Wittke FEATHERWEIGHT Maintenance Manual Download Page 119

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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

ITTKE

™ body (see Figure 7

27) or on the left-hand side,

mid-section body wall (see Figure 7

28). Rubber gaskets seal each valve section.

OTE

The left-side mounted main valve is protected by a protective cover.

Figure 7

27 Main valve (front mounted)

Figure 7

28 Main valve (left-side mounted)

The main valve powers all body functions (tailgate, arms, packer, etc.).
The valve bank on a commercial unit is comprised of the following:



The 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. Remove the cap on the quick coupler (see Figure 7

29) and install a pressure gauge to

read the system operating pressure.

Air control box

Protective cover

Main valve

Summary of Contents for FEATHERWEIGHT

Page 1: ...STARLIGHT SUPERDUTY MAINTENANCE MANUAL FEATHERWEIGHT ...

Page 2: ......

Page 3: ...STARLIGHT SUPERDUTY FEATHERWEIGHT MAINTENANCE MANUAL ...

Page 4: ...tion 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 Although careful precaution has been taken in the preparation of this document Labrie Enviroquip Group assumes no responsibility for errors or omissions January 2021 ...

Page 5: ......

Page 6: ......

Page 7: ...nsibilities 10 Things to Do 11 Things to Avoid 11 General Precautions 12 Fire 13 Safety Kits 14 Safety and Informative Decals 14 Safety Features 14 Centralized Grease Block 14 Global Motion Sensors Optional 14 Back Up Alarm 14 Service Hoist Safety Props optional 15 Tailgate Safety Prop 18 Securing Tailgate Safety Pins 20 Locking Out and Tagging Out the Vehicle 21 Shutting Down the Vehicle 23 Prior...

Page 8: ...lgate Unlocked Proximity Switch 52 Tailgate Fully Open Proximity Switch 53 Arms Partially Raised Proximity Switch 53 Arms and Forks Fully Retracted Proximity Switch 55 Body Raised Limit Switch optional 58 Multiplex System Related Interventions 59 IFM Program Update Process 59 J1939 Baud Rate 61 Checking Control Module Node Supply Voltage 63 Pneumatic System 65 How the pneumatic system works 65 Air...

Page 9: ...ptional 113 Pack Circuit Dump Valve 114 Tailgate Holding Valve 115 Service Hoist optional 117 Arms Down Work Section 118 Main System Pressure Adjustment 118 Hydraulic Hose 121 Pressure and Cycle Time Table 121 Hydraulic System Schematics 123 Packer Maintenance 129 Replacing Packer Wear Plates 129 Replacing Body Guide Wear Plates 130 Packer Removal 131 Replacing Packer Cylinders 133 Multiplexing 13...

Page 10: ...viii Table of Contents ...

Page 11: ...acking accident prevention systems For these options refer to the appropriate manufacturer s service manual Operating the WITTKE For procedures related to the operation of the WITTKE please refer to the Operator s Manual Parts and assemblies For parts and assemblies that make up the WITTKE and for their respective part number for ordering purposes please refer to the WITTKE Parts Manual About the ...

Page 12: ...ommercial waste Some trucks can be supplied with a carry can equipped with either a tipper or an automated arm to perform residential collection Body s main components are the packer the tailgate and the swing arms and forks The tailgate is the rear door that prevents refuse from exiting the body during collection At landfill the tailgate is raised to allow the discharge of the refuse that has bee...

Page 13: ...parts need regular maintenance and routine check up to prevent signs of deterioration as soon as possible NOTE Any time you have a problem with a Labrie unit you should contact your Labrie authorized dealer first They should be able to provide you with the proper help that you need whether it is for parts or technical service In this manual you will find the most common maintenance and inspection ...

Page 14: ... listed below 1 Packer Wear Shoes and Guides One of the most commonly overlooked wear items involves the packing system The packer wear strips and floor guides have a life which requires proper maintenance Improperly maintained packers can result in but are not limited to holes worn in the floor liner and or floor itself binding of the packing assembly due to uneven wear against the hopper side wa...

Page 15: ...maintenance of the hydraulics will ensure long trouble free life As directed in all service training the hydraulic filter needs to be replaced after the initial 50 hours of new truck operation and then again every 6 months or when the filter restriction gauge is in the yellow The hydraulic fluid needs to be replaced once a year along with the suction screen being removed inspected cleaned and or r...

Page 16: ...bes valves or pumps Leaks in the hydraulic system are an indicator of possibly overheating hydraulics damage to a seal over pressurization or general wear To avoid costly and premature replacement of parts ensure all leaks are addressed properly and timely 8 Cracks Ensure that there are not any cracks forming along the hopper floor edge body tailgate arms and forks This is an indicator that someth...

Page 17: ...nada Address 175A Route Marie Victorin Levis QC G7A 2T3 Toll Free 1 877 831 8250 Telephone 1 418 831 8250 Service Fax 1 418 831 1673 Parts Fax 1 418 831 7561 Parts and warranty During business hours 8 00 AM to 5 00 PM Eastern Standard Time Technical Support Service Available 24 hours Website www labriegroup com E mail sales labriegroup com IMPORTANT For technical support and parts ordering the ser...

Page 18: ...8 Introduction ...

Page 19: ...nic s responsibility He must heed all safety notions explained in this manual as well as warning decals placed on the truck Danger Indicates a hazardous situation which if not avoided will result in serious injury or death Warning Indicates a hazardous situation which if not avoided could result in serious injury or death Caution Indicates a hazardous situation which if not avoided may result in m...

Page 20: ...akdowns and malfunctions as well as any inspection and maintenance To ensure that all failures or malfunctions that may be affecting the safe use of the vehicle are repaired before the vehicle is put back into operation To make sure that the backup alarm works properly when the vehicle is in reverse To take necessary measures to correct any damage or malfunction reported by an employee To establis...

Page 21: ...pped with a service hoist system Always use the tailgate safety prop before entering the area between the main body and the tailgate Obey all warning and operation stickers Things to Avoid Do not operate or service any vehicle while under the influence of alcohol narcotics or other intoxicants Do not talk on a cell phone or listen to loud music while driving Do not wear jewelry or loose clothing D...

Page 22: ...TANT In such cases Labrie Enviroquip Group must be informed of every and all units that will be operated by more than one worker Labrie Enviroquip Group will then determine and supply at the customer s expense the required safety items Foradditional information please contact LabriePlus at 1 877 831 8250 in Canada or 1 800 231 2771 in the U S Do not operate this vehicle if there are any signs of d...

