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Wittke StarLight Maintenance Manual

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Summary of Contents for Wittke StarLight

  • Page 1 Maintenance Manual...
  • Page 3 ™ & S ™ IGHT UPER AINTENANCE ANUAL 10/19/07 : #90309 UMBER...

  • Page 5: Table Of Contents

    Table of Contents Maintenance Liability ..................... 1 Warning ....................1 Lifting Components for Service ............. 1 Lifting the Arms and Forks ............2 Lifting the Front Body ..............2 Lifting the Entire Body ............... 4 Prior to Hydraulic System Maintenance ..........6 Hydraulic Settings and materials ............
  • Page 6 Adjusting and Repairing Electrical Components ....... 36 Circuit Breakers and Fuses ............. 37 Fuses ..................37 Manual Reset Circuit Breakers ........... 37 Adjusting the Proximity/Limit Switch Settings ......39 Proximity Switches on the Street Side ........40 Proximity Switches on the Curb Side .......... 40 Lever Arm Limit Switches ............
  • Page 7 Valve Box and Air Valves ............56 Air Actuators ................57 Central Air Drain Cocks (optional) ..........57 Pneumatic System Schematics ..........58 Hydraulic System .................. 60 Hydraulic Oil Tank ..............60 Return Line Filter ..............61 Return Line Filter element ............61 Routine Maintenance ..............
  • Page 8 Arms Down Deceleration Valve (optional) ......72 Main System Pressure Adjustment ......... 74 Commercial Front Loader ............74 Hydraulic Hose ................ 75 Hydraulic System Schematics ..........76 Packer Maintenance ................80 Packer Wear Plates Replacement .......... 80 Body Guide Wear Plates Replacement ........82 Packer Removal Procedure ............

  • Page 9: Maintenance

    In addition, these mechanics should be fully versed in the operation of this unit. Please read the Operator Manual, prior to attempting any maintenance of your Wittke Front Loader. IFTING OMPONENTS FOR...

  • Page 10: Lifting The Arms And Forks

    While Labrie Environmental Group has included the specifications of the lift equipment we use, these specifications are intended as guides only. It is your responsability to ensure your lift equipment meets all safety standards and that only qualified personnel attempt these lifts. IFTING THE RMS AND ORKS...
  • Page 11 Remove the both outer grease fittings located on each side of the arm pivot tube. That way, you won’t damage the grease fittings or the lifting straps. Securely attach the slings to the lift beam, which was previoulsy installed on the overhead crane. Outer grease fitting Wrap a lift sling around each end of the arm pivot tube.

  • Page 12: Lifting The Entire Body

    IFTING THE NTIRE Note:All the ratings provided below are the minimum values. Lifting the W body requires securing both ends, front and ITTKE rear, to a lift beam. To do so, you will need two 3000-lb (1361 kgs) rated slings (rear, see picture below), two 3000-lb rated shackles (rear), two 6000-lb (2722 kgs) rated slings (front), one 12000-lb (5443 kgs) lift beam (front), one 6000-lb lift beam (rear) and one 18000-lb (8165 kgs) overhead crane.
  • Page 13 Sling Lift beam Install shackle here Fasten shackles securely on each 3000-lb lift sling. Securely attach the slings to the 6000-lb lift beam, which was previoulsy installed on the overhead crane. Lift the body. Make sure to raise both ends of the body at the same time.

  • Page 14: Prior To Hydraulic System Maintenance

    RIOR TO YDRAULIC YSTEM AINTENANCE 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, the unit is not performing in terms of payload, or the unit has recently been put into service and the system requires adjustment following a run-in period.

  • Page 15: Hydraulic Settings And Materials

    YDRAULIC ETTINGS AND MATERIALS YSTEM ETTINGS 2500 PSI 1500 ™) PRESSURE TARLIGHT RELIEF VALVE 1500 RPM) 2750 PSI 1500 RPM ™) UPERDUTY DOWN PORT 1000 PSI PRESSURE RELIEF VALVE 2350 PSI 1500 ™) TARLIGHT RESSURE SWITCH IN PACK CIRCUIT 2600 PSI 1500 RPM ™) UPERDUTY...

  • Page 16: Lubrication

    UBRICATION LUBRICATE, LUBRICATE, LUBRICATE! Insufficient lubrication is a major cause of component failure. The Wittke front laoders, like most equipment, have numerous points that require grease. Refer to the lubrication chart located on the side of the truck for a complete list of lube locations and the frequency they should be greased.

