manual for new way electric over air mammoth series front...
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Manualfor New Way
Electric over AirMammoth Series
Front Loaders
SCRANTON MANUFACTURING CO, INC.101 STATE ST, PO BOX 336SCRANTON, IOWA 51462
(712) 652-3396 OR (800) 831-1858FAX (712) 652-3399
www.drivingthedifference.com
PETERSON SMART STROBES TOP LIGHT BAR
DRIVING THE DIFFERENCE
Scranton Manufacturing Company, Inc. warrants its New Way Solid Waste Collection Equipment to be free fromdefects in material and workmanship under normal use when properly serviced and maintained as described in itsservice bulletins and operational manuals for a period of six months from the date when these products are deliveredto the first purchaser.
This warranty is expressly limited to the repair or replacement of any component or part thereof, of any such unitmanufactured by the Company, that is proven to the Company’s satisfaction to have been defective in material orworkmanship. Such components or parts shall be repaired or replaced at no cost to the first purchaser for parts andlabor provided such unit is returned for such repair or replacement with transportation charges prepaid to anauthorized Scranton Manufacturing Company, Inc., New Way distributor, or such other facility as may be designatedby the Company, within 30 days after discovery of the defect and within six months of the date on which the unitwas delivered to such first purchaser.
The Company will furnish without charge FOB its distributor a similar part to replace any part of a product of itsmanufacture which proved to be defective in material or workmanship while in normal use and service during thisperiod.
Normal adjustments or minor repairs, tightening of fittings or nuts and bolts or replacement of normally wearing ordisposable parts such as but not limited to slide blocks, seals, filter elements, bushing, etc., is not consideredgrounds for warranty.
The warranty is void if any factory unauthorized change, addition, or alteration is made to the machine.
To validate the new unit warranty, an authorized New Way distributor must have completed a predelivery inspectionbefore the unit is placed into service, and the delivery inspection form and warranty card must be signed by boththe customer and the distributor and submitted to the Company’s Service Department within two weeks of deliveryto the first purchaser of the unit.
Because the Company’s parts are engineered to work only with genuine company parts, this limited warranty willbe void and have no effect if: (a) Company parts are modified other than as done at its factory or as authorized tobe done by factory in writing or (b) Parts or assemblies of any other manufacturer are used as substitutes forgenuine Company parts.
Replacement parts, components and assemblies manufactured by Scranton Manufacturing Company, Inc., are soldunder a Limited Warranty to be free from defects in workmanship or material for a period of 90 days, providing thefactory inspection reveals a material or a workmanship defect. Labor to replace or repair such part shall be theresponsibility of the customer. There is no warranty on expendable items, wear components or used parts.
Scranton Manufacturing Company, Inc. makes no other warranty, expressed or implied, and makes no warranty ofmerchantability or fitness for any particular purpose. The company does not assume any liability for loss of profits,product, time, or any other direct or indirect or consequential losses, damages or delays. Any improper use,operation beyond rated capacity, substitution for parts not approved by the Company, or any alteration repairs byothers in such manner as in our judgment affects the product materially and adversely void this Warranty.
This Warranty supersedes and is in lieu of all other warranties expressed or implied. The Company reserves theright to redesign and/or discontinue the manufacture of parts, components and assemblies at any time. The Companyreserves the right to make changes in the design or make additions to or improvements on its products withoutimposing any obligation on itself to install them on its products previously manufactured.
