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Maintenance

Welding Information

The W

ITTKE

ETRO

consists primarily of 5 types of steel.

ASTM A569 - mild sheet steel, commercial grade

ASTM A715 - high strength, low alloy sheet and plate

ASTM A514 - high strength, quenched and tempered steel

QT440 - abrasion resistant steel

Ultra Wear - abrasion resistant steel

OTE

For welding, use either low hydrogen electrodes E11018 or Spool Arc 83 mig wire.

Figure 3-2 Caution decal - welding

Caution!

Disconnect all batteries and electronic modules

prior to welding on packer body.

Caution!

Remove paint before welding or heating!
Do not weld near lines that are pressurized or contain flammable fluid!

Содержание Pendpac WITTKE RETRO FL

Страница 1: ...WITTKE RETRO FLTM MAINTENANCE MANUAL...

Страница 2: ......

Страница 3: ...WITTKE RETRO FLTM MAINTENANCE MANUAL...

Страница 4: ...legal theory and or hypothesis Such damages include but are not limited to loss of profits savings capital or revenue loss of use of refuse body parts components or assemblies cost of rental equipment...

Страница 5: ......

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Страница 7: ...oist Handle 11 Do Not Climb on Canopy 12 Check All Bridge Clearances 12 Do Not Drive When Overheight Warning Lamp is Illuminated 13 Tailgate Locks Must Be In Place 13 Crush Hazard Body May Fall 14 The...

Страница 8: ...to Pack Function Locked Out by Tailgate Ajar 32 Test Eject Function Locked Out by Tailgate Not Fully Open 32 Test Auto Pack and Eject Locked Out by Arms Elevated 32 Test Arms Up Locked Out by Packer P...

Страница 9: ...Circuits Tip to Dump 99 Arms Up Deceleration Valve 99 Pack Circuit Dump Valve 100 Pressure Switch 100 Tailgate Lock Valves 101 Service Hoist optional 101 Hydraulic System Residential Type Fl 102 Prior...

Страница 10: ...viii Table of Contents...

Страница 11: ...adequate for production and transport purposes only In addition the return filter element must be replaced after 50 hours of use as per instructions shownon page 57 With your safety in mind we would...

Страница 12: ...Safety Administration In addition these defects should be immediately reported to Labrie Enviroquip Group by notifying our service department To contact NHTSA you may call 1 800 424 9393 or 1 202 366...

Страница 13: ...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 Su...

Страница 14: ...4 Introduction...

Страница 15: ...nviroquip Group cannot accept any responsibility for failures and or injuries caused by repairs done by the user NOTE Before doing any maintenance work on the unit all safety regulations must be respe...

Страница 16: ...the vehicle only as intended Perform a daily vehicle inspection that includes all operating systems all vehicle safety equipment and safety decals Ensure that the inspection is documented and bring a...

Страница 17: ...agout Procedure on page 37 Overheight Caution In some locations the front loader may be overheight when the arms are in the full up travel position Consult local regulations or confer with your superv...

Страница 18: ...erstanding the safety decals affixed to your vehicle can prevent damage and could prevent injury or even death Decals fall into the following four categories Figure 2 1 Safety decal categories Safety...

Страница 19: ...Safety 9 Do not Enter Hopper Extreme Crush Hazard Read and Understand Your Operating Manual Before Using This Vehicle...

Страница 20: ...10 Safety Keep Hands and Body Clear...

Страница 21: ...Safety 11 Stand Clear of Tailgate Extreme Crush Hazard Service Hoist Handle...

Страница 22: ...12 Safety Do Not Climb on Canopy Check All Bridge Clearances...

Страница 23: ...Safety 13 Do Not Drive When Overheight Warning Lamp is Illuminated Tailgate Locks Must Be In Place...

Страница 24: ...14 Safety Crush Hazard Body May Fall The Top of This Vehicle is High Enough...

Страница 25: ...Safety 15 Danger of Electrocution Damage to Vehicle Frame is Heat Treated...