  • Page 17: Centralized Grease Block

    ENTRALIZED REASE LOCK Pins at the packer end of the cylinders are remotely greased via two grease fittings on the curb side front of the packer. Pins at the front header end of the cylinders must be greased manually. Packer Grease fittings Grease fittings (view from inside...

  • Page 18: Packer Rails Lubrication

    ACKER AILS UBRICATION 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 (at back of the packer) to perform this task. Lubricant spray Spray all lubricant on...

  • Page 19: Maintenance Checklist

    AINTENANCE HECKLIST ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 1. LUBRICATION PACKER CYLINDER PINS RM CYLINDER PINS PIVOTS PIVOT TUBE COLLARS CYLINDER PINS PIVOT TUBE COLLARS Part #: 90309...
  • Page 20 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL AILGATE HINGE PINS AILGATE CYLINDER PINS PIVOTS AILGATE LATCH ROLLER PINS BODY HINGE PINS ACCESS DOOR HINGES LEANOUT DOOR HINGES DRIVE LINE **12 JOINTS AND SLIP YOKE Part #: 90309...
  • Page 21 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL PUSHER AXLE CONSULT MANUFACTURER VARY NSPECT LEAKS PACKER REMOTE GREASE LINES NSPECT HYDRAULIC OIL LEVEL IN TANK *Denotes option or not all units **Unit may be fitted with a driveline which does not require grease Part #: 90309...
  • Page 22 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 2. CLEANING SAFETY LABELS IRRORS LAMPS WINDOWS CAMERA LEAN DEBRIS TAILGATE SEAL EBRIS FRONT PACKER INSIDE HOPPER MORE OFTEN IF REQUIRED COMPLETE BODY CHASSIS MORE OFTEN IF REQUIRED Part #: 90309...
  • Page 23 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL THER *DENOTES OPTION OR NOT ALL UNITS O = OPERATOR M = MAINTENANCE ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 3. MECHANICAL INSPECTION (TRUCK AT REST) NSPECT FOR DISTORSION CRACKS OR UNUSUAL WEAR NSURE MOUNTING AND PIN RETAINER BOLTS ARE INTACT AND TIGHT ODY MOUNTS...
  • Page 24 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ERVICE HOIST CYLINDER MOUNTING BOLTS CHASSIS VARIES ERVICE HOIST SAFETY PROP PROP SOCKETS INSPECT PRIOR USING ASSEMBLIES ASSEMBLY MOUNTING BOLTS LOCK WASHERS AND (12) NUTS PIVOT TUBE PIVOT TUBE COLLARS RM CYLINDER (4), EARS PINS...
  • Page 25 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ASSEMBLY ASSEMBLY MOUNTING BOLTS PIVOT TUBE COLLARS CYLINDER (4), EARS PINS (4), RETAINING HARDWARE ESIDENTIAL CARRY AND MOUNTING HARDWARE RONT HEADER ASSEMBLY CYLINDER EARS Part #: 90309...
  • Page 26 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ACKER ASSEMBLY CYLINDER EARS ACKER CYLINDER PINS (4), RETAINING NUTS BOLTS ACKER GUIDE RAILS WEAR SHOES NTERIOR HOPPER MAIN BODY WALLS FLOOR AND TOP DOOR XTERIOR HOPPER MAIN BODY WALLS FLOOR AND TOP DOOR Part #: 90309...
  • Page 27 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ACCESS DOOR ASSEMBLY ANOPY ASSEMBLY EXTENSION HARDWARE DOOR ASSEMBLY DOOR CYLINDER PINS (2), (2), EARS RETAINING HARDWARE DOOR CYLINDER BOLT RELATED NUTS BOLTS TAILGATE ASSEMBLY TAILGATE CYLINDER (4), EARS PINS (4), RETAINING HARDWARE Part #: 90309...
  • Page 28 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL AILGATE LATCH (2), ASSEMBLY (2), PIVOTS ROLLER PINS AILGATE SEAL SEAL RETAINER AILGATE HINGE EARS (2), (2), PINS RETAINING HARDWARE AILGATE SAFETY PROP AFETY EQUIPMENT PRESENT FIRE EXTENGUISHER FIRST AID KIT THER *Denotes option or not all units O = Operator...
  • Page 29 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 4. OPERATION (MAIN CONTROLS) BSERVE TRAVEL IS SMOOTH AND EVEN SPEED IS NORMAL CONTROLS ARE RESPONSIVE ORKS DOWN DOWN ACKER PACK RETURN AUTOPACK AUTOSTOP OLLOWER PACK RETURN AUTOPACK AUTOSTOP OPPER DOOR OPEN CLOSE TAILGATE OPEN...