Page 23: ...ll people and obstructions are sufficiently cleared from the lifting arms before moving them Failure to do so may result in unit and or property damage personal injury or death Warning Make sure there is enough clearance between a raised container and overhead power lines The lifting arms or the container must not come in direct contact with the electrical cables for the power to go through the un...

Page 24: ...d the WITTKE Keep your decals clean and in good condition at all times For replacement decals please call LabriePlus Decals may vary from one unit to another depending on the options and features installed on the unit For an illustrated list of decals pertaining to most WITTKE units refer to the WITTKE Operator s Manual Safety Features Centralized Grease Block Refer to Centralized Grease Block on ...

Page 25: ...t safety props To set the service hoist safety props 1 Make sure that there is enough clearance above the body to raise it safely and that the truck is on safe level ground 2 Put the key to the ON position without starting the truck 3 Unlatch the 2 front body latches see Figure 2 3 Before unlatching them measure the length of the spring Spring should be between 3 25 and 3 5 long Warning Always unl...

Page 26: ... 2 4 and holding it until the body reaches the desired height IMPORTANT Do not raise the body higher than is required for the props Figure 2 4 Service hoist joystick 5 Release one of the safety props by pulling its latch towards you see Figure 2 5 and position the prop adequately see Figure 2 2 The safety prop must take place around the cylinder rod Bolt Spring Locknut Frame rail ...

Page 27: ...1 Make sure that there is enough clearance above the body to raise it safely and that the truck is on safe level ground 2 Put the key to the ON position without starting the truck 3 Raise the body until both safety props can move freely 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 4 Put one of the safety props ...

Page 28: ...y prop 1 Make sure that the body is empty 2 Remove the tailgate locking safety pins Figure 2 6 Safety pin in storage position left in locking position right 3 Start the engine 4 Turn ON the pump 5 With the TAILGATE UP Switch on the in cab control panel raise the tailgate until the safety prop can swivel into service position see Figure 2 7 Danger The tailgate safety prop shall be set each time the...

Page 29: ...cab control panel Putting theTailgate Safety Prop Back in Place To put the tailgate safety prop back in its home position 1 Start the engine 2 Turn ON the pump 3 Raise the tailgate until the prop can move freely 4 Raise the tailgate safety prop see Figure 2 8 Danger Stand clear of the tailgate path while setting the safety prop Danger Stand clear of the tailgate path while putting the safety prop ...

Page 30: ...he tailgate completely The TAILGATE OPEN light indicator should turn off 7 Put the safety pins back in place Securing Tailgate Safety Pins The tailgate safety pins ensure that the tailgate can not be open accidentally These pins must be in place unless you are unloading refuse or servicing the tailgate Remember these two critical points Before operating the WITTKE secure the tailgate with both saf...

Page 31: ...ing done on the vehicle whether on the road or at the shop it is the employer s responsibility to establish and see to the application of a proper lockout and tagout procedure To lock out and tag out a WITTKE vehicle 1 Park the vehicle on safe level ground and apply the parking brake see Figure 2 12 Warning Any vehicle with a tailgate not properly secured by a manual locking device e g tailgate sa...

Page 32: ... master switch IMPORTANT The battery set of the WITTKE is equipped with a master switch see Figure 2 13 that must be turned off Figure 2 13 Master switch 6 Chock all wheels 7 Put an OFF SERVICE tag on the driver s wheel and on the front windshield 8 Use safety props to block any system that could move by gravity open tailgate raised body etc 9 Drain all air tanks 10 Verify and inspect any security...

Page 33: ...s packer etc 3 Turn OFF in sequence the hydraulic pump see Figure 2 17 the electrical system the engine and the master switch see Figure 2 13 4 Drain the air tanks and the air filter assembly Figure 2 14 Drain valves on air tanks left and air filter assembly right Prior to Start Up Before starting the vehicle 1 Make sure no system will engage and or start to operate as you start the engine 2 Make ...

Page 34: ... Air pressure indicator IMPORTANT Do not operate or move the vehicle until the air pressure has reached 70 PSI 4 Engage the hydraulic system by switching ON the Pump ON OFF switch on the in cab control panel see Figure 2 17 Figure 2 17 Hydraulic pump ON OFF switch 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 ...

Page 35: ...lace a properly rated lift sling in the middle of the fork pivot tube Complete job then reconnect Keep the sling in place while you repressurize the system NOTE If both arm cylinders are replaced move the joystick back and forth in gradually increasing increments This will help distribute the oil evenly within the cylinders and prevent the arms from falling Lifting the Front Section of the Body Li...

Page 36: ... clearance before lifting the body 6 Raise the body front section Do not raise this section more than 28 inches high 7 Install proper safety props before performing maintenance under a lifted body Warning Always set proper lifting devices and safety props before performing any maintenance work under a lifted body Failure to do so may result in severe injury or even death ...

Page 37: ...le overhead crane to lift both sections of the WITTKE body is possible but you have to make sure of its lifting capacity taking into account the whole weight of the body to be lifted Lifting procedure 1 Perform steps 1 5 of the procedure for Lifting the Front section of the body see Lifting the Front Section of the Body on page 25 2 Install an appropriately rated shackle through each hole located ...

Page 38: ...ntly been put into service and the system requires adjustment following a run in period Please take note of the following Mechanics must have previous hydraulic knowledge as serious injury or death can result from following improper procedures Human skin can be easily penetrated by high pressure oil 2000 PSI and above Failure to take appropriate safety precautions may result in serious injury or d...

Page 39: ...nformation 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: ...ll find below the recommended types of lubricants Grease Any lithium based commercial multipurpose grease may be used Hydraulic Oil The most crucial element to the hydraulic system is the hydraulic oil It provides the system with vitality The oil transports damaging contaminants to filtering systems lubricates and provides anti wear protection against component corrosion Regular oil changes are vi...

Page 42: ...n ISO 22 might be more appropriate The International Standards Organization ISO assigns specification numbers in order that a consumer receives the same product from different suppliers Other important points to note The oil must contain anti wear and anti foam additives rust and oxidation neutralizers and self protecting agents It must also meet MIL H 5606 or SAE IOW MS standards The oil must be ...

Page 43: ...d 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 Figure 3 2 Standard grease fittings on back of packer blade ...

Page 44: ...igure 3 3 Standard manual grease fittings front end cylinder pins Figure 3 4 Optional remote grease fittings front end cylinder pins Optionalgreasefittings for front header end of packer cylinders on hopper access door ...