WARRANTY
1-I
STANDARD REAR LIGHTING WITH WHELEN STROBE
DRIVING THE DIFFERENCE
1-II
TABLE OF CONTENTSDRIVING THE DIFFERENCE
SECTION 1 - SAFETY PRECAUTIONSGENERAL........................................................................1-1SAFETY DECALS...........................................................1-1DANGER, WARNING, AND CAUTION DECALS........1-1PRIOR TO START UP......................................................1-2GENERAL OPERATION.................................................1-3ANSIZ245.1-2007............................................................1-7PRE-OPERATION INSPECTION CHECKLIST.............1-8HYDRAULICS.................................................................1-9FIRE PROTECTION........................................................1-9HOUSE KEEPING...........................................................1-9SHUT DOWN..................................................................1-9DECAL PLACEMENT...................................................1-10SECTION 2 - OPERATIONSTART UP & CHECK OFF..............................................2-1LOADING CONTAINER.................................................2-2PACKING & TOP DOOR................................................2-3UNLOADING...................................................................2-4CLEAN UP........................................................................2-5STOW TRUCK.................................................................2-5SECTION 3 - MAINTENANCEFRONT LOADER WARNING PRECAUTIONS............3-1LOCK OUT/TAG OUT PROCEDURE...........................3-1CRITICAL BOLT TORQUE VALUES............................3-4HYDRAULIC SCHEMATIC...........................................3-5FRONT LOADER DAILY MAINTENANCE.................3-6ROUTINE WASHING......................................................3-6FRONT LOADER WEEKLY MAINTENANCE.............3-7WEEKLY CYLINDER MAINTENANCE.......................3-7WEEKLY LUBRICATION POINTS................................3-8FRONT LOADER MONTHLY MAINTENANCE..........3-9OIL SUPPLY TANK MAINTENANCE...........................3-9HYDRAULIC OIL SPECIFICATIONS.........................3-10VALVE PRESSURE ADJUSTMENT.............................3-11DECELERATION VALVE ADJUSTMENT (BEFORESERIAL #8909F-01-09)...................................................3-1DECELERATION VALVE ADJUSTMENT (AFTERSERIAL #8909F-01-09)...................................................3-1SECTION 4 - ELECTRICAL INFORMATIONGENERATION ONE CONTROL BOX...........................4-1RELAY WIRING FOR GENERATION ONE BOX........4-2CHANGING THE GENERATION ONE BOX...............4-3NEUTRAL INTERLOCK AND ACCELERATOR SETUPFOR GENERATION ONE BOX.....................................4-5OVERVIEW OF INTERLOCKS FOR GENERATIONONE BOX........................................................................4-7
PLC PIN OUT GENERATION ONE BOX......................4-9GENERATION ONE BOX LAYOUT............................4-10IDEC CONTROLLER....................................................4-11DISPLAY FOR INPUTS AND OUTPUTS OF IDEC...4-12TROUBLE SHOOTING GUIDE FOR GENERATIONONE BOX AND ASSOCIATED COMPONENTS........4-13GENERATION TWO BOX LAYOUT...........................4-18CHANGING FROM GENERATION ONE TO GENERA-TION TWO CONTROL BOX........................................4-19GENERATION TWO NEUTRAL INTERLOCK ANDACCELERATOR SETUP...............................................4-21PACKER HARNESS LAYOUT.....................................4-22PACKER HARNESSES.................................................4-23SECTION 5 - TROUBLE SHOOTINGTROUBLE SHOOTING HELP........................................5-1ELECTRICAL TROUBLE SHOOTING GUIDE............5-2MAC AIR VALVE TO MAIN VALVE.............................5-5PUMP TROUBLE SHOOTING.......................................5-6TORQUE VALUES AND MARKINGS FOR CAPSCREWS...........................................................................5-8VALVE NAMING CONVENTION.................................5-9HOSE AND TUBING NAMING CONVENTION........5-10FITTING NAMING CONVENTION............................5-11
START/STOP ZELIO LOGIC CONTROLLER..............4-8
WHELEN STROBE
PETERSON SMART STROBES
DRIVING THE DIFFERENCE
GeneralThe New-Way Front Loaders were designed to work hard and withstand the rigors of daily use. The forces usedon the packer to compact refuse is accomplished with hydraulic pressures which are created and then directedthrough hoses to the packer panel. Extreme care and safety practices need to be used at all times while operatingthe packer. The owner is responsible to require all employees associated with this unit, read this manualthoroughly so that they fully understand all the instructions contained within it.
