 Pulling safety prop upward (left) and setting it down (right) Lower the tailgate onto the safety prop using the T Switch on the in-cab control AILGATE panel.
Page 30: Securing Tailgate Safety Pins
20 Safety Figure 2-8 Raising tailgate safety prop Release your grip on the safety prop to set it in its home position. Figure 2-9 Setting safety prop in its home position With the T Switch on the in-cab control panel, close the tailgate completely. AILGATE light indicator should turn off.
Page 31: Locking Out And Tagging Out The Vehicle
Safety 21  Before opening the tailgate remove both safety pins (see Figure 2-11). Warning! Any vehicle with a tailgate not properly secured by a manual locking device (e.g. tailgate safety pins) is considered unsafe and should not be operated on the highway. Figure 2-10 Tailgate safety pin in locking position Figure 2-11...
Page 32 22 Safety Figure 2-12 Parking brake knob Make sure that the body is completely empty. Switch OFF the hydraulic pump. Turn OFF the engine, remove the key from the ignition, store it in a safe and controlled area (preferably on yourself), and tape over the ignition switch. Turn OFF and lock the master switch.
Page 33: Shutting Down The Vehicle
Safety 23 Shutting Down the Vehicle If the vehicle has to be stored for an extended period of time, follow the chassis manufacturer’s shutdown and maintenance requirements. Also: Park the vehicle on a hard level surface and apply the parking brake (see Figure 2-12). Make sure that all moving parts are in their home position (tailgate, arms, forks, packer, etc.).
Page 34 24 Safety : The hydraulic tank model may vary according to the options installed on the vehicle. Warning! Failure to fully open the shut-off valve before starting the truck will cause immediate damage to the pump, even if the pump is not activated. Start the truck.
Page 35: Lifting Components For Service
Safety 25 Lifting Components for Service Lifting components of the W ™ requires special attention to safety. ITTKE Before performing any lifting operation, be sure to do the following:  Empty the body.  Chock both the front and rear wheels. ...
Page 36 26 Safety Figure 2-18 Outer grease fitting Figure 2-19 Lift sling around arm tube Unlatch the body latches (one on each side) [see Figure 2-3]. : Make sure there is enough clearance before lifting the body. Raise the body front section. Do not raise this section more than 28 inches high.
Page 37: Lifting The Entire Body
Safety 27 Lifting the Entire Body Lifting the body requires securing both ends, at front and rear, to two lift beams. To do so, you will need appropriate lifting devices for the rear section of the body (slings, shackles, lift beam and overhead crane) and also for the front section (slings, lift beam and overhead crane).
Page 38: Safety Precautions To Be Taken When Working With Hydraulic Systems
28 Safety Figure 2-22 Anchor points to which shackles are to be attached Fasten shackles securely on each appropriately rated lift sling. Securely attach the slings to the appropriately rated lift beam, which was previously installed on the overhead crane. Proceed with the lifting of the body.
Page 39: Welding Information
Safety 29 Welding Information Warning! Disconnect all batteries and electronic modules prior to welding on packer assembly. Warning! Remove paint before welding or heating. Do not weld near lines that are pressurized or contain flammable fluid.
Page 40 30 Safety...
Page 41: Lubrication
Lubrication To help the various systems of your truck run smoothly and extend the life time of the many critical parts that affect performance, there is one thing that you must do and that is: LUBRICATE, LUBRICATE AND LUBRICATE! Insufficient lubrication is a major cause of component failure.
Page 42: Engine Oil
32 Lubrication Following stringent maintenance schedules and performing routine oil analysis are effective methods of obtaining information to determine the cleanliness of the hydraulic oil. Labrie Enviroquip Group recommends that the hydraulic oil be replaced at least once a year or when contaminated. Failure to maintain hydraulic cleanliness to recommended guidelines may result in failure of hydraulic components and void your warranty.
Page 43: Centralized Grease Block
Lubrication 33 Figure 3-1 Lube chart Centralized Grease Block Pins at the packer blade end of the cylinders are remotely greased via two grease fittings on the curb side back of the packer blade (see Figure 3-2). Pins at the front header end of the cylinders should be greased manually (standard) [see Figure 3-3] or via a remote greasing system located on the hopper access door (optional) [see Figure 3-4].
Page 44 34 Lubrication Figure 3-3 Standard manual grease fittings (front-end cylinder pins) Figure 3-4 Optional remote grease fittings (front-end cylinder pins) Optional grease fittings for front header end of packer cylinders (on hopper access door)
Page 45: Lubricating Packer Rails
Lubrication 35 Lubricating Packer Rails It is very important to lubricate packer rails, mainly on the packing stroke area, in order to ensure their good condition. A lubricant spray is provided with the truck for that purpose, which is found behind the packer.
Page 46 36 Lubrication...
Page 47: Preventive Maintenance
Preventive Maintenance The W ™ has been designed for long periods of ITTKE efficient uninterrupted operation. Careful attention to proper preventive maintenance, as described in this chapter, will ensure and extend trouble-free operation of the unit. Particular attention to correct lubrication of the unit and maintenance of the return filter, are probably the two most vital areas of preventive maintenance required.