Page 45: ...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 Figure 3 5 Lubricating packer rails Lubricant spray Spray all lubricant on both rails mainly on the packing stroke area ...

Page 46: ...36 Lubrication ...

Page 47: ...to anticipate and prevent operational difficulties before they require extended shutdown for costly repairs Operating and Maintenance Records Prepare and adhere to a maintenance schedule Keep detailed records of all maintenance performed Regularly inspect operating and maintenance records for deviations from normal operating conditions Analyze the records for indications of potential trouble NOTE ...

Page 48: ...rrosion X Keep the contact surfaces clean between the body and the chassis X Wash body and chassis X Canopy assembly Do a visual inspection X Debris in front of packer and inside hopper Remove debris X Debris on tailgate seal Remove debris X Fork assembly and retaining hardware Do a visual inspection of these components X Fork cylinders and fittings Do a visual inspection of these components X For...

Page 49: ...prox switches X Lubrication See Lubrication Chart on side of truck Mirrors lamps windows camera Check for cleanliness clean if required X Mounting bolts body hinges springs Do a visual inspection of these components X Operator s controls arms forks packer tailgate top door Check for proper operation X Packer remote grease lines Inspect for leaks X Packing system Do a visual inspection of the follo...

Page 50: ...nd retaining hardware optional Do a visual inspection of these components X Side access door assembly Do a visual inspection X Tailgate assembly Do a visual inspection X Tailgate latch assembly Do a visual inspection X Tailgate safety prop Do a visual inspection X Tailgate seal Do a visual inspection X Top door optional Check for proper operation X Top door assembly optional Do a visual inspection...

Page 51: ...ovided as part of the WITTKE documentation package located inside the cab The electrical schematics show how components are wired to each other These schematics are useful when diagnosing electrical circuits and should be kept for future reference How the Electrical System Works The electrical system includes the following components Control panel Electronic controllers Harnesses Valve controls Li...

Page 52: ...troller enables mechanics to perform troubleshooting which facilitates the debugging process Labrie Enviroquip Group offers training on this technology To learn more about multiplex electronic controllers and training schedule please call LabriePlus Proximity switches control packer tailgate arm and fork operations and provide the means for safety lockouts Limit switches are used where there is la...

Page 53: ... The 40A circuit is subdivided into 2 secondary circuits 10A and 30A which are protected by in line fuses Figure 5 1 Circuit schematic Ignition relay box Figure 5 2 Ignition relay box with without cover NOTE When a fuse blows always replace it with a fuse of the same kind and same amperage Fuses 30A and 40A are protected by a plastic cover see Figure 5 3 Just remove that plastic cover to gain acce...

Page 54: ...installed 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 Figure 5 5 Circuit breaker Caution Never hold down the reset button when the reset operation fails This may result in severe electrical damage Report this problem to your supervisor and maintenance department Plastic cover Fuses ...

Page 55: ...y extended proximity switch Side access door proximity switch Top door fully open proximity switch optional Tailgate unlocked proximity switch Tailgate fully open proximity switch Arms fully retracted proximity switch Arms partially raised proximity switch Forks fully retracted proximity switch Body raised limit switch optional To know exactly where these switches are located on the truck see Figu...

Page 56: ...46 Electrical System Figure 5 6 Limit proximity switches streetside view Figure 5 7 Limit proximity switches curbside view ...

Page 57: ... flathead screwdriver turn the adjusting screw located at the center of the nut until a click is heard 6 Tighten up the nut 7 Test the operation 8 If necessary repeat steps 1 through 7 NOTE Limit switches are optional Proximity Switch Adjustment To adjust the proximity switch 1 Loosen the proximity switch nuts 2 Adjust the proximity switch so that there is a gap of approximately 3 16 inch 4 8 mm b...

Page 58: ...dy on the street side IMPORTANT This procedure must be performed by 2 people Testing procedure 1 Empty all refuse from the body 2 Initiate a pack cycle and observe the home position of the packer when the cycle completes 3 Adjust the Packer Fully Retracted proximity switch if The packer stops before reaching the fully home position The packer cylinders remain pressured up or abruptly bottom out at...

Page 59: ...all of the body on the street side IMPORTANT This procedure must be performed by 2 people Testing procedure 1 Empty all refuse from the body 2 Initiate a pack cycle and observe the fully extended position of the packer 3 Adjust the Packer Fully Extended proximity switch if The packer stops before or after reaching the fully extended position see illustration below Adjustment procedure 1 Move the p...

Page 60: ...access door is not closed Figure 5 10 Side Access Door proximity switch Location The Side Access Door proximity 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 2 If all hydraulic functions are not disabled the proximity switch is faulty and mus...

Page 61: ...imity switch which sends a signal to the in cab control panel to turn the Roof Open switch s light green Location The Top Door Fully Open proximity switch is located on the streetside edge of the body roof just above the rear end of the top door when fully open see Figure 5 12 Figure 5 12 Top Door Fully Open proximity switch Adjustment procedure 1 Fully open the hopper top door 2 Turn OFF the hydr...

Page 62: ...letely closed This proximity switch also disables packing Location The Tailgate Unlocked proximity switch is located on the street side of the tailgate near the tailgate cylinder Figure 5 13 Tailgate Unlocked proximity switch Adjustment procedure 1 Make sure that the tailgate is closed and locked 2 Fix the Tailgate Unlocked proximity switch in such a way that it faces and detects the tailgate cyli...

Page 63: ...e tailgate hinge Figure 5 14 Tailgate Fully Open proximity switch Adjustment procedure 1 Fully open the tailgate 2 Adjust the Tailgate Fully Open proximity switch so that it can detect the target see Figure 5 14 The Tailgate Up switch on the control panel should be green lighted NOTE When the tailgate is unlocked both the in cab buzzer and the backup alarm sound Also a red warning light located at...

Page 64: ...eencab andbody on the curb side Figure 5 15 Arms Partially Raised proximity switch Adjustment procedure 1 Raise the arms until the center of the fork pivot is at the same height as the center of the canopy hinge 2 Adjust the target so that it triggers the proximity switch amber light on Target Canopy Fork tube ...

Page 65: ...le the packer is in motion raise the arms These should stop at mid height on their way up 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 Arms Not Stowed switch on the control panel is red lighted if the arms are not completely retracted Both arms and forks must be comple...

Page 66: ...h on the control panel is red lighted if the forks are not completely retracted Both arms and forks must be completely retracted for the Arms Not Stowed switch to be green lighted Location The Forks Fully Retracted proximity switch is located on the curb side fork see Figure 5 17 Figure 5 17 Forks Fully Retracted proximity switch Adjustment procedure 1 Raise the arms until there is a distance of 5...

