Maintenance Manual
S TAR L IGHT ™ & S UPER D UTY ™ M AINTENANCE M ANUAL 10/19/07 PART NUMBER: #90309
Table of Contents Maintenance Liability ..................................................................................................... 1 Warning .................................................................................................... 1 Lifting Components for Service ............................................................. 1 Lifting the Arms and Forks ........................................................ 2 Lifting the Front Body .....................................................
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 ........................................
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 ........................................
Arms Down Deceleration Valve (optional) .............................. 72 Main System Pressure Adjustment ......................................... 74 Commercial Front Loader ........................................................... 74 Hydraulic Hose ........................................................................ 75 Hydraulic System Schematics ................................................ 76 Packer Maintenance ..............................................................................
MAINTENANCE LIABILITY Labrie Environmental Group assumes no liability for any incidental, consequential or other liability from the use of this information. All risks and damages, incidental or otherwise, arising from use or misuse of the information contained herein are entirely the responsibility of the user. Although careful precaution has been taken in the preparation of this material, we assume no responsibility for errors or omissions.
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. LIFTING THE ARMS AND FORKS You may need to lift the arms and forks manually.
Outer grease fitting 2. 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. 3. Securely attach the slings to the lift beam, which was previoulsy installed on the overhead crane. 4. Wrap a lift sling around each end of the arm pivot tube. 5. Unlatch the body latches (one on each side). CAUTION MAKE SURE THAT THERE IS ENOUGH CLEARANCE BEFORE LIFTING Lift sling THE BODY. 6. Raise the front body.
LIFTING THE ENTIRE BODY Note:All the ratings provided below are the minimum values. Lifting the WITTKE body requires securing both ends, front and 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.
Sling Lift beam Install shackle here Part #: 90309 3. Fasten shackles securely on each 3000-lb lift sling. 4. Securely attach the slings to the 6000-lb lift beam, which was previoulsy installed on the overhead crane. 5. Lift the body. Make sure to raise both ends of the body at the same time.
PRIOR TO HYDRAULIC SYSTEM MAINTENANCE 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. CAUTION FOLLOW A PROPER LOCKOUT/TAGOUT PROCEDURE PRIOR TO SERVICING THE HYDRAULICS. DEATH OR SERIOUS INJURY CAN RESULT.
HYDRAULIC SETTINGS AND MATERIALS SYSTEM SETTINGS: MAIN RELIEF PRESSURE VALVE DOWN PRESSURE 1500 RPM 2750 PSI AT (SUPERDUTY™) 1500 RPM (AT 1500 RPM) ARMS 2500 PSI AT (STARLIGHT™) PORT 1000 PSI RELIEF VALVE PRESSURE SWITCH IN PACK CIRCUIT 2350 PSI AT (STARLIGHT™) 1500 RPM 2600 PSI AT (SUPERDUTY™) 1500 RPM 1500 RPM THROTTLE ADVANCE WELDING INFORMATION CAUTION DISCONNECT ALL BATTERIES AND ELECTRONIC MODULES PRIOR TO WELDING ON PACKER BODY. CAUTION REMOVE PAINT BEFORE WELDING OR HEATING.
LUBRICATION 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.
CENTRALIZED GREASE BLOCK 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 RAILS LUBRICATION Lubricant spray 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.
MAINTENANCE CHECKLIST ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS 1.
ITEM 6 DESCRIPTION PRE-TRIP TAILGATE HINGE PINS (2) AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS X TAILGATE 7 CYLINDER PINS (2) AND PIVOTS X (2) TAILGATE 8 LATCH ROLLER PINS *9 *10 X (2) REAR BODY HINGE PINS (2) SIDE ACCESS DOOR HINGES X X (2) CLEANOUT *11 DOOR HINGES X (2) PUMP **12 12 DRIVE-LINE U-JOINTS AND SLIP YOKE (3) X Part #: 90309
ITEM DESCRIPTION TAG *13 PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS AND/OR PUSHER (QTY AXLE MAY CONSULT MANUFACTURER VARY) INSPECT LEAKS *14 FOR IN X PACKER REMOTE GREASE LINES INSPECT 15 HYDRAULIC OIL X LEVEL IN TANK *Denotes option or not all units **Unit may be fitted with a driveline which does not require grease Part #: 90309 13
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS 2.