  • Page 30 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ERVICE HOIST DOWN ERFORM SAFETY LOCKOUT TESTS TO CHECK PROXIMITY LIMIT SWITCHES ACCESS DOOR TEST SIDE ACCESS DOOR LIMIT PROXIMITY SWITCH PACK TEST PACKER FULLY EXTENDED PROXIMITY SWITCH UTOPACK TEST PACKER FULLY EXTENDED PROXIMITY SWITCH...
  • Page 31 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL AUTO PACK LOCK ARMS TEST ARMS ELEVATED PACK CUTOUT PROXIMITY SWITCH LOCKOUT HOPPER DOOR TEST OPPER DOOR PROXIMITY SWITCH LOCKOUT PACKER TEST PACKER FULLY RETRACTED PROXIMITY SWITCH THER *Denotes option or not all units O = Operator M = Maintenance Part #: 90309...
  • Page 32 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 5. OPERATION (MISC. CONTROLS AND FEATURES) HECK CONTROL CONSOLE WARNING DEVICES ARE FUNCTIONNING UMP SWITCH LAMP ACKER WARNING LAMP OPPER DOOR WARNING LAMP CCESS DOOR WARNING LAMP AILGATE UNLOCKED WARNING LAMP EXTERNAL ALARM TAILGATE UNLOCKED...
  • Page 33 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL ELEVATED WARNING LAMP ERVICE HOIST BODY RAISED WARNING LAMP BUZZER HECK EXTERNAL LAMPS AND MISCELLANEOUS ARE FUNCTIONING UXILIARY CONTROLS SIGNAL TAIL LAMPS ARKER LAMPS OPPER LAMP ACKUP LAMPS BACKUP FLOOD LAMPS Part #: 90309...
  • Page 34 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL TROBE LAMP AMERA DUAL LAMPS LTERNATING FLASHERS ACKUP ALARM LOBAL MOTION SENSORS HECK MISCELLANEOUS CONTROL CONSOLE DEVICES ARE FUNCTIONNING HROTTLE ADVANCE SWITCH ACTIVATED AUTOPACK SWITCH WIDTH SWITCH ASH TANK Part #: 90309...
  • Page 35 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL THER *Denotes option or not all units O = Operator M = Maintenance ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 6. HYDRAULIC SYSTEM HYDRAULIC OIL TANK: HECK LEAKS DAMAGE ON TANK HECK TANK SECURELY...
  • Page 36 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL HECK CONDITION EPLACE MORE OFTEN IF REQUIRED HECK SUCTION BALL VALVE FULLY OPEN LEAN BREATHER REPLACE IF NECESSARY MORE OFTEN IF REQUIRED LEAN SUCTION STRAINER WITH VARSOL COMPRESSED REPLACE DAMAGED MORE OFTEN IF REQUIRED O PROTECT THE HYDRAULIC COMPONENTS OF YOUR NEW EQUIPMENT THE RETURN LINE FILTER...
  • Page 37 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL HANGE HYDRAULIC RETURN LINE M (NEW UNIT) FILTER MORE OFTEN IF REQUIRED LEAN MAGNETIC PLUG MORE OFTEN REQUIRED PUMP: NSPECT PUMP FOR LEAKS NSURE PUMP SECURELY MOUNTED NSURE DRIVELINE SECURELY MOUNTED HYDRAULIC VALVE BANK: NSPECT...
  • Page 38 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL NSURE VALVE BANK IS SECURELY MOUNTED HECK SYSTEM PRESSURE RELIEF VALVE SETTINGS ADJUST REQUIRED PRESSURE GAUGE ECORD HECK ARMS DOWN PRESSURE RELIEF VALVE SETTINGS *109 ADJUST REQUIRED PRESSURE GAUGE ECORD Part #: 90309...
  • Page 39 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL MISCELLA- NEOUS: NSPECT HYDRAULIC LINES LEAKS CHAFING NSPECT HYDRAULIC CYLINDERS MISC HYDRAULIC COMPONENTS FOR LEAKS HECK PACK CIRCUIT PRESSURE SWITCH SETTING DJUST REQUIRED NSPECT ARMS DOWN *113 SECURE TRIPPING DECELERATION VALVES Part #: 90309...
  • Page 40 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL THER *Denotes option or not all units O = Operator M = Maintenance ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL 7. PNEUMATIC SYSTEM RAIN TANKS AT THE END OF EACH NSPECT LINES LEAKS EPLACE...
  • Page 41 ITEM DESCRIPTION PRE-TRIP DAILY WEEKLY MONTHLY 1000 LANDFILL IGHTLY ACTUATORS THERS Part #: 90309...