Page 48: Wittke ™ Preventive Maintenance Chart
38 Preventive Maintenance ™ Preventive Maintenance Chart ITTKE Component/System Task Daily Weekly Monthly Yearly Air system Check for leaks Air tanks Drain air tanks Arm assemblies and Do a visual inspection of these hardware components Arm cylinders and Do a visual inspection of these fittings components Arm pivot tube and...
Page 49 Preventive Maintenance 39 Component/System Task Daily Weekly Monthly Yearly Hydraulic system Check cylinders, pump, control valve and system for leaks. Repair or replace if required Replace return line filter Twice a element year Clean strainer and refill Check pressure Change oil Replace hoses Every 5 years...
Page 50 40 Preventive Maintenance Component/System Task Daily Weekly Monthly Yearly Rollers, hydraulic Do a visual inspection of these cylinders and cylinder components pins, hoses, pipes and connections, wear of floor Safety decals Keep them clean Safety systems Check for proper operation (tailgate alarm and special devices) Check proper operation of the...
Page 51: Electrical System
Electrical System This chapter is divided into two sections. The first section describes how the electrical components work and the second section describes how to adjust and repair some electrical components. Electrical Schematics Electrical schematics are provided as part of the ™...
Page 52 42 Electrical System The control panel is centrally mounted in the cab. It includes push- buttons, toggle switches, and warning lamps. The multiplexed monitor may be placed directly on the panel (as illustrated) or fixed next to it. Some units also have auxiliary controls located on the curbside or streetside of the truck.
Page 53: Adjusting And Repairing Electrical Components
Electrical System 43 Adjusting and Repairing Electrical Components The required electrical system adjustments include:  Fuses and circuit breakers  Limit and proximity switches Fuses and Circuit Breakers Power for the electrical system on board the W ™ is protected by a set of fuses and circuit ITTKE breakers.
Page 54 44 Electrical System Figure 5-3 Fuses inside relay box Plastic cover Fuses Figure 5-4 Fuses outside relay box Circuit breakers The W ™ may have up to 6 manual reset circuit breakers, depending on the options installed. ITTKE These breakers are located within the in-cab control box. Mounted on each circuit breaker is a button which, once pushed, resets the breaker (see Figure 5-5).
Page 55: Limit And Proximity Switches
Electrical System 45 : Consult the OEM manual for information on equipment not manufactured by Labrie Enviroquip Group. The following table provides a description of the circuit breakers located in the control box inside the truck cab. Function Ampere Circuit Number Monitor (W2) Cab fan (W3) Scale Air-Weigh System power &...
Page 56 46 Electrical System Figure 5-6 Limit/proximity switches - streetside view Figure 5-7 Limit/proximity switches - curbside view...
Page 57: Limit Switch Adjustment
Electrical System 47 Limit Switch Adjustment To adjust the limit switch: Loosen the limit switch nut. Move the lever arm to the approximate position where the switch is to be triggered. Tighten up the nut. To fine tune the adjustment, loosen the nut slightly. With a flathead screwdriver, turn the adjusting screw located at the center of the nut until a click is heard.
Page 58: Packer Fully Retracted Proximity Switch
48 Electrical System Test the operation. The proximity switch light should turn on when the target is detected; if not, repeat the adjustment procedure. Packer Fully Retracted Proximity Switch This proximity switch (see Figure 5-8) locks out the Arms up function and activates a warning lamps when the packer is not in the “home”...
Page 59: Packer Fully Extended Proximity Switch
Electrical System 49 Packer Fully Extended Proximity Switch This proximity switch stops the packer when it reaches its fully extended position (pack cycle). Figure 5-9 Packer Fully Extended proximity switch Location The Packer Fully Extended proximity switch is mounted on the front wall of the body, on the street side.
Page 60: Side Access Door Proximity Switch
50 Electrical System Adjust the proximity switch so that it is active (the amber light on the proximity switch should be ON) when the packer reaches this position. Ideally, there should be a gap of 3/16 inch (4.8 mm) between the proximity switch and its target. Test the packer for a full cycle.
Page 61: Top Door Fully Open Proximity Switch
Electrical System 51 Figure 5-11 Target Top Door Fully Open Proximity Switch The Top Door Fully Open proximity switch controls the cutout of the Arms Up function if the top door is not fully open. When the top door is fully open, it triggers the proximity switch which sends a signal to the in-cab control panel to turn the Roof Open switch’s light green.
Page 62: Tailgate Unlocked Proximity Switch
52 Electrical System Climb on the roof. Adjust the proximity switch so that it can detect the target when the top door is fully open. Start the engine and turn ON the hydraulic pump. Close the top door about an inch. The proximity switch should not detect the target and the Roof Open switch on the control panel will turn blue.
Page 63: Tailgate Fully Open Proximity Switch
Electrical System 53 The proximity switch should detect the cylinder when the tailgate is locked and should not detect it when the tailgate is unlocked. Tailgate Fully Open Proximity Switch The Tailgate Fully Open proximity switch allows you to enable the ejection cycle when the tailgate is fully open.
Page 64 54 Electrical System Location The Arms Partially Raised proximity switch is located on the arm pivot tube (between cab and body), on the curb side. Figure 5-15 Arms Partially Raised proximity switch Target Adjustment procedure: Raise the arms until the center of the fork pivot is at the same height as the center of the canopy hinge.