ITEM 21 DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS OTHER: *DENOTES OPTION OR NOT ALL UNITS O = OPERATOR M = MAINTENANCE ITEM DESCRIPTION MONTHLY 1000 HRS 3. MECHANICAL INSPECTION (TRUCK AT REST) INSPECT FOR DISTORSION, CRACKS, AND/OR UNUSUAL WEAR. ENSURE MOUNTING AND PIN RETAINER BOLTS ARE INTACT AND TIGHT.
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS SERVICE HOIST CYLINDER *25 MOUNTING ON BOLTS CHASSIS O M O M (QTY.
ITEM 31 DESCRIPTION FORK ASSEMBLY PRE-TRIP AT LANDFILL DAILY WEEKLY O M O M O M O M MONTHLY 1000 HRS FORK 32 ASSEMBLY MOUNTING BOLTS (4) FORK 33 PIVOT TUBE COLLARS (2) FORK CYLINDER 34 EARS (4), PINS (4), AND RETAINING HARDWARE RESIDENTIAL *35 CARRY CAN AND MOUNTING O M HARDWARE FRONT HEADER 36 ASSEMBLY O M INC.
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS PACKER 37 ASSEMBLY INC.
ITEM DESCRIPTION SIDE 42 PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS ACCESS DOOR O M O M ASSEMBLY CANOPY ASSEMBLY 43 AND EXTENSION HARDWARE 44 TOP DOOR ASSEMBLY TOP O M O M O M O M O M DOOR CYLINDER PINS 45 (2), EARS (2), AND RETAINING HARDWARE TOP DOOR U CYLINDER 46 BOLT AND RELATED NUTS/BOLTS 47 TAILGATE ASSEMBLY TAILGATE CYLINDER 48 EARS (4), PINS (4), AND RETAINING HARDWARE Part #: 90309 19
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS TAILGATE LATCH 49 (2), (2), ASSEMBLY PIVOTS AND PINS O M ROLLER (2) TAILGATE 50 SEAL AND O SEAL M RETAINER TAILGATE HINGE 51 EARS (2), PINS (2), O AND M RETAINING HARDWARE *52 TAILGATE SAFETY PROP O M SAFETY EQUIPMENT IS PRESENT? *53 (E.G. FIRE O EXTENGUISHER , FIRST AID KIT, ETC.
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS 4. OPERATION (MAIN CONTROLS) OBSERVE TRAVEL IS SMOOTH AND EVEN, SPEED IS NORMAL, CONTROLS ARE RESPONSIVE.
ITEM 61 DESCRIPTION PRE-TRIP SERVICE HOIST AT LANDFILL DAILY WEEKLY MONTHLY O UP/DOWN 1000 HRS M PERFORM SAFETY LOCKOUT TESTS TO CHECK PROXIMITY/LIMIT SWITCHES SIDE ACCESS DOOR 62 TEST (SIDE ACCESS LIMIT/ DOOR O M O M O M O M PROXIMITY SWITCH) PACK TEST (PACKER 63 FULLY EXTENDED PROXIMITY SWITCH) AUTOPACK (PACKER TEST 64 FULLY EXTENDED PROXIMITY SWITCH) PACK LOCKOUT/ TAILGATE TEST *65 (TAILGATE UNLOCKED PROXIMITY SWITCH) 22 Part #: 90309
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS PACK/AUTOLOCK- PACK OUT/ARMS 66 TEST (ARMS ELEVATED O M O M O M PACK CUTOUT PROXIMITY SWITCH) ARMS UP LOCKOUT/ HOPPER 67 DOOR TOP TEST (HOPPER TOP DOOR PROXIMITY SWITCH) ARMS UP LOCKOUT/ PACKER 68 TEST (PACKER FULLY RETRACTED PROXIMITY SWITCH) 69 OTHER *Denotes option or not all units O = Operator M = Maintenance Part #: 90309 23
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS 5. OPERATION (MISC. CONTROLS AND FEATURES) CHECK CONTROL CONSOLE WARNING DEVICES ARE FUNCTIONNING.