  • Page 42: Electrical System

    LECTRICAL CHEMATICS Two types of schematics are provided with Wittke trucks. First, there is the electrical schematic, which shows how components are wired to each other. This schematic is useful to diagnose electrical circuits.

  • Page 43: Relay Box (Located In The Cab)

    Relay Box (located in the cab) The relay logic consists of a control system made up with traditional relays. To troubleshoot such a system, please refer to the electrical schematic provided with the truck and use the appropriate tools. • Main relay: A high current relay centralizes power to the relay box in the cab.

  • Page 44: Proximity Switches

    Proximity Switches Body-mounted proximity switches control the packer operation and provide the means for safety lockouts. Harnesses Harnesses connect all electrical components. They are generic and may contain wires and plugs that are not used. DJUSTING AND EPAIRING LECTRICAL OMPONENTS The required electrical system adjustments include: •...

  • Page 45: Circuit Breakers And Fuses

    IRCUIT REAKERS AND USES Power for the Wittke front loaders’ electrical system is protected by two 30 A fuses and up to five manual reset circuit breakers (depending on the options). Fuses UNCTION OCATION ITTED IN THE BATTERY BOX ATTERY...
  • Page 46 UNCTION OCATION CONTROL CAB RELAY BOX CIRCUIT AMPS (F2) ROXIMITY LIMIT SWITCH CAB RELAY BOX AMPS SENSORS (F1) OPPER MIRROR LAMP CAB RELAY BOX AMPS SWITCHES (F3) ONITOR CAB RELAY BOX (F4) TROBE LAMP LTERNAT ING FLASH CAB RELAY BOX ING LIGHTS ACKUP (F5)

  • Page 47: Adjusting The Proximity/Limit Switch Settings

    DJUSTING THE ROXIMITY IMIT WITCH ETTINGS Proximity/limit switches act as remote electrical on/off switches. CAUTION ROXIMITY LIMIT SWITCHES MUST FUNCTION PROPERLY ERIOUS DAMAGE OR DEATH MAY RESULT IF YOU OPERATE THE FRONT LAODER WITH IMPROPERLY ADJUSTED PROXIMITY SWITCHES Part #: 90309...

  • Page 48: Proximity Switches On The Street Side

    Proximity Switches on the Street Side Tailgate Forks fully fully open Top Door fully retracted proximity open proximity proximity switch switch Packer proximity switches Tailgate unlocked Arm fully Body raised proximity switch retracted limit switch proximity switch Proximity Switches on the Curb Side Side access door limit/proximity switch...

  • Page 49: Lever Arm Limit Switches

    EVER IMIT WITCHES General adjustment procedure: Loosen limit switch nut. Move lever arm to approximate position where limit switch is to trip. Tighten nut. To fine tune limit switch, loosen nut slightly. With a flathead screwdriver, turn the adjusting screw located at the center of the nut until a click is heard.

  • Page 50: Packer Fully Retracted Proximity Switch

    ACKER ULLY ETRACTED ROXIMITY WITCH This proximity switch locks out the Arms up function and activates a warning lamps when the packer is not in the “home” position and also stops the packer when it reaches its fully retracted position. It is very important to adjust this proximity switch properly in order to avoid the packer hitting the hopper at the end of its stroke.

  • Page 51: Packer Fully Extended Proximity Switch

    ACKER ULLY XTENDED ROXIMITY WITCH This proximity switch stops the packer when it reaches its fully extended position (pack cycle). This proximity switch is mounted on the front wall of the body, on the street side. IMPORTANT HIS PROCEDURE MUST BE PERFORMED BY TWO PEOPLE Testing procedure: Empty all refuse from the body.
  • Page 52 reaches this position. Ideally, there should be a gap of 3/8 inch between the proximity switch and its target. Test the packer for a full cycle. Part #: 90309...