Page 67: ...Adjust the target so that it triggers the proximity switch amber light on switch should be on 3 Lower the arms 4 Retract the forks until there is a distance of 31 inches between both fork cylinder attachments center to center ...

Page 68: ...ghted if the forks or the arms are fully retracted 7 If the Arm Not Stowed switch does not react properly readjust both proximity switches and their targets Body Raised Limit Switch optional Located on the truck chassis this optional limit switch activates the backup alarm and the in cab warning buzzer as soon as the body is about one foot above the chassis If needed adjust the limit switch accord...

Page 69: ...nstalled Place the vehicle ignition key in the on run position When the IFM display shows its home screen press the button below Menu on the IFM display The system MAIN MENU screen will appear Using the up down arrow on the IFM display module highlight Program Version and press the button below OK The current program and revision is listed next to Module 10 The program number should match the new ...

Page 70: ...rogram will result in it being lost when the revised program is installed Connect a PC with the CoDeSys program installed to the Labrie control console Turn the vehicle ignition to the on run position Open the IFM Download program on the PC Select the Identity tab to ensure that the PC is communicating with the Labrie IFM system Select the Upload tab A prompt will appear to name the program typica...

Page 71: ...rogramming the system or replacing node 10 the baud rate should be recorded prior to the work being performed then checked adjusted after the work is performed to match the previous setting Failure to do so may result in chassis fault codes To ensure the baud rate setting is correct and the chassis is communicating with the Labrie multiplex system it may be checked and adjusted using the Labrie mu...

Page 72: ...assis tachometer the baud rate most likely needs to be reset to 500 Kbps Effective early 2016 The Labrie system has been modified to allow changes to this value Using the directional pad select the SETTINGS option in the main menu and press OK Then highlight the J1939 BAUDRATE and press OK The baud rate may be changed by depressing either the left or right arrow on the directional pad to select 50...

Page 73: ...tic features of the IFM multiplex control system have been further enhanced supply voltages for the control modules Nodes may now be checked through the on board display as follows 1 Turn the ignition switch to the run position activating the IFM display 2 On the IFM display select Menu then select I O Status 3 Using the up down arrows on the directional pad scroll down and select Others 4 The rea...

Page 74: ...64 Electrical System ...

Page 75: ... filter system or air filter assembly and into the pneumatic valve box The system runs at approximately 120 PSI Figure 6 1 Air tanks Filter System The chassis air supply is filtered before it is used in the control circuit Two filters the water filter element and the coalescing filter or mist filter are fitted on the curbside of the chassis see Figure 6 2 Air supply is passed through an air filter...

Page 76: ...e the coalescing filter bowl helps capture particles in the air stream 3 Once both bowls have been completely drained screw back the two drain screws To change both filters of the air filter assembly do the following 1 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 21 2 Shut off the air supply and depressurize the unit before servicing 3 Unscrew the retaining ...

Page 77: ... one quarter turn counter clockwise Figure 6 3 Drain valves IMPORTANT Pay particular attention to the dryer cartridge On this type of equipment the compressor works all the time due to the frequent use of the brake system As a result a lot of moisture is injected into the air system For more information see Air Dryer below Air Dryer Some units are equipped with an air dryer and or alcohol evaporat...

Page 78: ...e Figure 6 5 mounted next to the driver The joystick operates at 90 and 45 angles For example you can lower the arms and forks simultaneously Figure 6 5 Pneumatic joystick NOTE The Arms Up and main joystick s air lines are the only lines with a cutout valve This cutout valve cuts air to the joystick and to the Arms Up function when the packer is not in the home position or when the top door is not...

Page 79: ...ottle advance switch or speed up is also provided to speed up the packing process and the raising lowering of the arms see Figure 6 6 Figure 6 6 Auxiliary controls Figure 6 7 Auxiliary control switch Speed Up Switch optional Located on the in cab control panel this switch see Figure 6 8 engages disengages the optional speed up feature which is used to increase the engine speed up to 1500 RPM whene...

Page 80: ...ank Power is required to energize the solenoid so that air can pass to the work section dedicated to that particular air valve NOTE On newer vehicles the pneumatic valve box may be located on the left hand side mid section body wall see Figure 7 28 Figure 6 9 Pneumatic valve box Air supply from the chassis air tank passes through the filters then feeds the air valves in the pneumatic valve box Exc...

Page 81: ... 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 Once the air supply is removed from the actuator the valve spool is centered by its spring and the actuator returns to the neutral position Figure 6 10 Air actuators Table 1 Valve commands Position Air valves 1 Tailgate Close 2 Ta...

Page 82: ... is receiving the proper air pressure To do this Install a 0 150 PSI air gauge in line with the pressurized line The gauge should read a minimum of 90 PSI Verify the opposite port of the air actuator is not plugged To do this Remove the air line from the air actuator and operate Verify that the air pressure inside the air actuator is not bypassing internally by following these simple steps Remove ...

Page 83: ...m those illustrated above Control System Pneumatic Pressure Switch All WITTKE products with a pneumatically controlled hydraulic valve incorporate an air pressure switch to provide confirmation that adequate air pressure is available to engage the hydraulics This is located inside the pneumatic valve box on the MAC valve manifold and is a normally open switch that closes at 90 PSI When this switch...

Page 84: ...ectly this pressure switch may provide intermittent operation due to debris blocking the intake port of the air pressure switch When installing a new pressure switch special care must be taken to ensure there are no contaminates introduced to the system that may affect operation of the pressure switch see Filter System on page 65 If contamination is suspected remove the air pressure switch from th...

Page 85: ...mp arm up arm down fork up and fork down functions When the auto dump cycle is started at ground level to dump a container the hydraulic valve shift rate is varied through the use of potentiometers programming and Speed Coils to control the speed and position of the arms and forks through their mid height full dump and return of the container to the ground The regulated pressures on the Speed Coil...

Page 86: ...hematics The following schematics are for illustrative purposes only and may differ from the actual schematics provided with your truck Air Schematic STD Single Joystick NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 87: ...Pneumatic System 77 Air Schematic Single Joystick Adjustable Forks NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 88: ...78 Pneumatic System Air Schematic Dual Joystick Curotto Container NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 89: ...Pneumatic System 79 Air Schematic Dual Joystick Dual Control NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 90: ...80 Pneumatic System ...