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS ARMS 75 ELEVATED O WARNING O M LAMP SERVICE HOIST *76 BODY RAISED O WARNING M LAMP/BUZZER CHECK EXTERNAL LAMPS AND MISCELLANEOUS ARE FUNCTIONING *77 AUXILIARY CONTROLS O M O M O M O M O M O M STOP, SIGNAL 78 AND TAIL LAMPS 79 80 81 82 Part #: 90309 MARKER LAMPS HOPPER LAMP BACKUP LAMPS BACKUP FLOOD LAMPS 25
ITEM 83 84 85 86 DESCRIPTION STROBE LAMP CAMERA DUAL LAMPS ALTERNATING FLASHERS BACKUP ALARM PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS O M O M O M O M O M GLOBAL *87 MOTION SENSORS CHECK MISCELLANEOUS CONTROL CONSOLE DEVICES ARE FUNCTIONNING THROTTLE 88 ADVANCE O M O M O M SWITCH ARMS *89 ACTIVATED AUTOPACK SWITCH *90 *91 26 FORK WIDTH SWITCH WASH TANK O M Part #: 90309
ITEM 92 DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS OTHER: *Denotes option or not all units O = Operator M = Maintenance ITEM DESCRIPTION 6. HYDRAULIC SYSTEM HYDRAULIC OIL TANK: CHECK 93 FOR LEAKS, DAMAGE, ETC.
ITEM 96 97 DESCRIPTION CHECK PRE-TRIP OIL CONDITION O AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS M REPLACE OIL (MORE OFTEN IF REQUIRED) M CHECK 98 SUCTION BALL IS VALVE O M FULLY OPEN CLEAN THE BREATHER 99 CAP (REPLACE M IF NECESSARY) (MORE OFTEN IF REQUIRED) CLEAN SUCTION STRAINER WITH VARSOL/ 100 M COMPRESSED AIR IF (REPLACE DAMAGED) (MORE OFTEN IF REQUIRED) TO PROTECT THE HYDRAULIC COMPONENTS OF YOUR NEW EQUIPMENT, THE RETURN LINE FILTER MUST BE CHANGED AFTER THE 50 F
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS CHANGE HYDRAULIC 101 LINE RETURN M (NEW UNIT) FILTER OIL M (MORE OFTEN IF REQUIRED) CLEAN MAGNETIC 102 PLUG (MORE M IF OFTEN REQUIRED) PUMP: 103 INSPECT PUMP FOR LEAKS O M ENSURE PUMP 104 IS O SECURELY M MOUNTED ENSURE 105 DRIVELINE IS M SECURELY MOUNTED HYDRAULIC VALVE BANK: INSPECT 106 VALVE BANK O M FOR LEAKS Part #: 90309 29
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS ENSURE 107 VALVE BANK IS SECURELY O M MOUNTED CHECK SYSTEM PRESSURE RELIEF VALVE(S) 108 SETTINGS. ADJUST IF M REQUIRED. (USE PRESSURE GAUGE. RECORD.) CHECK ARMS DOWN PRESSURE RELIEF VALVE SETTINGS. *109 ADJUST IF M REQUIRED. (USE PRESSURE GAUGE. RECORD.
ITEM DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS MISCELLANEOUS: INSPECT ALL HYDRAULIC 110 FOR LINES O M O M LEAKS, CHAFING INSPECT ALL HYDRAULIC CYLINDERS 111 AND MISC. HYDRAULIC COMPONENTS FOR LEAKS CHECK PACK CIRCUIT PRESSURE 112 M SWITCH SETTING. ADJUST IF REQUIRED.
ITEM 114 DESCRIPTION PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS OTHER: *Denotes option or not all units O = Operator M = Maintenance ITEM DESCRIPTION 7.
ITEM DESCRIPTION LIGHTLY 119 AIR PRE-TRIP AT LANDFILL DAILY WEEKLY MONTHLY 1000 HRS OIL M ACTUATORS 120 Part #: 90309 OTHERS: 33
ELECTRICAL SYSTEM The electrical system is divided into two sections. The first section describes how the electrical components work and the second section describes how to adjust and repair the electrical components. Wittke offers two different electrical systems. One is controlled by relay logic and the other one is controlled by an electronic controller (optional). Both systems are equivalent. The only difference between both of them is the control box located inside 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. • Circuit breakers: Manual reset breakers protect systems from excessive current.