Publication of these safety precautions does not imply and should not be considered an all inclusive list. It is theoperator’s responsibility to learn and follow the proper operational procedures that are in accordance with allsafety codes and requirements including the American National Standards Institute (ANSI) requirements andOccupational Safety & Health Act (OSHA) regulations.ANSI Z245.1-2007 has been released and should be followed.Failure to operate this machine correctly, or failure to heed warnings in the operator manual or on safetydecals, may cause Death or Dismemberment to the operator, co-workers or bystanders.
Safety DecalsSafety Decals are very important and should be clearly seen and obeyed at all times. Section 1-10 describes adetailed diagram of where the decals should be displayed. If any of these decals are missing or cannot beclearly read, they must be replaced immediately with the proper decal. New decals can be ordered free ofcharge from New Way by calling (800) 831-1858.
Danger, Warning and CautionAs you are reading this manual you may see “WARNING”, “CAUTION”, and “DANGER” graphics such asyou see below. These graphics are there to alert the operator or mechanic of specific safety issues concerning acertain operation. Operators and maintenance personnel shall read the instructions that accompany thesegraphics and follow them carefully. Compliance and common sense are crucial for safe operational procedures.
DANGER - Immediatehazards which WILLresult in severe personalinjury or death.
WARNING - Hazards orunsafe practices whichCOULD result in severepersonal injury or death.
CAUTION - Hazards or unsafe prac-tices which could result in minorpersonal injury or prop-erty or product damage.
The word “NOTE” is also used at times throughout the manual and is followed by information that will clarify orprovide emphasis to a certain point in the manual.
1-1-1
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
DRIVING THE DIFFERENCE
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
Prior to Start Up
1. At a minimum, Scranton Manufacturing Co., Inc.recommends that operators wear steel toed safetyshoes, OSHA approved safety glasses, and gloves.The company also recommends that operators donot wear any jewelry on their wrists or hands, orloose fitting clothing that could catch on operatinglevers or moving components of the packer.
2. Do not operate any machinery while under theinfluence of drugs or alcohol.
3. Before operating this refuse packer, the person(s)should be properly instructed and trained in theoperation of the equipment. He/She must also befamiliar with all warning devices, hand signals, andtraffic rules.
4. Perform a pre-operation inspection of the unit bywalking around it and:
Inspect it in accordance with the chassismanufacturer’s guidelines.
Inspect it in accordance with our “RefusePacker” guidelines listed in Section 3 –“OPERATION” of this manual. DO NOTSTART OR OPERATE ANY EQUIPMENTTHAT IS MALFUNCTIONING.
Make sure all obstructions and people are clear.
Inspect all lights, back-up and tailgate ajar alarms.
Check all mounting bolts, cylinder pins, and otherfasteners for placement and tightness. Adjust orreplace as necessary with the same grade and size.
5. Any malfunctions should be reported to a supervisoror mechanic. Before walking away from amalfunctioning unit do the following:
Set the parking brakes.
Disengage the PTO.
Turn off the engine.
Remove the ignition key.
6. Any service work completed on the unit should bedone with the proper tools and procedures as shownin this service manual. Only authorized personnelshould attempt the repair work. Use ONLY properreplacement parts on the unit.
7. If the height of your unit was altered, recheck theoverall height and make sure this height plus threeinches is noted on the decals.
8. Thoroughly understand the functioning of everyoperating control. Be aware of the function andlocation of every instrument, control, gauge, andprotective device.
9. Know where to get help in case of an emergency.1-2
1-2
DRIVING THE DIFFERENCE
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
1-3
General Operation
1. The operator is responsible for making sure that operation of this unit is in accordance with the instructionscontained in this manual and all codes including those of the Occupational Safety and Health Act (OSHA)regulations and the American National Standards Institute (ANSI) standards.
2. Do not operate any equipment without proper instruction and training.NOTE* A good source for training is “Coaching the Refuse Truck Driver II” from “National Solid WastesManagement Association”, Washington, D.C. Call (800) 424-2869 for pricing information.
3. Before operating this refuse packer, the operator(s) must be properly instructed and trained to be a qualifiedoperator(s). They must be familiar with all danger, caution and warning decals, warning devices, handsignals, and traffic rules.