Page 65: Arms And Forks Fully Retracted Proximity Switch
Electrical System 55 Make sure that the proximity switch detects the target on all the detection zone shown below. Once the proximity switch and the target are adjusted, lower the arms. Press the green push-button on the control panel to start the packer. While the packer is in motion, raise the arms.
Page 66 56 Electrical System Location The Arms Fully Retracted proximity switch is located on the arm pivot tube (between cab and body), on the street side. Figure 5-16 Arms Fully Retracted proximity switch Target The Forks Fully Retracted proximity switch ensures that the Arms Not Stowed switch on the control panel is red-lighted if the forks are not completely retracted.
Page 67 Electrical System 57 Adjust the target so that it triggers the proximity switch (amber light on switch should be on). Lower the arms. Retract the forks until there is a distance of 31 inches between both fork cylinder attachments (center to center).
Page 68: Body Raised Limit Switch (Optional)
58 Electrical System Adjust the target so that it triggers the proximity switch (amber light on proximity switch should be on). Carry out tests to see if the Arm Not Stowed switch on the control panel “reacts” properly when the forks or the arms are not fully retracted. This switch should be red-lighted if the forks or the arms are not fully retracted.
Page 69: Multiplex System-Related Interventions
Electrical System 59 Figure 5-18 Body Raised limit switch : The location on the truck of the Body Raised limit switch may vary according to the chassis type or model. Multiplex System-Related Interventions The following interventions will enhance the effectiveness and efficiency of the Multiplex control system.
Page 70 60 Electrical System • In the “MAIN MENU” screen, using the up/down arrow button on the IFM display module, highlight “Settings”, and press the button below “OK”. The “Settings” screen will appear. • Using the up/down button, highlight “J1939 Baud rate”, and press the button below “OK”. The “J1939 Baud rate”...
Page 71: J1939 Baud Rate
Electrical System 61 Figure 5-20 Download program Once the updated program is loaded and verified to be working correctly the original uploaded file should be deleted from the PC to avoid future confusion. J1939 Baud Rate Starting in 2016, chassis manufacturers increased the J1939 communication data bus baud rate from 250 Kbps to 500 Kbps.
Page 72 62 Electrical System The J1939 screen shows the values that Labrie’s multiplex system is sampling from the chassis multiplex system. Verify that these systems are correctly communicating by accelerating the engine; the Engine RPM value on the Labrie J1939 screen should match the chassis dash tachometer. If the engine RPM value on the Labrie system is not changing and synchronized with the chassis tachometer, the baud rate most likely needs to be reset to 500 Kbps.
Page 73: Checking Control Module (Node) Supply Voltage
Electrical System 63 Ensure that the Labrie system and the chassis system are communicating correctly by checking the engine RPM as explained earlier. Checking Control Module (Node) Supply Voltage A benefit to the IFM multiplex control systems used on W ™...
Page 74 64 Electrical System...
Page 75: Pneumatic System
Pneumatic System How the pneumatic system works The pneumatic system comprises the following:  Air supply  Filtering system  Controls  Pneumatic valve box and air valves  Air Actuators Air Supply Air is drawn from the chassis air tanks, passes through an air and mist filter system (or air filter assembly) and into the pneumatic valve box.
Page 76 66 Pneumatic System To avoid affecting control of the packer or other air systems on the vehicle (especially under cold weather conditions), you must maintain the air system regularly: drain the air tanks (see Figure 6-1) and the air filter assembly (see Figure 6-2) at the end of every workday and prior to any maintenance. Both filters of the air filter assembly must be changed twice a year.
Page 77: Air Dryer
Pneumatic System 67 To drain the air tanks, apply the following procedure: Locate the drain valves on air tanks (see Figure 6-3). : Some trucks are equipped with more than one drain valve. Open the valves by turning them one-quarter turn clockwise. Before opening the valves, be sure to stay away from the stream.
Page 78: Controls
68 Pneumatic System Figure 6-4 Air dryer : Poorly maintained pneumatic control systems are a major cause of packer control failure. Controls Standard arms/forks control is by means of a pneumatic joystick (see Figure 6-5) mounted next to the driver. The joystick operates at 90°...
Page 79: Auxiliary Controls (Optional)
Pneumatic System 69 Auxiliary Controls (optional) Auxiliary controls, if installed on your unit, are located outside, directly behind the cab on the street side (see Figure 6-6). For these controls to be enabled, the operator must press the Auxiliary Controls switch on the control panel (see Figure 6-7).
Page 80: Pneumatic Valve Box And Air Valves
70 Pneumatic System Figure 6-8 Speed-Up switch : The unit transmission must be in neutral before this Speed-Up switch can be turned on in ON or AUTO mode. Pneumatic Valve Box and Air Valves Mounted on the exterior front body wall, on the streetside, the pneumatic valve box houses the solenoid-operated air valves that direct air to the air actuators on the hydraulic valve bank.
Page 81: Air Actuators
Pneumatic System 71 with manifold ends with ports for supply and exhaust air to be routed. When an air valve opens, air passes through a single air line from the air valve and leads to one of two ports on an air actuator on the hydraulic valve bank or to the joystick (cutout).