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.
CIRCUIT BREAKERS AND FUSES 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 FUNCTION AMPS LOCATION MAIN BATTERY POWER (2) 30 FITTED IN THE BATTERY BOX AMPS TO EACH POWER SUPPLY PROTECT RELAY BOX Manual Reset Circuit Breakers Push the in-cab relay box’s circuit breaker button to reset these circuits. CAUTION NEVER HOLD A CIRCUIT BREAKER BUTTON DOWN WHEN IT REFUSES TO RESET.
FUNCTION AMPS LOCATION MAIN CONTROL 10 CIRCUIT AMPS IN-CAB RELAY BOX (F2) PROXIMITY/ LIMIT SWITCH SENSORS 10 AMPS IN-CAB RELAY BOX (F1) HOPPER/ MIRROR LAMP SWITCHES 10 AMPS IN-CAB RELAY BOX (F3) MONITOR (F4) STROBE LAMP/ ALTERNATING FLASH- ING LIGHTS/ 10 AMPS IN-CAB RELAY BOX 15 AMPS IN-CAB RELAY BOX BACKUP (F5) LIGHTS 38 Part #: 90309
ADJUSTING THE PROXIMITY/LIMIT SWITCH SETTINGS Proximity/limit switches act as remote electrical on/off switches. CAUTION PROXIMITY/LIMIT SWITCHES MUST FUNCTION PROPERLY. SERIOUS DAMAGE OR DEATH MAY RESULT IF YOU OPERATE THE FRONT LAODER WITH IMPROPERLY ADJUSTED PROXIMITY SWITCHES.
Proximity Switches on the Street Side Forks fully retracted proximity switch Tailgate fully open proximity switch Top Door fully open proximity Packer proximity switches (2) Arm fully retracted proximity switch Tailgate unlocked proximity switch Body raised limit switch Proximity Switches on the Curb Side Side access door limit/proximity switch Arm partially raised proximity switch 40 Part #: 90309
LEVER ARM LIMIT SWITCHES General adjustment procedure: 1. Loosen limit switch nut. 2. Move lever arm to approximate position where limit switch is to trip. 3. Tighten nut. 4. To fine tune limit switch, loosen nut slightly. 5. With a flathead screwdriver, turn the adjusting screw located at the center of the nut until a click is heard. 6. Tighten the nut. 7. Test operation; repeat steps 1 to 7 if necessary.
PACKER FULLY RETRACTED PROXIMITY SWITCH 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. Location: This proximity switch is mounted on the front wall of the body, on the street side.
PACKER FULLY EXTENDED PROXIMITY SWITCH 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 THIS PROCEDURE MUST BE PERFORMED BY TWO PEOPLE. Testing procedure: 1. Empty all refuse from the body. 2. Initiate a pack cycle and observe the fully extended position of the packer.
reaches this position. Ideally, there should be a gap of 3/8 inch between the proximity switch and its target. 3. 44 Test the packer for a full cycle.
SIDE ACCESS DOOR LIMIT SWITCH 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. Testing procedure: 1. Open the side access door approximately 2 inches (5 cm) and attempt to operate any hydraulic function. All hydraulic functions should be disabled.
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. It also illuminates the Top door warning lamp on the control console. Proximity switch Target Towards cab Location: The Top door fully open proximity switch is located on the street side, on rear part of the top door. Adjustment procedure: 1. Fully open the hopper top door. 2. Turn off the hydraulic pump and the engine. 3. Climb on the roof.
4. 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. TAILGATE FULLY OPEN PROXIMITY SWITCH Proximity switch target The tailgate fully open proximity switch allows you to enable the ejection cycle when the tailgate is fully open.
To perform the adjustment, the center of forks pivot must be at the same height as the center of the canopy hinge 0 2. Adjust the target so it activates the proximity switch. Arm partially raised proximity 3. 48 Target Make sure that the proximity switch detects the target on all the detection zone shown below.