Страница 26: ...16 Safety Disconnect All Batteries and Electronic Control Modules Remove Cap Slowly...

Страница 27: ...Safety 17 Extension Ladder Must Be Secured Lubrication Points...

Страница 28: ...18 Safety Service Hoist Instructions Air Tank Drain Notice...

Страница 29: ...Safety 19 Setting the Tailgate Props Curb Side...

Страница 30: ...20 Safety Setting the Tailgate Props Street Side...

Страница 31: ...Safety 21 Diesel Fuel Notice Programmed PTO Settings NOTE Do not use PTO settings use MDM for overspeed Hydraulic Fluid Notice...

Страница 32: ...22 Safety Hydraulic Oil Grade Notice Hydraulic Oil Fill Level IMPORTANT Failure to heed all safety decals on your vehicle and in this manual may lead to injury or death...

Страница 33: ...manual for more information Figure 2 2 Automatic Grease System External Access Pack Cylinder Grease Fittings Pins at the packer blade end of the cylinders are remotely greased via two grease fittings...

Страница 34: ...wered down In other words it cannot close via gravity These lock valves also prevent the tailgate from unlocking if it is not powered up Tailgate Restrictor Fittings Located in the bottom part of the...

Страница 35: ...or service hoist cylinders the restrictor prevents rapid descent of the body in the case of a hose failure Backup Alarm Located at the rear of the chassis the backup alarm emits an audible warning wh...

Страница 36: ...uction is detected behind the unit Consult the OEM manual for more information Figure 2 3 Global motion sensor Rear Vision Camera A camera is mounted to the tailgate sending a live image of the view b...

Страница 37: ...on the chassis frame Access Door Open Buzzer An audible warning is transmitted by the MDM control panel whenever the hopper access door is not completely closed Amber Warning Lamp An amber warning la...

Страница 38: ...tenance purposes only The prop will only support an empty body Never support a loaded body with this prop Also before using the body safety prop be sure the truck is on solid level ground Setting the...

Страница 39: ...and seat securely on to the chassis frame 9 Complete the lockout tagout procedure see Lockout Tagout Procedure on page 37 Tailgate Props The tailgate props one each side when engaged ensure that the...

Страница 40: ...f the tailgate latch The blocks must be engaged to prevent unintentional opening of the tailgate which could cause serious damage to the tailgate and latch Fire Extinguisher The fire extinguisher opti...

Страница 41: ...Procedure on page 37 For this test proceed as follows 1 With the hydraulic pump on open the hopper access door 2 The red illuminated danger warning lamp along with the audible buzzer should be activat...

Страница 42: ...For this test proceed as follows 1 With the packing panel fully forward to its home position remove the tailgate lock blocks and activate the Tailgate Open function so that the tailgate is at least pa...

Страница 43: ...is triggered it allows the arms to lift and dump a container If the proximity switch is not triggered the operator can only raise the arms until they trigger overheight proximity switch 1 which rough...

Страница 44: ...should not move 4 If the tailgate does move refer to Adjusting Body Raised Proximity Switch Tip to Dump Units on page 85 Test Hoist Locked Out by Arms Not Stowed Referring to tip to dump units only t...

Страница 45: ...ounted breaker bar at the top rear of the hopper 2 If the packing panel does not stop at this point or stops too soon refer to Adjusting Half Pack Proximity Switch on page 76 Table 1 Lockout summary F...

Страница 46: ...rol unit ECU serve to alert the operator that a dangerous condition exists and to pay close attention to how the unit is operated in order to prevent damage or serious injury The warning indicators ar...

Страница 47: ...er body work it is necessary to set the body prop as explained later in this manual The following is the lockout tagout procedure 1 Set the chassis parking brake 2 Turn off the hydraulic pump 3 Activa...

Страница 48: ...imilar lifting devices when doing any lifts Do not stand or walk under a load that is suspended unless there are additional safety blocking devices in place While Labrie Enviroquip Group has included...