Page 91: ...ttings pipes or any other ingress points from dirt that would eventually get into the oil Plug hoses that are not connected Inspect the hydraulic system at least once a month and adjust pressure if necessary see Main System Pressure Adjustment on page 118 For new vehicles change the return filter element after 50 hours of use and twice a year afterwards see Element Replacement Procedure on page 10...

Page 92: ...re mandatory to change the return line filter and the hydraulic fluid and to clean the strainer as per the recommended maintenance schedule mentioned above Hydraulic fluid contamination will severely damage hydraulic components It is recommended to have the hydraulic fluid tested and analyzed by a lab to prevent hydraulic system or pump breakdown This will also optimize the frequency of hydraulic ...

Page 93: ...d it will stay engaged at any engine speed under 2300 RPM Inspecting the Pump The hydraulic pump is powered by the vehicle engine through a drive shaft The pump should be visually inspected every working day NOTE On some units the pump is directly installed on a PTO with no drive shaft between them Figure 7 3 Hydraulic pump When inspecting the pump 1 Start the engine and engage the hydraulic pump ...

Page 94: ...haft and direct mount PTO Basically each setup calls for the same replacement method but with some differences due to the position of the pump A To replace a front mounted hydraulic pump perform the following procedure 1 Disengage the pump and turn OFF the engine 2 Make sure the parking brake is applied and the vehicle is tagged out for maintenance purposes refer to Locking Out and Tagging Out the...

Page 95: ...ure 7 5 Suction block 9 Disconnect the drive shaft by removing the 4 bolts that secure the shaft to the engine Some mechanics may rather want to disconnect the drive shaft from the pump The choice is up to the mechanics and is based on the type of chassis the vehicle is built on 10 Attach the pump to a lifting device and remove both 5 8 bolts that hold the pump to the pump support 11 Remove the pu...

Page 96: ...ement pump must be oriented in such a way to facilitate reconnection to the hydraulic system and attachment to the chassis frame NOTE Both sections of the pump are indexable the body section and the arm section To index the new pump proceed this way 12 a Put the pump on a flat surface or in a vise BODY SECTION 12 b Remove all 4 retaining bolts that hold the mounting cap in place NOTE You may leave...

Page 97: ...ting cap clockwise or counter clockwise with your hands or by using a metallic bar as illustrated in the above picture NOTE Make sure pump sections do not separate NOTE The cartridge will rotate with the housing IMPORTANT Do not pull on the mounting cap as inside components may move and damage the pump ...

Page 98: ...e to avoid damaging the seals ARM SECTION 12 g Remove all 7 retaining bolts that hold the front cap in place NOTE You may leave two retaining bolts partially unscrewed to facilitate rotation with a metallic bar 12 h Rotate the front cap accordingly Rotation can be done by turning the front cap clockwise or counter clockwise with your hands or by using a metallic bar NOTE Make sure pump sections do...

Page 99: ... if the shaft rotates freely 12 k Tighten up all bolts to the torque of 50 ft lb When tightening bolts be sure to respect the following number sequence to avoid damaging the seals 13 Reinstall the drive shaft if it has been removed from the engine Before proceeding with the installation of the drive shaft apply the following procedure 13 a On the drive shaft mark the location where a hole must be ...

Page 100: ... to properly secure the yoke to the shaft 13 f Install a steel wire on the yoke bolt the wire must be fixed tight around the bolt see Figure 7 11 14 Using a lifting device install the new pump on the pump support 15 Put both 5 8 bolts back in to secure the pump to the plate 16 Go through Steps 9 to 5 inclusively to reinstall the various components of the pump assembly 17 Prime the new pump see Pri...

Page 101: ...lve if equipped NOTE The dump valve is usually but not necessarily located atop the pump NOTE Always reinstall the dump valve and its components shims block assembly as they were before uninstallation Make sure you do not invert them 7 Remove the suction block see Figure 7 7 and save it for the new pump Figure 7 7 Suction block 8 Disconnect the drive shaft by removing the 4 bolts that secure the s...

Page 102: ...ng with the installation of the drive shaft apply the following procedure 12 a On the drive shaft mark the location where a hole must be drilled Use the yoke as a jig to determine where exactly the hole must be drilled then remove it NOTE The yoke must be fully engaged on the shaft before determining the exact location where the hole must be drilled 12 b Drill a hole with a 5 16 diameter on the dr...

Page 103: ...poses refer to Locking Out and Tagging Out the Vehicle on page 21 3 Close the shut off valve see Figure 7 14 4 Disconnect the electric coil on the dump valve if equipped 5 Place a pan under the pump to catch dripping oil and unscrew all hydraulic hoses 4 that are attached to the pump 6 Remove the dump valve if equipped NOTE The dump valve is usually but not necessarily located atop the pump NOTE A...

Page 104: ...n 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 Go to page 86 to know how to index the new pump procedure begins with Step 12 a NOTE If the old pump ha...

Page 105: ...to reinstall the various components of the pump assembly 14 Prime the new pump see Priming a New Pump on page 97 NOTE Labrie Enviroquip Group strongly recommends you change the filter element and the hydraulic oil as well as clean the hydraulic tank before starting a new pump see Element Replacement Procedure on page 104 and Changing Hydraulic Oil on page 106 Caution Check the level of hydraulic o...

Page 106: ... the drive shaft see illustration below 2 Place the yoke on the shaft as illustrated above The yoke must be fully engaged on the shaft with both holes aligned one hole over the other 3 Apply Loctite 243 medium strength to bolt threads and insert the bolt firmly into the holes to properly secure the yoke to the shaft 4 Install a steel wire on the yoke bolt the wire must be fixed tight around the bo...

Page 107: ...r maintenance purposes refer to Locking Out and Tagging Out the Vehicle on page 21 2 With the shut off valve closed see Figure 7 14 fill the suction line before installing it on the pump 3 Fill the pump housing with new oil 4 Reinstall the pressure hose on the pump housing 5 Open the shut off valve on the suction line 6 Crank the engine repeatedly about five times without letting it start in order...

Page 108: ...the reservoir return line filter assembly as well as a suction line strainer Fitted to the tank is a breather cap see Figure 7 13 which allows the tank to breathe as oil is drawn out of the tank The breather cap should be replaced once a year A ball valve or shut off valve see Figure 7 14 is provided in the suction line in order to isolate the tank during maintenance Figure 7 12 Hydraulic oil tank...