Page 82: Central Air Drain Cocks (Optional)
72 Pneumatic System Air Actuator Maintenance and Replacement The air actuators on the main body valve shift the spools of the valve to operate the various functions of the valve. The air actuators have two ports in a cylinder case located on either side of a piston, which is attached to the valve spool.
Page 83: Control System Pneumatic Pressure Switch
Pneumatic System 73 Take note of the following:  All air tanks should be drained daily.  Be sure to drain the wet tank first.  Poorly maintained pneumatic control systems are a major cause of packer control failure.  Your air drain cocks may differ slightly from those illustrated above. Control System Pneumatic Pressure Switch All W ™...
Page 84 74 Pneumatic System Prior to chassis air pressure building to at least 90 PSI, the pump will not be allowed to engage. On multiplex units, a yellow banner on the Labrie IFM display screen showing “Pump: main air pressure” and an audible beep will occur if an attempt is made to engage the pump without sufficient air pressure;...
Page 85: Auto-Dump System (Optional)
Pneumatic System 75 Once the air pressure switch is cleaned and re-assembled, the pressure switch must be adjusted. Install the switch into the MAC valve manifold, leaving the red and black wires loose. Using a Tee, install an air pressure regulator with gauge into the air supply line to the pneumatic valve box and adjust it to 90 PSI.
Page 86: Pneumatic System Schematics
76 Pneumatic System Pneumatic System Schematics The following schematics are for illustrative purposes only and may differ from the actual schematics provided with your truck.
Page 87 Pneumatic System 77...
Page 88 78 Pneumatic System...
Page 89 Pneumatic System 79...
Page 90 80 Pneumatic System...
Page 91: Hydraulic System
Hydraulic System As with all hydraulic systems, it may be necessary to periodically check and adjust the pressure relief settings. It may be that a major hydraulic component has been changed, that the vehicle is not performing in terms of payload, or that the vehicle has recently been put into service and the system requires adjustment following a run-in period.
Page 92: Hydraulic Pump
82 Hydraulic System  Clean the strainer inside the hydraulic tank after the first 50 hours of use, and once a year afterwards (see Cleaning the Strainer on page 101).  Hydraulic oil must be replaced at least once a year, or when contaminated (see Changing Hydraulic Oil on page 106).
Page 93: Inspecting The Pump
Hydraulic System 83 Figure 7-2 Electric solenoid on pump When the pump is turned on, the transmission electronic control unit ( ) starts monitoring the vehicle speed and the engine RPM, and allows the pump to engage (or not). If the vehicle is going faster than 15 mph (25 km/h) or if the engine speed exceeds 900 RPM, the pump will not engage.
Page 94: Replacing The Hydraulic Pump
84 Hydraulic System Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 21). Caution! If the unit has to be driven away for repairs on the hydraulic system, remove the drive shaft between the engine and the pump before restarting the engine.
Page 95 Hydraulic System 85 Place a pan under the pump to catch dripping oil and unscrew all hydraulic hoses (4) that are attached to the pump. Caution! Before disconnecting the hydraulic hoses from the pump, place a pan under the pump to catch oil that may drip down from the disconnected lines.
Page 96 86 Hydraulic System Before attempting to install the new pump, it is very important to check the port configuration on that pump; the ports on the replacement pump must be positioned the same way as on the old pump. If they are not, proceed with the indexing of the new pump. The replacement pump must be oriented in such a way to facilitate reconnection to the hydraulic system and attachment to the chassis frame.
Page 97 Hydraulic System 87 Rotate the mounting cap accordingly. 12 c. Rotation can be done by turning the mounting cap clockwise or counter-clockwise with your hands or by using a metallic bar as illustrated in the above picture. : Make sure pump sections do not separate. : The cartridge will rotate with the housing.
Page 98 88 Hydraulic System Put all 4 bolts back in place. 12 d. Check if the shaft rotates freely. 12 e. Tighten up all bolts to the torque of 138-140 ft-lb. 12 f. When tightening bolts, be sure to respect the following number sequence to avoid damaging the seals: ARM SECTION Remove all 7 retaining bolts that hold the front cap in place.
Page 99 Hydraulic System 89 Be sure not to pull on the front cap as inside components may shift and cause damage to the pump. MPORTANT : The cartridge will rotate with the housing. Put all 7 bolts back in place. 12 i. Check if the shaft rotates freely.
Page 100 90 Hydraulic System Use the yoke as a jig to determine where exactly the hole must be drilled then remove it. : The yoke must be fully engaged on the shaft before determining the exact location where the hole must be drilled. Drill a hole with a 5/16”...
Page 101 Hydraulic System 91 B. To replace a PTO-driven hydraulic pump, perform the following procedure: Disengage the pump and turn OFF the engine. Make sure the parking brake is applied and the vehicle is tagged out for maintenance purposes (refer to “Locking Out and Tagging Out the Vehicle” on page 21). Close the shut-off valve (see Figure 7-14).
Page 102 92 Hydraulic System Attach the pump to a lifting device and remove both 5/8” bolts that hold the pump to the pump support. Remove the pump. If need be, disconnect the drive shaft from the pump and save it for the replacement pump. Install the new pump.