Страница 49: ...ed to the chassis via a hinge or you may need to install a lifting device Securing the Rear Body to a Lift Beam You will need one lift beam two 5 ft 1 524 m lengths of chain two shackles and two grab...

Страница 50: ...ough the shackle and attach each chain s grab hook onto the original chain 6 Attach each shackle to its respective lifting lug Figure 2 5 Lifting lug Figure 2 6 Proper lift setup Lifting the Front Bod...

Страница 51: ...lbs at 90 degrees To lift the front body 1 Secure the rear body 2 Raise the arms and forks until they are resting on the rubber arm stops on the sides of the body 3 Insert a lift spool into each end o...

Страница 52: ...r body until you have secured the front body to another lifting device To lift the body 1 Secure the rear body to a lift beam Refer to Securing the Rear Body on page 39 2 Raise the arms and forks unti...

Страница 53: ...Safety 43 5 Lift the body Figure 2 9 Proper lift setup...

Страница 54: ...44 Safety...

Страница 55: ...ON sections of the Operator s Manual prior to attempting any maintenance of your WITTKE RETRO FL TM Prior to Hydraulic System Maintenance As with all hydraulic systems it may be necessary to periodica...

Страница 56: ...specifically describes the hydraulic oil your equipment was filled with at the Labrie factory Record this data in your service records for future reference Figure 3 1 Oil identification tag Hydraulic...

Страница 57: ...cribes the oil the unit was filled with when it left the Labrie factory Refer to Oil Identification Tag on page 46 Castrol HVI 32 or equivalent Suction line 100 mesh suction strainer Return line 10 mi...

Страница 58: ...uenched and tempered steel QT440 abrasion resistant steel Ultra Wear abrasion resistant steel NOTE For welding use either low hydrogen electrodes E11018 or Spool Arc 83 mig wire Figure 3 2 Caution dec...

Страница 59: ...ication is a major cause of component failure The WITTKE RETRO FLTM like most equipment has numerous points that require grease see Figure 3 3 Figure 3 3 Lubrication points See Table 1 on page 50 for...

Страница 60: ...ilgate latch roller pins 2 X 11a a Denotes option or not all units Rear body hinge pins 2 X 12 Hoist cylinder pins 4 X 13 Cart Tipper quantity may vary not shown Consult manufacturer 14 Side access do...

Страница 61: ...blade inside hopper more often if required O 26 Wash complete body and chassis more often if required O Mc c M Maintenance 27 Other Table 3 Mechanical Inspection truck at rest cont d Item Description...

Страница 62: ...bly mounting bolts 4 O M 42 Fork pivot tube collars 2 O M 43 Fork cylinder ears 4 pins 4 and retaining hardware O M 44 Residential carry can and mounting hardware O M 45 Cart attachment assembly O M 4...

Страница 63: ...Top door cylinder clamp related nut bolts O M 61 Tailgate assembly O M 62 Tailgate cylinder ears 4 pins 4 and retaining hardware O M 63 Tailgate latch assembly 2 pivots 2 and roller pins 2 O M 64 Tai...

Страница 64: ...ate open close O M 76 Hoist up down tailgate must be open O M 77 Service hoist up down O M Perform safety lockout tests to check proximity switches 78 Side access door test side access door proximity...

Страница 65: ...control console warning devices are functioning 89 Pump switch lamp O M 90 Packer blade warning lamp O M 91 Top door warning lamp O M 92 Access door warning lamp buzzer O M 93 Tailgate ajar warning la...

Страница 66: ...ch O M 111 Wash tank switch O M 112 Other Table 6 Hydraulic system cont d Item Description Pre trip At landfill Daily Weekly Monthly 1000 hours Hydralic oil tank 113 Check for leaks damage etc on tank...

Страница 67: ...3 Inspect pump for leaks O M 124 Ensure pump is securely mounted O M 125 Ensure driveline is securely mounted M Hydraulic valve bank 126 Inspect valve bank for leaks O M 127 Ensure valve bank is secur...