4. Know the function and location of all instruments, gauges, protective devices, and controls of the unit.
5. Know where to get help in case of an emergency.
6. Each day, prior to the first cycling of the packer panel, open the side access door and visually inspect the areabehind the ejection panel. Also inspect the internal body cavity and hopper for abnormal obstructions, equip-ment, or personnel.
7. Make sure the “back-up” warning alarm is working properly.
8. Notify the manufacturer of any malfunction or any other observation that could be unsafe for the operator.The manufacturer’s name and address are on the cover of this manual.
9. Refer to chassis manufacturer’s manual for safety precautions on the chassis.
10. Any damaged Safety or Operational decals should be replaced immediately. Contact New Way at (800) 831-1858 to order free replacements. (Refer to the diagram on Page 1-10).
11. Before operating the unit, put on proper safety equipment such as protective shoes, glasses, appropriategloves and a safety vest. Also, turn on appropriate warning lights.
12. Seat (safety) belt must be worn at all times - It’s The Law!
13. When starting the unit’s engine, use the proper procedure as listed in the chassis manufacturer’s instructionmanual.
DRIVING THE DIFFERENCE
14. Before moving the unit or operating any controls make sure co-workers can be seen and that they are in a safeposition.
15. While operating the unit, all access doors and service-opening covers must be latched in place and maintained.
16. Personnel should ride only in the cab. Personnel are prohibited from riding on any specified riding platformsor steps if vehicle speeds will exceed 10 mph or more, or if the vehicle will be travelling further that 2/10 ofa mile without stopping. Personnel must never dismount any part of the vehicle when it is in motion.
17. Keep side access door and rear tailgate in closed and latched position.
18. Never operate the equipment with the side access door in the open position.
19. Never “push” or “tow” anything with the unit.
20. Before traveling in reverse, make sure the area behind the unit is clear of obstructions and then move thevehicle as slowly as possible. Do not travel in reverse further than distances allowed by local ordinances. Iftraveling in reverse further than ten feet use a “guide.”
21. Stop unit immediately if the warning light for the “tailgate ajar” system comes on.
22. Before leaving the cab, always set the parking brake.
23. Controls or hoses should never be used as hand holds.
24. Before starting to load the packer, make sure all tailgate locks are properly engaged.
25. If the accelerator system is engaged, do not step on the throttle.
26. Do not place head, body, hands, arms, fingers, or any limbs, etc. into a pinch point or any movingparts.- Death or Dismemberment May Occur.
27. Do not attempt to dislodge any material unless wearing “approved” safety glasses or a full-face shield.
28. Never use this unit to transport a container from one location to another.
29. Container handling cables or chains should never be used for pulling or towing.
30. Container lids should be closed and latched when not being handled.
31. Set the vehicle parking brake before handling a container.
32. Raise the container slowly and smoothly.
1-4
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
DRIVING THE DIFFERENCE
33. Read and obey all container decals issued by the container manufacturer.
34. Read and follow container manufacturer’s information on accepted use practices.
35. Do not attempt to lift overloaded containers.
36. Center the container on the attachment
37. All containers should be inspected and repaired if not in a safe, usable condition.
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
DRIVING THE DIFFERENCE
1-5
38. Never cross under a raised container.
39. Stand clear when dumping containers.
40. In cold weather, make sure container is not frozen to the ground before attempting to lift it.
41. If debris needs to be cleaned from container, first make sure the container is firmly on the ground, then reachinside with a probe or other tool – Do not use hands. Never place any part of the body between the packerbody and the container.
42. Make sure there is enough overhead clearance before dumping a container.
43. Place the container on a flat, level surface.
44. Detach container before moving the vehicle.
45. Do not attempt to unload uphill, into the bank of a hill, or against a pile of garbage.
46. Never walk or stand under the tailgate when in the raised position.
47. Before opening the tailgate, be sure there is sufficient overhead clearance.
48. Before raising or lowering the tailgate, warn others and make sure that they are clear of the area.
49. Never move the unit with the tailgate raised unless it is needed to assist unloading of packer contents.
50. The tailgate should always be raised and lowered slowly.
51. Proper maintenance and service of the equipment is necessary to ensure safe and reliable operation. Followthe maintenance schedule and conduct repairs as needed.