Page 103 Hydraulic System 93 Go through Steps 8 to 5 inclusively to reinstall the various components of the pump assembly. Prime the new pump (see Priming a New Pump on page 97). Caution! Check the level of hydraulic oil in the tank. Add oil if needed. : Labrie Enviroquip Group strongly recommends you change the filter element and the hydraulic oil as well as clean the hydraulic tank after the installation of a new pump (see Element Replacement Procedure on page 104 and Changing Hydraulic Oil on page 106).
Page 104 94 Hydraulic System Figure 7-9 Suction block Attach the pump to a suitable lifting device and remove all 5/8” bolts that hold the pump to the PTO extension shaft. Remove the pump. Install the new pump using a suitable lifting device. Before attempting to install the new pump, it is very important to check the port configuration on that pump;...
Page 105 Hydraulic System 95 Connect the pump to the PTO extension shaft. Align the splines on the PTO to those on the pump for ease of connection. Figure 7-10 Splines on pump Put all 5/8” bolts back in to secure the pump to the shaft. Go through Steps 8 to 5 inclusively to reinstall the various components of the pump assembly.
Page 106: Installing A Yoke-Locking Bolt
96 Hydraulic System Installing a Yoke-Locking Bolt : It is important to perform this procedure after a pump replacement or a pump drive shaft replacement. To install a yoke locking-bolt, do the following: Locate the hole on the yoke and the hole on the drive shaft (see illustration below). Hole on shaft Hole on yoke Bolt...
Page 107: Priming A New Pump
Hydraulic System 97 Figure 7-11 Steel wire on yoke Drive shaft Yoke Bolt Steel wire : Use the following parts: QUB00700 (bolt) and 154503 (steel wire). Priming a New Pump To prevent cavitation or air in the hydraulic system after installing a new pump or even when flushing the hydraulic system, make sure to prime the pump before starting the engine.
Page 108: Hydraulic Tank
98 Hydraulic System Start the engine. You can slowly raise the engine RPM only after 5 minutes. When you raise the RPM, always make sure that the pump does not make excessive noise. Before putting the vehicle back in service, recalibrate the system pressures. Hydraulic Tank The hydraulic tank is a 60 US gallon capacity reservoir mounted to the chassis frame.
Page 109: Inspecting The Hydraulic Tank
Hydraulic System 99 Figure 7-13 Breather filter Figure 7-14 Ball valve (or shut-off valve) Inspecting the Hydraulic Tank Verify that the oil in the tank is clean (not colored) and always at the appropriate level. Caution! Maximum temperature for hydraulic oil is 77 °C (180 °F). To inspect the hydraulic tank: Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 21).
Page 110: Emptying The Hydraulic Tank
100 Hydraulic System Figure 7-15 Filter housing element For more information on maintenance schedule, see W ™ P ITTKE REVENTIVE AINTENANCE on page 38. HART Make sure that the filler cap (see Figure 7-16) is not obstructed and works properly. Make sure that the hydraulic oil is clean (not colored) and at least ¾...
Page 111: Cleaning The Strainer
Hydraulic System 101 Retract all cylinders (packer, forks, arms, tailgate, etc.). 1 d. Disengage the hydraulic pump. 1 e. Stop the engine. 1 f. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 21). Clean around the filler cap (see Figure 7-16) and remove it.
Page 112: Return Line Filter
102 Hydraulic System Figure 7-18 Strainer Return Line Filter To protect new components of the hydraulic system, the return line filter element must be changed MPORTANT after the first 50 hours of operation of the vehicle. Change the element twice a year afterwards (see ™...
Page 113: Return Line Filter Element
Hydraulic System 103 Return Line Filter Element Oil returning from the valve bank passes through a 7 micron filter mounted in the tank. While every effort is made at the Labrie Enviroquip Group factory to ensure clean hydraulic systems, it should be noted that most hydraulic system manufacturers recommend the filter be replaced after a break-in period.
Page 114: Element Replacement Procedure
104 Hydraulic System Element Replacement Procedure Element replacement will ensure that contaminants trapped due to ingestion and component wear are removed from the system. To replace the return line filter element, proceed this way: Complete the lockout/tagout procedure (refer to “Locking Out and Tagging Out the Vehicle” on page 21).
Page 115: Hydraulic Oil
Hydraulic System 105 Figure 7-24 Removing filter element Inspect the O-rings (on filter and on cover plate) and the housing for damage. Replace as necessary. Figure 7-25 Seal on cover plate Moisten sealing surfaces (with oil) on the filter housing and cover plate. Install the element into the housing, carefully locating the element onto the spigot.
Page 116: Changing Hydraulic Oil
106 Hydraulic System The changing interval of hydraulic oil may be determined by operational duty cycle, operating conditions and local maintenance schedule. It is recommended to change the hydraulic oil at least once a year or when contaminated. MPORTANT For proper oil properties and requirements as well as some words of caution, see Hydraulic Oil on page 31.
Page 117: Hydraulic Cylinders
Hydraulic System 107 Prime the pump (see Priming a New Pump on page 97). Start the engine. Hydraulic Cylinders Inspecting Hydraulic Cylinders Danger! Always lock out and tag out the vehicle when inspecting or performing maintenance on it (see Locking Out and Tagging Out the Vehicle on page 21). You must inspect all hydraulic cylinders at least once a month.