Страница 68: ...l units Table 7 Pneumatic system Item Description Pre trip At landfill Daily Weekly Monthly 1000 hours 136 Drain air tanks at the end of each day Oa a O Operator 137 Inspect air lines for leaks O Mb b...

Страница 69: ...in conjunction with the operational controls located in the control panel The electrical control system activates air solenoid valves that in turn provide control air pressure to the main hydraulic d...

Страница 70: ...c The software also provides interlocks that prevent operation of some functions when it is not safe to do so The IQAN hardware replaces all the hard wired control relays that would be required to do...

Страница 71: ...bute outputs The WITTKE RETRO FLTM system is an electric over air over hydraulic system which is controlled by the MDM Communications between the various components of the IQAN MDM system are performe...

Страница 72: ...or down through the different screens Measurements Screen Through the MDM screen you can read the different inputs and outputs for troubleshooting purposes To read measurements do the following 1 You...

Страница 73: ...MOM 35 Top Door OPN MOM 36 Top Door CLS MOM 37 Access Door Prox 38 Body Prox 39 XT2 A1 C1 __ 200S Joystick Select 21 Hoist UP MOM 22 Hoist DN MOM 23 Forks Wide MOM 24 Forks NAR MOM 25 Auto Pack Engag...

Страница 74: ...Measure Inputs Digital Outputs Arm Stowed Prox 36 Arm Over Prox 37 Fork Stowed Prox 38 Top Door Prox 39 XT2 A0 C1 __ 100S Red LED 02 Yellow LED 03 Pump Engage 04 Hoist UP 05 Hoist DN 06 Auto Pack Ligh...

Страница 75: ...ure Outputs XT2 A1 C1 __ 200S Joystick Selector 02 OCB Joystick LOW 03 Fork Tilt LO 04 Arms Overheight 05 Pump Indicator 06 Back Up Alarm 07 XT2 A2 C1 __ 300S Arm UP Lockout 02 Joystick Lockout 03 For...

Страница 76: ...66 Maintenance Current Outputs Current Measure Outputs PWM Outputs XT2 A2 C1 __ 300S Tailgate UP DN UP 17 18 DN 31 32 Top Door Open Close Open 19 20 Close 33 34 XT2 A2 C1 __ 300S Pack 06 Retract 07...

Страница 77: ...kes for the optional arms activated auto pack Apply the following procedure to set the function parameters 1 Go to the main menu 2 Scroll up or down to the properties function 3 Press other F4 Functio...

Страница 78: ...l Press F3 to reset to factory settings Screen Setting Adjustments Information Screen The Information Screen shows the status of your MDM and Module Diagnostics including voltage temperature and curre...

Страница 79: ...ed schematics and an overview were sent to you at time of delivery Please call LabriePlus for free replacements or visit our website see To Contact Labrie Plus on page 3 MDM Control Panel located cent...

Страница 80: ...the solenoid so air can pass to the work section dedicated to that particular air valve Figure 3 8 Pneumatic box Proximity switches Body mounted proximity switches control the packer operation and pr...

Страница 81: ...nual for information on equipment not manufactured by Labrie Function Amps Location Main battery power 50 Fitted under the street side dash to protect the packer system circuits that utilize ignition...

Страница 82: ...ump pack circuits 10 In cab box Marker lamps 15 In cab box Backup lamps 15 In cab box Pack hopper lamps 15 In cab box Strobe lamp 15 In cab box Alternating flashing lights 15 In cab box Caution Proxim...

Страница 83: ...switch Body raised proximity switch Half pack proximity switch Packer blade ahead proximity switch Top door proximity switch Arm partially raised proximity switch Arm fully retracted proximity switch...

Страница 84: ...p of approximately 1 4 with the tab 3 TIGHTEN the proximity switch nuts 4 TEST the operation The proximity switch light should turn on when the tab is detected if not repeat the adjustment procedure F...

Страница 85: ...de Ahead Proximity Switch if the packer blade stops before reaching the fully home position or the pack cylinders remain pressured up or abruptly bottom out at the home position Adjustment Procedure 1...