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
52. The following minimal lockout/tagout procedure must be completed before entering into or under any part ofthe packer.
– Park on level surface.– Engage the emergency/park brake.– Disengage the power take-off, pump controls, accelerator switch and place all control handles on the packer
in the centered neutral position.– Turn off the truck ignition. Remove key.– Place the truck keys in pocket.– Attach “DO NOT OPERATE” tag or cover on steering wheel– Chock the wheels.
(Refer to the LOCKOUT/TAG OUT Procedure beginning on page 4-1.)
53. In the event the tailgate must be in the open position during maintenance, securely block tailgate and thor-oughly test method of blocking prior to proceeding. (Also refer to number 5 on page 1-2). Tailgate SafetyProps have been pre-mounted at the factory for this purpose, and include an operation decal stating proper useprocedures to obtain the required two feet of clearance.
54. All hydraulic pressure and electrical programming settings, including over-speed and acceleratorsettings, are set at the factory and should not be modified. Modifications to these settings may create safetyhazards and/or cause serious damage to the equipment. Any modifications to these settings not authorized by the
Customer Service Manager or the Chief Engineer of Scranton Mfg. will void warranties.
55. This manual in its entirety is to be considered a permanent part of the equipment. In the event there is atransfer of ownership the manual should be included/transferred with the equipment.
56. Scranton Manufacturing must be notified of the name and address of the new owner in order to make the newowner aware of any safety or service bulletins issued. Scranton Manufacturing can be reached at
(800) 831-1858.
DRIVING THE DIFFERENCE
1-6
1-7
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
DRIVING THE DIFFERENCE
In accordance with ANSI Z245.1-2007 the new standard for the transit (transitis defined as all opera-tion of the front loader between collection points when speed exceeds 20 mph) position of the forksis either with the arms in the full up position or with the fork pivot shaft above the top of the wind-shield. Drivers must take note of overhead clearences such as power lines and during transit the forksnor arms nor the pivot tube should be higher than 13 feet, 6 inches above the road except wherepermitted by local or state authorities.
ARMS IN FULL UP POSITION PIVOT SHAFT ABOVE WINDSHIELD
NOT ALADDER
Another issue covered in this new standard is the windshield guard should not be used as a ladder toclimb to the roof of the cab. The guard is to keep the container from coming in contact with thewindshield.
Pre-operation Inspection Checklist
1. Placement and readability of decals.
2. No fluid leaks.
3. Mounting hardware in place and fastened tightly.
4. No metal fatigue or cracks in welds.
5. Hydraulic fluid reservoir at recommended level, with cylinders retracted.
6. All operation controls function correctly.
7. All debris removed from under and behind ejection panel, and all areas around packing cylinder. Also, between cab and body.
8. All operating and running lights are functional.
9. Engine warmed up according to manufacturer’s instructions.
10. Loader arms and forks operate properly.
11. Lid opens and closes properly.
12. Packing cycle operates properly.
13. Back-up and tailgate ajar alarms are functional.
14. Fully charged Fire Extinguisher is in cab.
15. Problems are reported to authorized personnel.
OK NOT OK COMMENTS
Inspector’s Signature: ________________________________________________________
Date of Inspection: ________________________________
1-8
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
DRIVING THE DIFFERENCE
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
Hydraulics
1. Hydraulic fluid flows through at very hot temperatures and can cause burns. To protect yourself from suchburns, do not touch cylinders, piping, or hoses.
2. When checking for hydraulic fluid leaks never use the hands since escaping hydraulic fluid can cause inju-ries.(DANGER)-“High Pressure Injection of Hydraulic Fluid through the skin and into the bloodstream may cause seriousinjury and/or Death.”