  • Page 53: Side Access Door Limit Switch

    CCESS IMIT WITCH This limit switch cuts all hydraulic power when the side access door is not closed. Note:Some units can be equipped with a proximity switch. Location: The side access door limit switch is mounted on the side door frame.

  • Page 54: Top Door Fully Open Proximity Switch

    ULLY ROXIMITY WITCH The Top door fully open proximity switch controls the cutout of Proximity the arms up function if the top door is not fully open. It also switch illuminates the Top door warning lamp on the control console. Target Location: The Top door fully open proximity switch is located on the street...

  • Page 55: Tailgate Fully Open Proximity Switch

    Repeat the adjustment procedure until the proximity switch detects the cylinder when the tailgate is locked and does not detect the cylinder when the tailgate is unlocked. AILGATE ULLY ROXIMITY WITCH The tailgate fully open proximity switch allows you to enable the ejection cycle when the tailgate is fully open.
  • Page 56 To perform the adjust- ment, the center of forks pivot must be at the same height as the center of the canopy hinge Adjust the target so it activates the proximity switch. Arm partially raised proximity Target Make sure that the proximity switch detects the target on all the detection zone shown below.
  • Page 57 DETECTION ZONE Once the proximity switch and the target are adjusted, lower the arms. Start the packer. While the packer is in motion, raise the arms. They should stop at mid-height. If it is not the case, readjust the proximity switch and its target.

  • Page 58: Arms And Forks Fully Retracted Proximity Switch

    RMS AND ORKS ULLY ETRACTED ROXIMITY WITCH The Arms fully retracted proximity switch ensures that the Arm not stowed warning lamp on the console illuminate if the arms are not completely parked. Both arms and forks must be completely parked in order to turn off the Arm not stowed warning lamp.
  • Page 59 Adjustment procedure: Raise the arms until there is 57 3/8 inches between both cylinder attachments (center to center). Part #: 90309...
  • Page 60 Adjust the target so it activates the proximity switch. (proximity switch light on). Arms fully retracted proximity switch Target Lower the arms. Retract the forks until there is a distance of 31 inches between both fork cylinder attachments (center to center). 31”...

  • Page 61: Body Raised Limit Switch (Optional)

    If the Arm not stowed warning lamp does not “react” properly, readjust the proximity switches and their targets. The Arm not stowed warning lamp should turn off only when the arms are fully raised and the forks fully retracted. AISED IMIT WITCH OPTIONAL...

  • Page 62: Pneumatic System

    NEUMATIC YSTEM OW THE NEUMATIC YSTEM ORKS The pneumatic system includes: • Air supply • Filtering system • Controls • Valve box and air valves • Air Actuators Air supply Air is drawn from the chassis air tank, passes through an air and mist filter system and into the valve box.

  • Page 63: In-Line Lubricator (Optional)

    In-Line Lubricator (optional) Recommended for use in cold and dry climates, the optional lubricator is fitted in line after the mist separator. It is filled with air tool oil which is bled into the system to ensure adequate lubrication. Controls Standard arms/forks control is by mean of a dual handle joystick, mounted next to the driver.

  • Page 64: Valve Box And Air Valves

    Valve Box and Air Valves Mounted behind the cab, the valve box houses the solenoid-operated air valves that direct air to the air actuators on the hydraulic valve bank. Power is required to energize the solenoid so air can pass to the work section dedicated to that particular air valve.

  • Page 65: Air Actuators

    Valve Box Air Valves UTS AIR USED TO RETRACT THE UTOUT ARM CYLINDERS IPPER YCLES TIPPER ACTUATOR UP YCLES TIPPER ACTUATOR IPPER DOWN MAIN OYSTICK ISABLES JOYSTICK OPERATION UTOUT WITH THE HYDRAULIC PUMP OFF Air Actuators Air from the air valves and joystick is routed to the air actuators mounted on the hydraulic valve sections.

  • Page 66: Pneumatic System Schematics

    NEUMATIC YSTEM CHEMATICS Each W truck is provided with its specific pneumatic ITTKE schematic. For more details on the pneumatic system of your unit, refer to this schematic. 5-section Hydraulic Valve (w/o Auto-dump Part #: 90309...
  • Page 67 5-section Hydraulic Valve with Auxiliary Controls Part #: 90309...