Page 109: ...he appropriate level To inspect the hydraulic tank 1 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 21 2 Clean the strainer and replace the filter element inside the tank after the first 50 hours of service see Cleaning the Strainer on page 101 and Element Replacement Procedure on page 104 Caution Maximum temperature for hydraulic oil is 77 C 180 F ...

Page 110: ...obstructed and works properly 4 Make sure that the hydraulic oil is clean not colored and at least full on the oil level gauge with all cylinders retracted The complete system requires between 50 and 60 gallons of oil Figure 7 16 Filler cap Emptying the Hydraulic Tank To empty the hydraulic tank 1 Prepare the vehicle accordingly 1 a Apply the parking brake 1 b Start the engine 1 c Engage the hydra...

Page 111: ...he drain plug see Figure 7 17 5 Remove the drain plug under the tank and let the tank drain completely 6 Reinstall the drain plug Figure 7 17 Drain plug Cleaning the Strainer To clean the strainer 1 Empty the hydraulic tank see previous section 2 Remove the hose clamp from the suction hose 3 Slide the hose over the pipe until it clears the ball valve 4 Remove the strainer from the tank port see Fi...

Page 112: ...he vehicle Change the element twice a year afterwards see WITTKE PREVENTIVE MAINTENANCE CHART on page 38 The filter restriction indicator see Figure 7 19 will indicate when the engine is running if the filter needs to be changed Replace the filter before the indicator reaches the red zone This will keep the oil clean extend component life expectancy and reduce failures Figure 7 19 Filter restricti...

Page 113: ...raulic systems it should be noted that most hydraulic system manufacturers recommend the filter be replaced after a break in period Labrie Enviroquip Group s recommendation is to replace this filter element after a break in period of 50 hour operational use The element must also be changed following a major hydraulic component failure Figure 7 20 Return line filter element housing Figure 7 21 Retu...

Page 114: ... 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 NOTE The filter housing is fitted with a check valve Therefore it is not necessary to drain the hydraulic tank before the replacement procedure 2 Loosen the 4 cover plate bolts using a inch wrench rotate through 45 and lift off Figure 7 22 Loosening plate bolts 3...

Page 115: ...the cover plate 9 Engage the hydraulic system and check for leaks 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 over time Therefore regular oil changes will most likely extend the life of components and equipment Oil should be changed when it becomes oxidized when it has a significant...

Page 116: ...t your hand inside the tank through the opening left by the removal of the strainer and clean the interior 4 Put back the strainer 5 Change the return filter element see Element Replacement Procedure on page 104 6 Using a filtering screen refill the tank with high quality oil until it reaches the mark on the oil gauge see Recommended Lubricants on page 31 for specifications The entire system will ...

Page 117: ...nting points pins retaining bolts etc Detecting Cylinder Internal Leaks An internal leak is caused by a damaged seal inside the hydraulic cylinder see 1 on Figure 7 26 Because the cylinder is leaking oil inside bypassing a certain amount of pressure is lost reducing the efficiency of the cylinder and its capacity to push and or pull If the packer cylinders are bypassing the seal inside the cylinde...

Page 118: ...ial position 6 Disconnect and plug hose A 7 Engage the hydraulic pump 8 Push the green button and see if oil is leaking from port A then push the emergency STOP button If oil leaks out of port A when pressure is applied there might be an internal leak replace or repair the cylinder Figure 7 26 Detecting cylinder internal leaks 1 2 3 4 5 A A A ...

Page 119: ... Figure 7 27 Main valve front mounted Figure 7 28 Main valve left side mounted The main valve powers all body functions tailgate arms packer etc The valve bank on a commercial unit is comprised of the following The 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 t...

Page 120: ...direction to allow pressurized oil to operate the hydraulic cylinders Returning oil is allowed to escape to tank via the return passage outlet section and return lines Outlet Section This section caps the bottom end of the valve bank to provide a path for returning oil to travel to the return line filter in the tank NOTE All work sections are air actuated Electro hydraulic actuators are also avail...

Page 121: ...s they appear in the valve bank assembly NOTE The following list is for the commercial front loader only Hopper Top Door Circuit The hopper top door circuit includes one double acting hydraulic cylinder and two flow restrictors Tailgate Circuit The tailgate circuit consists of two double acting hydraulic cylinders one holding valve and two flow restrictors Arms Circuit The arms circuit consists of...

Page 122: ...greatly reduces the impact on the arm assembly body structure and hydraulic components Location The Arms Up deceleration valve is fitted to the underside of the body behind the arm pivot tube on the curbside Figure 7 32 The Arms Up deceleration valve Adjustment procedure 1 Raise the arms until they rest on the arms stops 2 Position the cam so that it depresses the spool of the deceleration valve u...

Page 123: ...t a container on the forks 8 Tighten the locking setscrew Arms Down DecelerationValve optional The Arms Down deceleration valve automatically decelerates the arms as they are lowered A cam bolted to the arm pivot tube rotates as the arms are lowered and gradually depresses the valve spool reducing the flow of oil exiting the shaft end of the arm cylinders NOTE The deceleration valve greatly reduce...

Page 124: ... to go down low enough to proceed with the correct adjustment 7 Remove the container from the forks and repeat Steps 5 and 6 until the arms properly decelerate with and without a container on the forks 8 Tighten the locking setscrew Pack Circuit DumpValve The pilot operated check valve dump valve is fitted into the pack hydraulic circuit for the purpose of reducing power which is required for the ...

Page 125: ...ms 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 holding 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 when the packer is working The pressure burs...

Page 126: ...ders Since the rod side is being pressurized with the Power bleed system the other side has to drain to avoid any pressure build up The velocity fuse makes the piston side open to tank when the oil flows under a certain amount of gallons per minute and will shut when a flow signal is sent NOTE Refer to the main hydraulic schematic Figure 7 38 Velocity fuse D2 D1 U2 U1 Main relief Velocity fuse ...

Page 127: ...d for maintenance purposes Adjustment procedure NOTE Should the adjustment be required an adjustment screw is located on the side of the pump body under the protective cover 1 Remove the protective cover Figure 7 39 Pump protective cover 2 Install a 3000 psi gauge on the quick coupler of the pump see Figure 7 40 Figure 7 40 Quick coupler Warning The service hoist is not intended to lift a loaded b...

Page 128: ... the front header of the body or on the left hand side mid section body wall Main System Pressure Adjustment As with all hydraulic systems it may be necessary to periodically check and adjust pressure relief settings NOTE The system pressure should be 2500 psi STARLIGHT and FEATHERWEIGHT or 2750 psi SUPERDUTY NOTE The following twoprocedures are used to adjust the main systempressure The first one...