Page 118 108 Hydraulic System Disconnect the packer fully extended proximity switch (see Figure 5-9). This prevents the packer from returning to its initial position. Disconnect and plug hose “A”. Engage the hydraulic pump. Push the green button and see if oil is leaking from port “A”, then push the emergency S button.
Page 119: Main Valve
Hydraulic System 109 Main Valve Pressurized oil is directed from the hydraulic pump to a bank of stack-type directional control valves mounted either on the front header of the W ™ body (see Figure 7-27) or on the left-hand side, ITTKE mid-section body wall (see Figure 7-28).
Page 120 110 Hydraulic System Figure 7-29 Quick coupler (on lateral valve, left; front valve, right)  Work sections: Hopper top door, tailgate, arms, forks and pack circuits are controlled by a work section dedicated to each function. Air actuators attached to each of the work sections shift the spool in the desired direction to allow pressurized oil to operate the hydraulic cylinders.
Page 121: Pressure Relief Valve
Hydraulic System 111 Figure 7-31 Work sections of the main valve (left-side mounted) Top door Tailgate Arms Forks Packer Pressure Relief Valve The pressure relief valve is fitted in the inlet section of the valve bank and protects the hydraulic components from damage caused by loads in excess of 2500 psi (S ™...
Page 122: Arms Up Deceleration Valve
112 Hydraulic System Arms Up Deceleration Valve The Arms Up deceleration valve automatically decelerate the arms as they are raised to the dump position. A cam bolted to the arm pivot tube rotates as the arms are raised and gradually depresses the valve spool, reducing the flow of oil exiting the tube end of the arm cylinders.
Page 123: Arms Down Deceleration Valve (Optional)
Hydraulic System 113 Lower and raise the arms while running the engine at idle speed and again while running the engine at 1500 RPM. : The arms should slow down when they are at approximately 18 inches (45.72 cm) away from the arm stops and then gently come to rest against them.
Page 124: Pack Circuit Dump Valve
114 Hydraulic System Raise and lower the arms while running the engine at idle speed and again while running the engine at 1500 RPM. : The arms should slow down when they are approximately 18 inches (45.72 cm) away from being lowered and gently come to rest at the bottom of their travel.
Page 125: Tailgate Holding Valve
Hydraulic System 115 Location On a unit equipped with a front-mounted main valve, the pack circuit dump valve is fitted next to the main valve (see Figure 7-35). On a unit equipped with a side-mounted main valve, the pack circuit dump valve is installed on the lower section of the front inside wall (see Figure 7-36).
Page 126 116 Hydraulic System Figure 7-37 Holding valve The velocity fuse (see Figure 7-38), located on the valve, will make sure to drain any slow moving oil coming from the piston side of the tailgate cylinders. Since the rod side is being pressurized with the “Power bleed”...
Page 127: Service Hoist (Optional)
Hydraulic System 117 Service Hoist (optional) The service hoist circuit is independent of the main work circuits and is operated by an electric hydraulic pump with adjoining oil tank. Two small bore cylinders allow the body to be raised for maintenance purposes.
Page 128: Arms Down Work Section
118 Hydraulic System By using the pump lever, raise the body until the cylinders reach the end of their stroke. Check pressure while the body is held fully raised. The pressure reading shall be at 2000 psi. Adjust the relief if necessary. Turn the adjustment screw clockwise to increase the pressure and counterclockwise to decrease Arms Down Work Section Designed to protect the arm hydraulic circuits, the Arms Down Work Section is equipped with a...
Page 129 Hydraulic System 119 Figure 7-41 Pneumatically-operated main valve Quick coupler Main relief With the engine running and the pump switch ON, increase the engine RPM to 1500 and activate the Tailgate Closed function. Have a helper note the reading on the gauge. If an adjustment is required (system pressure is higher or lower than 2500/2750 psi, depending on the truck model), locate the pressure relief valve screwed into the inlet section of the main valve bank (see Figure 7-41).
Page 130 120 Hydraulic System B) Electrically-Operated Valve This valve (see Figure 7-42) is fully electric and has one more section than the pneumatically- operated valve. This added section is used to generate a pilot pressure and is subject to various pressure adjustments which must be made carefully to ensure optimal system operation. This is the key to a successful and satisfactory adjustment of the system.
Page 131: Hydraulic Hose
Hydraulic System 121 Hydraulic Hose Labrie Enviroquip Group uses premium quality hydraulic hose designed specifically for use in our hydraulic systems. All pressure hoses have a maximum working pressure of at least 3000 psi, with a x4 burst pressure rating. The hydraulic hose type is identified on the hose covers, in the “lay line”. When replacing any hydraulic hose, it is extremely important that the replacement hose carries the same SAE rating as the original hose.
Page 132 122 Hydraulic System Engine Cycle Time Cycle Time Function Pressure Setting (PSI) (min.) (max.) Top door close 700 ± 150 (non- adjustable) Top door complete cycle 13,0 17,0 Arms up System pressure 12,0 14,0 Arms down 1000 ± 150 (non- 10,0 12,0 adjustable)
Page 133: Hydraulic System Schematics
Hydraulic System 123 Hydraulic System Schematics The following schematics are for reference purposes only. For the specific hydraulic schematic related to your W ™ unit, look for the plastic pouch located inside the cab. All schematics ITTKE pertaining to your truck are found in this pouch.