DETECTION ZONE Part #: 90309 4. Once the proximity switch and the target are adjusted, lower the arms. 5. Start the packer. 6. While the packer is in motion, raise the arms. They should stop at mid-height. 7. If it is not the case, readjust the proximity switch and its target.
ARMS AND FORKS FULLY RETRACTED PROXIMITY SWITCH 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. Location: The Arms fully retracted proximity switch is located on the arm pivot tube (between cab and body), on the street side.
Adjustment procedure: 1. Part #: 90309 Raise the arms until there is 57 3/8 inches between both cylinder attachments (center to center).
2. Adjust the target so it activates the proximity switch. (proximity switch light on). Arms fully retracted proximity switch Target 3. Lower the arms. 4. Retract the forks until there is a distance of 31 inches between both fork cylinder attachments (center to center). 31” 52 5. Adjust the target so it activates the proximity switch (proximity switch light on). 6. Perform tests to see if the Arm not stowed warning lamp reacts properly when the forks or the arms are not fully parked.
7. 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. BODY RAISED LIMIT SWITCH (OPTIONAL) A limit switch located on the truck chassis activates the backup alarm, and a warning buzzer sounds as soon as the body is about one foot above the chassis. Adjust the limit switch accordingly (refer to “Lever Arm Limit Switches” on page 41).
PNEUMATIC SYSTEM HOW THE PNEUMATIC SYSTEM WORKS 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. The system runs at approximately 120 psi. Filter System The chassis air supply is filtered before it is used in the control circuit. Two filters are fitted on the street side.
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. ? Note:The arms up and main joystick’s air lines are the only lines with a cutout valve.
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. Supply air from the chassis air tank passes through the filters then feeds the air valves in the valve box.
Valve Box Air Valves ARMS UP CUTOUT TIPPER UP ARM CYLINDERS CYCLES TIPPER ACTUATOR UP TIPPER DOWN MAIN CUTS AIR USED TO RETRACT THE JOYSTICK CUTOUT CYCLES TIPPER ACTUATOR DOWN DISABLES JOYSTICK OPERATION 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. The air actuators are dedicated to a particular hydraulic function and influence the direction in which the valve spool is moved.
PNEUMATIC SYSTEM SCHEMATICS Each WITTKE truck is provided with its specific pneumatic schematic. For more details on the pneumatic system of your unit, refer to this schematic.
5-section Hydraulic Valve with Auxiliary Controls Part #: 90309 59
HYDRAULIC SYSTEM HYDRAULIC OIL TANK 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. It is critical to inspect the breather cap for cleanliness and serviceability on a regular basis. A ball valve is provided in the suction line in order to isolate the tank during maintenance.
RETURN LINE FILTER 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. RETURN LINE FILTER 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.
ELEMENT REPLACEMENT PROCEDURE 1. ? 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. Oil tray 2. Loosen the 4 cover plate bolts using a ½-inch wrench, rotate through 45° and lift off. 3. Use an oil tray to pick up oil. 4.
HYDRAULIC OIL 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. Laboratory analysis is an effective method of obtaining accurate information on the cleanliness of hydraulic oil.
DIRECTIONAL CONTROL VALVE Pressurized oil is directed from the hydraulic pump to a bank of stack-type directional control valves mounted on the front header of the WITTKE body. Rubber gaskets seal each valve section. The valve bank on a commercial unit is comprised of: a 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. The pressure test port is located at the front of the inlet section.
WORK CIRCUITS 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. 1. Hopper Top Door Circuit: The hopper top door circuit includes one double-acting hydraulic cylinder and two flow restrictors. 2. Tailgate Circuit: The tailgate circuit consists of two double-acting hydraulic cylinders, one lock valve and two flow restrictors. 3.
4. ? 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. 5. 66 Lower and raise the arms while running the engine at idle speed and again while running the engine at 1500 rpm. If the arms reach the stops with jarring impact or the arms stop before reaching the arm stops: a Loosen one retaining bolt and tap the cam in the required direction. b Tighten the retaining bolt of the cam and repeat step 4. 6.
PACK CIRCUIT DUMP VALVE 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. The dump valve is non-adjustable.