  • Page 68: Hydraulic System

    YDRAULIC YSTEM YDRAULIC The hydraulic oil tank is 60 US gallon capacity reservoir mounted to the chassis frame. It houses the reservoir return line filter assembly, as well as a suction line strainer. Fitted to the tank is a breather cap which allows the tank to breathe as oil is drawn out of the tank.

  • Page 69: Return Line Filter

    ETURN ILTER Oil returning from the valve bank passes through a 7 micron filter mounted in the tank. Refer to “Maintenance Checklist” for more details on the replacement frequency. ETURN ILTER ELEMENT While every effort is made at the Labrie Environmental Group factory to ensure clean hydraulic systems, it should be noted that most hydraulic system manufacturer’s recommend the filter be replaced after a break-in period.

  • Page 70: Element Replacement Procedure

    LEMENT EPLACEMENT ROCEDURE Complete the lockout/tagout procedure. Note: Keep tools, working area and equipment clean. A pan will be required to collect a small amount of oil lost as the element is removed. The filter housing is fitted with a check valve, therefore it is not necessary to drain the hydraulic tank.

  • Page 71: Hydraulic Oil

    YDRAULIC Factory filled oil is tested for cleanliness. Hydraulic oil is the lifeblood of the system. Particles in the oil will devastate any hydraulic system overtime, therefore regular oil changes will most likely extend the life of components and equipment. Oil should be replaced when it becomes oxidized, when it has a significant change in color and/or becomes milky or cloudy.

  • Page 72: Directional Control Valve

    IRECTIONAL ONTROL ALVE Pressurized oil is directed from the hydraulic pump to a bank of stack-type directional control valves mounted on the front header of the W body. Rubber gaskets seal each valve ITTKE section. The valve bank on a commercial unit is comprised of: Inlet Section: the oil enters the valve bank through the top of the inlet section where it is then directed to the work sections below.

  • Page 73: Work Circuits

    IRCUITS The circuits have been listed from top to bottom as they appear in the valve bank assembly. Note: The following list is for the commercial front loader only. See following section for residential configuration. Hopper Top Door Circuit: The hopper top door circuit includes one double-acting hydraulic cylinder and two flow restrictors.
  • Page 74 Lower and raise the arms while running the engine at idle speed and again while running the engine at 1500 rpm. Note:The arms should slow when they are at approximately 18 inches (45.72 cm) away from the arm stops and gently come to rest against the arm stops.

  • Page 75: Pack Circuit Dump Valve

    IRCUIT ALVE The pilot operated check valve (dump valve) is fitted into the pack hydraulic circuit for the purpose of speeding up the return stroke of the packer. Pressure in the pilot line during the return stroke opens the dump valve and allows approximately 50 percent of the oil exiting the cylinders to go directly to the hydraulic tank.

  • Page 76: Timer Adjustment

    Note:Leave the pressure gauge in place. Locate the pressure switch and remove the cap screw plug. Insert the allen wrench into the adjustment screw. With the engine running and the pump switch on, raise the engine rpm to 1500 and initiate a pack cycle and watch the pressure gauge.
  • Page 77 Time scale (0.1 or 1) is selected with the time scale selector at the upper left corner of the front panel, it appears in the scale range display window above the selector. IMPORTANT LWAYS SET THE TIME SCALE TO To adjust the timer: Open relay box.

  • Page 78: Tailgate Lock Valve

    AILGATE ALVE The tailgate locking mechanism is equipped with hydraulic safety systems that prevent accidental unlocking of the tailgate during operation. One of the systems is the velocity fuse with the “power bleed” and the other is the lock valve. The spool inside the tailgate section of the valve is designed in such a way that it will allow pressure to pass through it each time the pressure is building up in the hydraulic system (i.e.:...

  • Page 79: Service Hoist (Optional)

    ERVICE OIST OPTIONAL The service hoist circuit is independant 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. CAUTION HE SERVICE HOIST IS NOT INTENDED TO LIFT A LOADED BODY Adjustment procedure: Note:Should adjustment be required, an adjustement screw...