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Page 139: Packer Maintenance
Packer Maintenance The W ™ packing system has a heavy duty ITTKE guiding system using special hardened steel wear plates. Because of the frequent use of the packer, Labrie Enviroquip Group recommends the operator to perform daily inspections and the maintenance personnel to perform weekly inspections.
Page 140: Replacing Body Guide Wear Plates
130 Packer Maintenance Verify corresponding wear plates under guiding tracks. Install new wear plates on the packer. Reinstall the packer inside the body. Figure 8-1 Packer wear plates Wear Plates Welds to be removed Replacing Body Guide Wear Plates Danger! Always lock out and tag out the vehicle when inspecting or performing maintenance on it (see Locking Out and Tagging Out the Vehicle on page 21).
Page 141: Packer Removal
Packer Maintenance 131 Clean surfaces and install new plates by tacking them in place. Once well positioned, stitch weld the plates in place. Reinstall the packer. Figure 8-2 Body guide wear plate Packer Removal To remove the packer: Start the engine and engage the hydraulic system. Bring the packer to the rear end of the body (full eject) to easily access the pins.
Page 142 132 Packer Maintenance Figure 8-3 Grease fitting hoses Warning! Cylinders must be properly secured before removing their retaining pins. Failure to do so may result in damage, severe injury or even death. Remove the packer end cylinder pin bolts (4 on each pin). Figure 8-4 Pin bolts Exit the hopper and close the side access door.
Page 143: Replacing Packer Cylinders
Packer Maintenance 133 Be extra careful when conducting this step. You may use straps to secure the packer. Warning! Make sure that the packer is properly secured before pulling it out of the body and always use an appropriate lifting device. Failure to do so may result in damage, severe injury or even death.
Page 144 134 Packer Maintenance Enter the hopper and remove the grease fitting hoses (on each cylinder) [see Figure 8-3]. Warning! Cylinders must be properly secured before removing their retaining pins. Failure to do so may result in damage, severe injury or even death. Remove the packer end cylinder pins.
Page 145: Multiplexing
Multiplexing As Labrie Enviroquip Group vehicles become more and more efficient, they require more automation features and thus some programming. Currently, ™ vehicles require programming of Labrie’s ITTKE CAN bus-based multiplexed system. The following pages provide the necessary information for this task. Labrie’s Multiplex System Labrie has equipped your W ™...
Page 146: Main Page
136 Multiplexing Each time the operator turns the ignition key on, a complete bit test of the multiplex system is conducted. This test takes about 5 seconds to complete. : A flashing green light on the monitor indicates that the power is on. This light should be blinking steadily at 2 Hz during normal operation.
Page 147 Multiplexing 137 Figure 9-3 Main page Press the far right button to reset the counter display to zero. Time and Date Indicator (optional) A time and date indicator may be found on the upper left-hand side corner of the screen. The availability of this indicator is based on the chassis on which the body is mounted.
Page 148 138 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solutions ArmRaise:AirWeigh Signal Unload Body ArmRaise:Packer Not Retract Packer Retracted ArmRaise:Roof Not Opened Open Roof (Top Door) Auto-Dump: Wrong Driver Change Driver Position Switch Position to Correct Position Auto-Dump:Arm Too High to Lower Arms Start Auto-Dump:Max Angle...
Page 149 Multiplexing 139 Table 1 Warning messages (cont’d) Warning and Caution Messages Solutions Packer:Roof Not Opened Open Roof (Top Door) Pump Stop:Main Air Pressure Let the Air Build Up to Required Pressure Pump:Auto-Dump Button ON Button Must be OFF to Engage Pump Pump:Aux EStop Pull Up Aux EStop Button...
Page 150 140 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solutions Pump:SpeedUpON Switch ON Switch Must be OFF to Engage Pump Pump:TagAxle Down Switch Switch Must be OFF to Engage Pump Pump:TagAxle Up Switch ON Switch Must be OFF to Engage Pump Pump:TailGate Down Switch Switch Must be OFF to Engage...
Page 151 Multiplexing 141 Table 2 Error messages (cont’d) Error Messages Solution CAN Error Level 2 Refer to LabriePlus CAN Error Level 3 Refer to LabriePlus Comm. Lost with Master Refer to Maintenance Personnel or LabriePlus Module 11 is disconnected Refer to Maintenance Personnel or LabriePlus Module 11 not Connected Refer to Maintenance...
Page 152: Main Menu
142 Multiplexing Figure 9-5 Example of possible cause : If the system detects a problem, a beep will sound and a message will appear on the monitor screen. : To go back to the Main Page or Main Menu, press “Esc” as needed until the desired page is displayed.
Page 153 Multiplexing 143 To choose a particular module, use the up/down arrows to select it and press “OK”. : Pressing “OK” can be done two ways: either press the far right button or the “OK” button. Press “Esc” to return to the preceding page. Figure 9-6 Module I/O Status page 11: Display...