? ? Note:Leave the pressure gauge in place. 2. Locate the pressure switch and remove the cap screw plug. 3. Insert the allen wrench into the adjustment screw. 4. 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. Note when the packer begins the return cycle.
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 ALWAYS SET THE TIME SCALE TO 1. To adjust the timer: Part #: 90309 1. Open relay box. 2. Adjust the potentiometer to set up the timer.
TAILGATE LOCK VALVE U2 U1 D2 D1 Velocity fuse Main relief 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.
SERVICE HOIST (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 THE SERVICE HOIST IS NOT INTENDED TO LIFT A LOADED BODY. Adjustment procedure: ? Quick coupler Adjustment screw Part #: 90309 Note:Should adjustment be required, an adjustement screw is located on the side of the pump body, under the protective cover. 1.
ARMS DOWN WORK SECTION 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 TAMPERING 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.
Part #: 90309 a Loosen the retaining bolt. b tap the cam in the required direction. c Tighten the retaining bolt of the cam and repeat step 4. 6. Attach a container or carry can to the forks and repeat step 4 and step 5. 7. 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. 8. Tighten the locking setscrew.
MAIN SYSTEM PRESSURE ADJUSTMENT 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 (STARLIGHT™) or 2750 psi (SUPERDUTY™). Adjustment procedure: 1. Remove the cap on the quick coupler located at the top of the main valve bank. Insert a 0-3000 psi pressure gauge. 2.
HYDRAULIC HOSE 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.
HYDRAULIC SYSTEM SCHEMATICS Each WITTKE truck is provided with its specific hydraulic schematic. For more details on the hydraulic system of your unit, refer to this schematic.
Valve with Pneumatic Control – 2 Deceleration Valves on Forks Part #: 90309 77
Hydraulic Diagram Auto-dump with One Deceleration Valve 78 Part #: 90309
Hydraulic Diagram Auto-dump with Two Deceleration Valves Part #: 90309 79
PACKER MAINTENANCE The WITTKE packing system has a heavy duty guiding system 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.
To replace packer wear plates: 1. Remove the packer (refer to “Packer Removal Procedure” on page 84). 2. Remove the wear plates from the packer by cutting the welds. 3. Verify corresponding wear plates under guiding tracks. 4. Install new wear plates on packer. 5. Reinstall packer in the unit.
BODY GUIDE WEAR PLATES REPLACEMENT DANGER APPLY THE LOCKOUT/TAGOUT PROCEDURE AT ALL TIMES. FAILURE TO DO SO MAY RESULT IN SEVERE INJURY OR DEATH. To replace body guide wear plates: 82 1. Remove the packer (refer to “Packer Removal Procedure” on page 84). 2. Retract the packer cylinders and move them out of the way. 3. Remove body wear plates by grinding or cutting the stitch welds attaching plates to guide. 4. Clean surfaces and install new plates by tacking them in place. 5.
6. Reinstall the packer.
PACKER REMOVAL PROCEDURE To remove the packer: Cylinder pin bolts (4) 1. Start the engine and hydraulic system. Bring the packer to the rear end of the body (full eject) to easily access the pins.. 2. Stop the engine and turn off the hydraulic pump. 3. Enter the hopper and remove the grease fitting hoses (on each cylinder). Grease fitting hoses 4. Remove the packer end cylinder pin bolts (4 on each pin). 5. Secure both cylinders to keep them from falling on the body floor. 6.
Packer at the rear end of the body PACKER CYLINDER REPLACEMENT CAUTION USE AN APPROPRIATE LIFTING DEVICE TO REMOVE CYLINDERS. To replace packer cylinders: Part #: 90309 1. Fully extend the packer. 2. Stop the engine and turn off the hydraulic pump. 3. Enter the hopper and remove the grease fitting hoses (on each cylinder).
Grease fitting hoses Front header end cylinder pin bolts 86 4. Remove packer end cylinder pins. 5. Secure both cylinders to avoid them falling on the body floor. 6. Get out of the hopper and close the side access door. 7. Start the engine and turn on the hydraulic pump. 8. Retract packer cylinders. 9. Remove hoses and front header end pins from both cylinders. 10. To reinstall cylinders, perform the reverse procedure.
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.