Page 129: ...750 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 4 Loosen the locknut and using an Allen key turn the screw clockwise to increase the system pressure counterclockwise to decrease 5 When the hydraulic pressure is properly set to 2500 2750 psi depending on the truck model tighten the locknut and recheck 6 If t...

Page 130: ...ee Figure 7 42 3 Start the engine and engage the hydraulic pump 4 Press and keep holding the Tailgate Down button on the control panel There should be a tension applied to the Pilot Pressure Generating Solenoid 5 With the engine at idle adjust the generated pilot pressure using the adjustment screw see Figure 7 42 The correct pressure value is 420 psi 20 psi 6 Reconnect the tailgate solenoid 7 Pre...

Page 131: ... and tubing daily for abrasion cuts cracks and damage Replace any hydraulic hose which shows signs of damage Pressure and CycleTimeTable Function Pressure Setting PSI Engine RPM CycleTime min CycleTime max Main valve STARLIGHT FEATHERWEIGHT 2500 50 1500 n a n a Main valve SUPERDUTY 2750 50 1500 n a n a Dump valve R5P STARLIGHT FEATHERWEIGHT Denison pump only 2750 50 1500 n a n a Dump valve R5P SUP...

Page 132: ...System pressure 700 12 0 14 0 Arms down 1000 150 non adjustable 700 10 0 12 0 Forks up System pressure 700 3 5 4 5 Forks down System pressure 700 3 5 4 5 Forks complete cycle System pressure 700 7 0 9 0 Adjustable forks complete cycle 1400 50 700 n a n a Function Pressure Setting PSI Engine RPM CycleTime min CycleTime max ...

Page 133: ... For the specific hydraulic schematic related to your WITTKE unit look for the plastic pouch located inside the cab All schematics pertaining to your truck are found in this pouch Hydraulic Schematic 2 Deceleration Valves Live Pack Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 134: ...124 Hydraulic System Hydraulic Schematic F EATHERWEIGHT 1 Deceleration Valve Live Pack Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 135: ...Hydraulic System 125 Hydraulic Schematic F EATHERWEIGHT Denison Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 136: ...126 Hydraulic System Hydraulic Schematic 1 Deceleration Valve Live Pack Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 137: ...Hydraulic System 127 Hydraulic Schematic 1 Deceleration Valve Single Denison Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 138: ...128 Hydraulic System Hydraulic Schematic 2 Deceleration Valves Dual Denison Pump NOTE If lines seem incomplete please zoom in the page for clearer view ...

Page 139: ...ear Plates If the packer has a vertical movement greater than 3 16 inch or a side movement greater than 1 8 inch verify the packer wear plates and body guides Different types of steel are used Hardox 500 bottom of the body Hardox 450 packer Chromium overlay wear strips on packer shoes and channels Optional 3 8 Chromium overlay wear strips on hopper bottom rails 3 8 Hardox 500 on hopper side rails ...

Page 140: ...ce the body guide wear plates 1 Remove the packer refer to Packer Removal on page 131 2 Retract the packer cylinders and move them out of the way 3 Remove the body wear plates by grinding or cutting the stitch welds joining the plates to the guide 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 We...

Page 141: ... Figure 8 2 Body guide wear plate Packer Removal To remove the packer 1 Start the engine and engage the hydraulic system 2 Bring the packer to the rear end of the body full eject to easily access the pins 3 Stop the engine and turn OFF the hydraulic system 4 Perform the lockout tagout procedure 5 Enter the hopper and remove the grease fitting hoses on each cylinder ...

Page 142: ...N the hydraulic pump 9 Fully retract both packer cylinders 10 Once both packer cylinders fully retracted turn OFF the hydraulic pump and the engine 11 Perform the lockout tagout procedure 12 Using an appropriate and safe lifting device pull the packer out of the body Warning Cylinders must be properly secured before removing their retaining pins Failure to do so may result in damage severe injury ...

Page 143: ...er cylinders 1 Start the engine and engage the hydraulic pump 2 Extend the packer until it reaches the end of the packing stroke with tailgate closed 3 Stop the engine and turn OFF the hydraulic pump 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 W...

Page 144: ...linders Install plugs to disconnected hoses to avoid oil spill and hydraulic system contamination Figure 8 6 Hydraulic hoses 12 Using an appropriate and safe lifting device pull the cylinders out of the body by the roof Be extra careful when conducting this step NOTE A packer cylinder weighs approximately 450 lbs without oil 13 To reinstall both cylinders perform the procedure in reverse Warning C...

Page 145: ...has been designed to help you operate your unit in an efficient and easy way Labrie s multiplexed system is reliable and safe and it requires less wiring harnesses to operate It can also monitor various function status of the body and display warning and caution messages Through its monitor see Figure 9 1 Labrie s multiplexed system informs you of any malfunctions that may occur during the operati...

Page 146: ...ntinuously there may be a communication problem between the monitor and the master control module Report this problem to the maintenance personnel NOTE The monitor screen works even if the engine is not started All it needs is electrical power However if you start the engine the monitor will reboot to reflect the changes caused by the starting of the truck Main Page The next page that comes up aft...

Page 147: ...he Time and Date indicator go to the Main Menu and choose Time Adjust Hydraulic Oil Temperature Indicator optional This optional indicator when provided shows you the current hydraulic oil temperature This indicator is found on the upper right hand side corner of the screen Warning and Caution Messages On the monitor screen yellow highlighted messages indicate that caution should be used and red h...

Page 148: ...op Override Switch then Move Container out of Bar Stop Buzzer Body Raised Lower Body Buzzer TailGate Unlocked Lock Tailgate Control is External Disable External Control ESTOP Aux Emergency Stop Pull Up Aux EStop Button ESTOP Cab Emergency Stop Pull Up Cab EStop Button ESTOP Ext Emergency Stop Pull Up Ext EStop Button Fork Arm Above MidHeight Lower Arms Below MidHeight Fork Pump Not Started Engage ...

Page 149: ...Switch ON Switch Must be OFF to Engage Pump Pump Hopper Door Not Closed Close Hopper Door Pump Main Air Pressure Let the Air Build Up to Required Pressure Pump Packer Extend Switch ON Switch Must be OFF to Engage Pump Pump Packer Retract Switch ON Switch Must be OFF to Engage Pump Pump PTO Not OK Refer to Maintenance Personnel or LabriePlus Pump Roof Open Switch ON Switch Must be OFF to Engage Pum...