  • Page 80: Arms Down Work Section

    ECTION Designed to protect the arm hydraulic circuits, the arms down work section is equipped with a work port relief valve in the arms down outlet port only and is preset to 1000 psi. CAUTION AMPERING WITH THE WORK PORT RELIEF VALVE MAY CAUSE SERIOUS DAMAGE TO THE ARMS CIRCUIT AND VOID WARRANTY Location: Main hydraulic valve bank, on the front header of the body.
  • Page 81 Loosen the retaining bolt. tap the cam in the required direction. Tighten the retaining bolt of the cam and repeat step Attach a container or carry can to the forks and repeat step 4 and step 5. Remove the container from the forks and repeat step 5 and step 6 until the arms decelerate with and without a container on the forks.

  • Page 82: Main System Pressure Adjustment

    YSTEM RESSURE DJUSTMENT As with all hydraulic systems, it may be necessary to periodically check and adjust pressure relief settings. Commercial Front Loader Note: The system pressure should be at 2500 psi ™) or 2750 psi (S ™). TARLIGHT UPERDUTY Adjustment procedure: Remove the cap on the quick coupler located at the top of the main valve bank.

  • Page 83: Hydraulic Hose

    YDRAULIC Labrie Environmental 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 84: Hydraulic System Schematics

    YDRAULIC YSTEM CHEMATICS Each W truck is provided with its specific hydraulic ITTKE schematic. For more details on the hydraulic system of your unit, refer to this schematic. Valve with Pneumatic Control (standard) Part #: 90309...
  • Page 85 Valve with Pneumatic Control – 2 Deceleration Valves on Forks Part #: 90309...
  • Page 86 Hydraulic Diagram Auto-dump with One Deceleration Valve Part #: 90309...
  • Page 87 Hydraulic Diagram Auto-dump with Two Deceleration Valves Part #: 90309...

  • Page 88: Packer Maintenance

    ACKER AINTENANCE The W packing system has a heavy duty guiding system ITTKE using special hardened steel wear plates. Because of the frequent use of the packer, we recommend to perform daily inspections (operator) and weekly inspections (maintenance personnel) Greasing all moving parts on a daily basis is very important. The proper adjustment of the proximity switches is also very important (refer to “Packer Fully Retracted Proximity Switch”...
  • Page 89 To replace packer wear plates: Remove the packer (refer to “Packer Removal Procedure” on page 84). Remove the wear plates from the packer by cutting the welds. Verify corresponding wear plates under guiding tracks. Install new wear plates on packer. Reinstall packer in the unit.

  • Page 90: Body Guide Wear Plates Replacement

    UIDE LATES EPLACEMENT DANGER PPLY THE LOCKOUT TAGOUT PROCEDURE AT ALL TIMES AILURE TO DO SO MAY RESULT IN SEVERE INJURY OR DEATH To replace body guide wear plates: Remove the packer (refer to “Packer Removal Procedure” on page 84). Retract the packer cylinders and move them out of the way.
  • Page 91 Reinstall the packer. Body guide wear plates Part #: 90309...

  • Page 92: Packer Removal Procedure

    ACKER EMOVAL ROCEDURE To remove the packer: Start the engine and hydraulic system. Bring the packer to the rear end of the body (full eject) to easily access the pins.. Stop the engine and turn off the hydraulic pump. Enter the hopper and remove the grease fitting hoses (on Cylinder pin each cylinder).

  • Page 93: Packer Cylinder Replacement

    Packer at the rear end of the body ACKER YLINDER EPLACEMENT CAUTION SE AN APPROPRIATE LIFTING DEVICE TO REMOVE CYLINDERS To replace packer cylinders: Fully extend the packer. Stop the engine and turn off the hydraulic pump. Enter the hopper and remove the grease fitting hoses (on each cylinder).
  • Page 94 Grease fitting hoses Remove packer end cylinder pins. Secure both cylinders to avoid them falling on the body floor. Get out of the hopper and close the side access door. Start the engine and turn on the hydraulic pump. Retract packer cylinders. Remove hoses and front header end pins from both cylinders.
  • Page 95 3630 Stearns Drive, Oshkosh, WI 54904 Toll free: 1-800-231-2771 Telephone: 1-920-233-2770 General Fax: 1-920-232-2496 Sales Fax: 1-920-232-2498 Mailing Address: P.O. Box 2785 Oshkosh, WI 54903-2785 Parts, Service and Warranty (during business hours 7:00 AM to 7:00 PM Central Standard Time) Technical Support Service (24 hours) Part # 90309...

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