Страница 86: ...backward in the mount to achieve a gap of approximately 1 4 with the tab 3 b Tighten the proximity switch nuts 3 c Test the operation 4 Continue with the adjustment of the half pack proximity switch...

Страница 87: ...en the proximity switch and the tab If the gap is too wide or too narrow proceed with the adjustment 3 a Loosen the proximity switch mounting nuts Slide the switch forward or backward in the mount to...

Страница 88: ...Proximity Switch The top door proximity switch controls the cutout of the arms up function if the top door is not fully open It also illuminates the warning lamp on the MDM control console Location T...

Страница 89: ...so it can detect the tab The Tailgate Fully Open warning message should appear on the MDM screen 3 Slightly close the tailgate to about an inch Detection of the tab by the proximity switch should not...

Страница 90: ...ontact is not working properly To do so 6 a Complete lockout tagout procedure see Lockout Tagout Procedure on page 37 6 b Loosen the proximity switch mounting nuts Slide the switch forward or backward...

Страница 91: ...ensure the packer blade completes a full eject cycle 7 Close the tailgate and re insert the tail light NOTE Tip to Dump Gravity Dump units are equipped with this mercury switch although the packer bla...

Страница 92: ...the windshield NOTE The warning lamp on the MDM control module should illuminate and the optional buzzer should sound while the forks travel above the windshield The PACK function is disabled with the...

Страница 93: ...completely parked Both arms and forks must be completely parked in order to turn off the warning lamp and to delete the Arms not Stowed message from the monitor display Location The fork fully retrac...

Страница 94: ...k fully retracted proximity switch 6 Perform tests to see if the warning lamp on the MDM control module reacts properly and the Arm not Stowed message appears on the monitor when the forks or the arms...

Страница 95: ...cedure refer to Lockout Tagout Procedure on page 37 3 Loosen the proximity switch mounting nuts Slide the switch forward or backward in the mount to achieve a gap of approximately 1 4 with the tab 4 T...

Страница 96: ...he packer control circuit Two filters are fitted behind the cab Air supply is passed through an air filter a mist separator and then routed to the air valve box NOTE Filter elements should be replaced...

Страница 97: ...cutout valve cuts air to the joystick and to the arm up function when the packer is not in the home position or when the top door is not fully open Outside Curbside Controls Auxiliary controls can in...

Страница 98: ...h in the auto position the system will advance to 1500 RPM when the PACK RETURN or AUTOPACK functions are activated Figure 3 28 Outside controls mounted behind cab Figure 3 29 Curbside controls Valve...

Страница 99: ...ve all the air valves listed below Valve Box Air Valves Tailgate open extends the tailgate cylinders Tailgate close retracts the tailgate cylinders Top door open retracts the top door cylinder Top doo...

Страница 100: ...3 31 Air actuators Central Air Drain Cocks optional A series of air drain cocks are provided on a bracket at the battery box IMPORTANT All air tanks should be drained daily NOTE Be sure to drain the w...

Страница 101: ...e 91 Pneumatic System Schematics Each WITTKE RETRO FLTM unit is provided with its specific schematic Please refer to this schematic for more details on the pneumatic system of your unit Commercial Fro...

Страница 102: ...92 Maintenance Residential Front Loader...

Страница 103: ...Maintenance 93 Tip to Dump...

Страница 104: ...reather 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 i...

Страница 105: ...ational duty cycle operating conditions and local maintenance schedules Labrie Enviroquip Group recommends the filter element be replaced every 1000 hours operational use Refer to Maintenance Checklis...

Страница 106: ...lter housing and cover plate 8 Install element into housing carefully locating the element onto the spigot 9 Replace cover plate 10 Operate hydraulic system and check for leaks Hydraulic Oil Factory f...

Страница 107: ...nk enters the hydraulic pump through the suction line Pressurized oil exits the hydraulic pump through the pressure line directly to the directional control valves A return line exits the hydraulic pu...

Страница 108: ...ilter in the tank Figure 3 37 Directional control valves Pressure Relief Valve The pressure relief valve is fitted in the inlet section of the valve bank and protects the hydraulic components from dam...