Page 150: ...Service Oil Filter 2 Replace Oil Filter 2 TailGate Packer Not Retracted Retract Packer TailGate Pump NOT Started Engage Pump Wrong Driver Position Move Driver Position Switch to Opposite Position Table 2 Error messages cont d Error Messages Solution Button Pack 12 is disconnected Refer to Maintenance Personnel or LabriePlus Button Pack 13 is disconnected Refer to Maintenance Personnel or LabriePlu...

Page 151: ...art of the screen are causes that have already been dealt with non active causes see Figure 9 5 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 Personnel or LabriePlus Module 20 is disconne...

Page 152: ...twork This indicator is called Network Load and it shows values that reflect such traffic NOTE The higher the network load value is the heavier the traffic is on the network To exit this page and return to the Main Page press Esc To choose a section from the Main Menu highlight the desired section using the up down arrows and press the OK button I O Status In this section you will find helpful inf...

Page 153: ... the OK button Press Esc to return to the preceding page Figure 9 6 Module I O Status page Input Status The Input Status page is accessible from the Module I O Status page After selecting the desired module and pressing OK the Input Status page of the selected module is displayed see Figure 9 7 Figure 9 7 Input Status page 11 Display 30 Tailgate 50 Chassis 60 Body J1939 ...

Page 154: ...the input element coming from the service brake pressure switch NOTE 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 Press Esc to return to the preceding page Press the Output button to display the Output Status page Output Status The Output Status page see Figure 9 8 is accessible from the Inpu...

Page 155: ... the desired page is displayed Force The Force page is accessible from the Output Status page Just press the corresponding button to access the Force page But before the Force page is displayed a warning message appears on the monitor screen see Figure 9 9 Figure 9 9 Warning message This message stays on for 15 seconds Then an OK prompt appears on the lower right end corner of the screen IMPORTANT...

Page 156: ...rs 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 button to go to the following page see Figure 9 12 Figure 9 12 Force page output The Force page allows the operator to force a function to be overridden that is to make an inactive function active and an active function inactive ...

Page 157: ...e screen After selecting a rectangle press ON to activate the corresponding function rectangle turns from blue to green press OFF to deactivate the corresponding function rectangle turns from green to blue press RESET to have the software control the status of the corresponding function NOTE To cancel changes made in this page and restore the default values simply cut power to the multiplexed syst...

Page 158: ...o be used to change or remove already saved passwords Data that can be protected by passwords relate to the following features Output Force Multicycle and J1939 baudrate NOTE Only adjustable data in Output Force Multicycle and J1939 Baudrate can be protected by passwords The Password Menu is available through the Settings Menu An associated menu Locked Features is also available allowing you to ch...

Page 159: ...word using the arrow keys Press ESC to quit or OK to set password 5 If a password already exists enter it using the arrow keys Press ESC to quit or OK to erase the password 6 Enter a new password using the arrow keys Press ESC to quit or OK to create a new password ...

Page 160: ...t in deactivating the password function 7 Go back to the Settings Menu by pressing ESC 8 In the Settings Menu select Locked Features 9 Select the feature s that you want to lock using the password created or saved NOTE If you have forgotten your password please contact the LabriePlus Service Department ...

Page 161: ...the preceding page Pump Usage This section contains an optional hour meter that tracks pump usage for maintenance purposes Press Esc to return to the preceding page Time Adjust This section allows you to set the Time and Date indicator Press Esc to return to the preceding page NOTE To go back to the Main Page or Main Menu press Esc as needed until the desired page is displayed Module Locations The...

Page 162: ...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 This module is located inside the left hand side light box near the upper edge of the tailgate see Figure 9 16 Figure 9 16 Node 30 module location ...

Page 163: ...PERDUTY TM and STARLIGHT TM basic checks must be made Verify that the module is correctly receiving sending inputs and outputs locate the LED light near the wire connector a module operating correctly will have a green blinking light commonly referred to as a heartbeat see Figure 9 18 If solid green light exists not blinking the module is not running and will need to be restarted If there is a fas...

Page 164: ...e Once module light status condition has been verified the connector condition should be checked 1 Check for proper connection to module Figure 9 19 Connection status 2 Check for any moisture or corrosion in the connector or on the module terminals ...

Page 165: ...s to the module and also check the CAN_H CAN_L side to the module 4 a Verify all power supplies IGN to the module if there is a suspicion that power is intermittent check the ignition relay which is located next to the battery box 4 b Verify that grounds are good to the module Need to isolate and check the resistance on the individual grounds Check the CAN_H CAN_L wires and verify that there is 60...

Page 166: ...truck is in reverse or when the body and or tailgate are being raised Figure 9 21 Warning buzzer Plugging a Computer The in cab control panel of the WITTKE has a computer plug that can be used to connect a laptop computer for reprogramming purposes see Figure 9 22 Connecting a laptop to this plug requires special hardware and software included in the service kit For more information on this contac...

Page 167: ...arameters NOTE The following tables show parameters that are not necessarily specific to your vehicle These are general parameters To obtain the parameters that are closely related to your vehicle contact LabriePlus and ask for the electrical schematic pertaining to your truck model with all the options installed Programming the TCM affects the engine speed the PTO engagement and operation as well...

Page 168: ...Engine Speed for Engagement 900 PTO Drive Interface 1 Maximum Engine Speed for Operation 4000 PTO Drive Interface 1 Maximum Output Speed for Engagement 5000 PTO Drive Interface 1 Maximum Output Speed for Operation 5000 Maximum Output Speed for Automatic Neutral 500 7 MPH Table 6 Allison wires to be enabled Wires Wire WTEC IV Pack enable 117 Input PTO enable 143 Output PTO enable 130 Output neutral...

Page 169: ...is used to allow fast idle engagement For more details refer to the electrical schematic provided with the vehicle Table 9 Customer modifiable constant change only if Labrie auto neutral Description Value Automatic neutral Single input w selector override GPI CD if defined Automatic neutral Dual input GPI AG if defined Automatic neutral Dual input w automatic return to range Disabled Automatic neu...

Page 170: ...160 Multiplexing ...

Page 171: ...66 Parts Fax 1 418 831 7561 Mailing Address Mailing Address P O Box 530 175A Route Marie Victorin LaFayette GA 30728 Levis QC G7A 2T3 Parts and Warranty Parts and Warranty During business hours During business hours 8 00 AM to 6 00 PM Eastern Standard Time 8 00 AM to 5 00 PM Eastern Standard Time Technical Support Service Technical Support Service Toll Free 1 800 231 2771 Toll Free 1 877 831 8250 ...

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