Page 154 144 Multiplexing The Input Status page contains a set of rectangles. Each of these rectangles represents input elements, which in turn correspond to a particular function of the truck. For example, if you select rectangle I00, a short description appears in the lower part of the screen, which indicates that this rectangle relates to the input element coming from the service brake pressure switch.
Page 155 Multiplexing 145 The rectangles on this page are used to check the status of different outputs. : Each rectangle is numbered and relates to a specific function of the truck. However, for a given number, the related function may vary from truck to truck. Table 4 Colored rectangles Rectangles...
Page 156 146 Multiplexing Figure 9-10 Warning message w/ “OK” prompt Press “OK” to go to the Force page or “Esc” to return to the preceding page. After pressing “OK”, the Force page appears on the screen. Figure 9-11 Force page (input) As no input function can be forced to be active or inactive, the operator must press the “Output”...
Page 157 Multiplexing 147 This page contains a set of rectangles. Each of these rectangles is numbered and relates to a specific function of the truck. Colors are used to indicate whether the corresponding function is active or not:  a blue rectangle means the corresponding function is inactive ...
Page 158 148 Multiplexing  the CANopen bus, which is used for the body. These 2 communication buses are completely independent of one another, except for some specific data that are transferred from the chassis J1939 bus to Labrie’s multiplexed system where they are used.
Page 159 Multiplexing 149 If no password has been created, enter a password using the arrow keys. Press ESC to quit or OK to set password. If a password already exists, enter it using the arrow keys. Press ESC to quit or OK to erase the password. Enter a new password using the arrow keys.
Page 160 150 Multiplexing : Entering a new password with only zeros as the number, such as “000000”, will result in deactivating the password function. Go back to the Settings Menu by pressing ESC. In the Settings Menu, select Locked Features. Select the feature(s) that you want to lock using the password created or saved. : If you have forgotten your password, please contact the LabriePlus Service Department.
Page 161: Module Locations
Module Locations The multiplex control system used on all Labrie & Wittke models has a number of control modules located throughout the unit. At times, it may be necessary to access those modules to perform maintenance or diagnostic procedures.
Page 162: Node 10 Module Location
152 Multiplexing Node 10 Module Location Module #10 will always be located in the truck cab. In some units, it will be located inside the console; in other units, it will be located in the central section of the cab (see Figure 9-15). Figure 9-15 Node 10 module location Node 30 Module Location...
Page 163: Node 50/60 Module Location
Multiplexing 153 Node 50/60 Module Location The module is located inside the hopper area behind the packer blade. It is mounted to the inside of the front bulkhead RH side. The module can be accessed by opening the hopper door on the RH side of the unit.
Page 164 154 Multiplexing Figure 9-18 LED light on module Once module light status condition has been verified, the connector condition should be checked: Check for proper connection to module Figure 9-19 Connection status Check for any moisture or corrosion in the connector or on the module terminals.
Page 165 Multiplexing 155 It is highly recommended that dielectric grease be applied to connector. Check the condition of the harness and ensure that it is not secured too tight with tie-wraps, which may pull the wires back within the connector. Figure 9-20 Connectors, terminals and harness Connectors Terminals...
Page 166: Warning Buzzer
156 Multiplexing Warning Buzzer Among the many buttons on the control panel you will find a warning buzzer (see Figure 9-21). This buzzer sounds and a red light in its center flashes to warn the operator of any situation that might be hazardous.
Page 167: Allison Transmission Parameters
Multiplexing 157 Allison Transmission Parameters In Allison transmissions used on automated vehicles, the Transmission Control Module (TCM) manages several functions:  It prevents the pump from engaging if the engine speed is higher than 900 RPM.  It also controls the auto-neutral system (if present). The TCM is programmed using the Allison DOC software installed on a laptop computer.
Page 168 158 Multiplexing This page and the next page show how Allison TCMs are programmed for Labrie vehicles. : The parameters shown in the following tables are typical values and are given for guidance only. Some vehicles may need different parameters based on the options installed. Please call LabriePlus for the values that are specific to your vehicle.
Page 169: Cummins Engine Parameters
Multiplexing 159 Table 8 Output Wire # Description State PTO enable output Active when the PTO switch is ON and when all engine and vehicle speed criteria are respected (+12V signal). See Programmed Parameters on page 157. Neutral signal output Active when the transmission is in neutral.
Page 170 160 Multiplexing...
Page 171 Our office in the U.S. Our office in Canada 1198 Shattuck Industrial Blvd. 175A Route Marie-Victorin LaFayette, GA 30728 Levis, QC G7A 2T3 Toll Free: 1-800-231-2771 Toll Free: 1-877-831-8250 Telephone: 1-706-591-8764 Telephone: 1-418-831-8250 General Fax: 1-706-639-9275 Service Fax: 1-418-831-1673 Oshkosh General Fax: 1-706-591-8766 Parts Fax: 1-418-831-7561 Mailing Address Mailing Address...

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Wittke STARLIGHT Maintenance Manual

Table of Contents

Introduction

Safety

Lubrication

Preventive Maintenance

Electrical System

Pneumatic System

Hydraulic System

Packer Maintenance

Multiplexing

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