Страница 109: ...t The remaining circuits follow in the same order as the commercial work circuits NOTE The cart tipper is optional and therefore this circuit may not appear on your vehicle Work Circuits Tip to Dump T...

Страница 110: ...ank The dump valve is non adjustable NOTE Symptoms of pack circuit dump valve failure include poor payloads slow cycle times and low pressure readings during the pack cycle Location The pack circuit d...

Страница 111: ...re must be applied to the lock valve in order to open the return passage The valves are non adjustable Location The tailgate lock valves 2 are located on the underside of the body near the tailgate on...

Страница 112: ...ith the cart tipper option includes Priority Valve Directional Control Valves Pressure Relief Valves and Work Circuits Priority Valve The priority valve cartridge see Figure 3 45 divides hydraulic oil...

Страница 113: ...s split and enters the valve via a top inlet section and mid inlet section The top inlet section receives 3 GPM priority flow for use in the cart tipper circuit All remaining oil enters the mid inlet...

Страница 114: ...Main hydraulic valve bank on the front header of the body Figure 3 47 Auxiliary hydraulic attachment work section Arms Down Work Section Designed to protect the arm hydraulic circuits the arms down wo...

Страница 115: ...celeration valve greatly reduces impact on the arm assembly body structure and hydraulic components Location Fitted to the underside of the body behind the arm pivot tube on the streetside For adjustm...

Страница 116: ...eed see Figure 3 52 1 2 Pressure builds in the system as resistance increases When pressure reaches 2 000 psi the kick down relief valve opens simultaneously closing the pilot to close check valve Pac...

Страница 117: ...usting the Main System Pressure Adjusting the Pressure Switch Adjusting the Arms Up Deceleration Valve For description of this valve refer to Arms Up Deceleration Valve on page 99 To adjust the arms u...

Страница 118: ...he arms decelerate with and without a container on the forks 8 Tighten the locking setscrew Adjusting the Arms Down Deceleration Valve For description of this valve refer to Adjusting the Arms Down De...

Страница 119: ...Loader To adjust the main system pressure NOTE The system pressure should be at 2250 psi 1 Remove the plug from the test port located at the top of the main valve bank Insert an 0 3000 psi pressure g...

Страница 120: ...top inlet section relief valve is set slightly higher since the cart tipper circuit is protected with work port relief valves set at 1500 psi refer to Auxiliary Hydraulic Attachment Work Section on pa...

Страница 121: ...ockwise to decrease see Figure 3 57 Figure 3 57 Pressure relief valve top inlect section 7 Repeat the operation of the hydraulic function and check the pressure is at 2350 psi Tighten the locknut 8 No...

Страница 122: ...ne RPM to 1500 and initiate an AUTOPACK cycle and watch the pressure gauge Note when the blade begins the RETURN cycle NOTE If the setting is incorrect the blade will either RETURN early before the sy...

Страница 123: ...to 2250 psi The two cart tipper port pressure relief valves protect the lines leading to the cart tipper and are set to 1500 psi The arms down port pressure relief valve reduces downward pressure all...

Страница 124: ...nders used by Labrie Enviroquip Group incorporate the very latest designs and technology Many cylinders feature rods treated with a nitration process to achieve exceptional wear resistance and protect...

Страница 125: ...flow dividers mounted on the fork assembly The flow dividers ensure the cylinders receive equal amounts of oil Curotto Automated Can The Curotto Can see Figure 3 63 is a hydraulic attachment which al...

Страница 126: ...116 Maintenance Hydraulic System Schematics Commercial Front Loader...

Страница 127: ...Maintenance 117...

Страница 128: ...118 Maintenance...

Страница 129: ...Maintenance 119...

Страница 130: ...418 831 7561 Mailing Address Mailing Address P O Box 2785 175 Route du Pont Oshkosh WI 54903 2785 St Nicolas QC G7A 2T3 Parts and Warranty Parts and Warranty During business hours During business hou...

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