Fire Protection
1. Always have a fire extinguisher available and check it monthly to make sure it is fully charged and operable.
2. Never have an open flame around flammable / combustible materials.
3. Never load smoldering ashes into the packer because they could ignite the refuse.
Housekeeping
1. Keep driving area, as well as steps and handholds, clean and free of debris and grease.
2. Make sure maintenance equipment, etc. is kept away from packer controls so they cannot be accidentallyactivated.
Shutdown
1. Set parking brake.
2. Put all controls in neutral.
3. Disengage PTO.
4. Shut off engine.
5. Shut off accelerator dashboard switch.
6. Shut off all accessory switches;work light, strobe or beacon light.
7. Remove ignition key.
8. Lock vehicle.
DRIVING THE DIFFERENCE
1-9
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
Decal Placement, Check Monthly.
CC CC
AA
AAAA
H H
A A
C C
AA
AA
AA
DD
DDA
X
BB+
A
X
A
A E
E
I
IIL BKJ
FF DD
AA
AAAA
EE C AA
BH
AA
Y
GG
GG
Y
KK DD FF
T W C EE
BH
Front Loader Safety and Operation Decal Diagram:
HH
HH
inside Z
JJJJ
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1-10
1-9
A (qty-6)
B (qty-3) C (qty-2)
E (qty-2) H (qty-4) I (qty-3)
K (qty-1)
L (qty-1)
1-11
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
PART #105207
PART # 101437 PART# 101427
PART # 101432 PART #101431 PART #101433
JJ qty-2PART # 112484 PART # 101436
PART # 101438
FOR COMPLETE KIT ORDER PART #110100
DRIVING THE DIFFERENCE
Serial Tag(Permanent-Riveted)
Serial Tag(Adhesive Backed)
Amber Reflectors
Red Reflectors
Alternating Reflective Safety Stripes
Silver Reflective Tape
T (qty-1)
W (qty-1)
X (qty-2)
Y (qty-2)
AA (qty-NA)
CC (qty-NA)
DD (qty-4) EE (qty-5)
FF (qty-2)HH (qty-1 set)
BB (qty-1)BB+ (qty-1)
GG (qty-2)
1-12
Z (qty-1)
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
PART # 101429PART # 101434 PART # 103582
PART # 105208PART # 105211
PART # 101425
PART # 105209
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1-13
Chassis Cab (Dash or Visor)(Qty-1)
Chassis Cab (Dash or Visor)(Qty-1) PART# 101436f
*Chassis Cab (Optional)(Qty-1)
*Chassis Frame (Optional)(near pto shaft)(Qty-1)
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
PART # 110110f
PART # 37924
DRIVING THE DIFFERENCE
Part # 110110
KK (Qty 1)
LL (Qty 1)Part #108638
JJ(qty-1) 1-14
Saftey PrecautionsFEL - Full Eject Model
SECTION 1
PART # 101423
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C (qty 2)Part # 101427
Left Mud Flap Extension Right Mud Flap Extension
1-15
2-1
Start-Up Instructions& Check-Off
1. Close Air Bleeders(usually found on the batteryhousing).2. Start Engine.3. Do Pre-Trip Inspection.4. Check Hydraulic Reservoir Oil Level.
5. Press Reset Button On Cab Console.6. Check All Body Functions.
The Mammoth Series Front Loader has been created to safely and efficiently load, compact,transport, and unload refuse. The following text describes how to accomplish those tasks.
PTO RESET
HYDRAULIC OIL GAGE
OperationFEL - Full Eject Model
SECTION 2
DRIVING THE DIFFERENCE
Loading Containers
1. Ensure “Lid” is open and packer panel is fully retracted and lid open light is on.2. Penetrate container pockets fully with forks, then hit “Arms Up.”
3. When the bottom of the container is at eye level, hit “Forks Down” to level the container while stillholding “Arms Up.”
4. Continue holding “Arms Up” until the arms come to rest, then hit “Forks Up” to dump container.
5. When container is empty, hit “Forks Down” until the bottom of the container is approximately 10degrees before vertical.6. Hit “Arms Down” to set container on the ground.7. Ensure forks are level, then back out of container.8. When out of container;
a. Moving to second container, hit “Forks Up” until forks are vertical, and proceed to second container.b. Moving to another location, hit “Arms Up” until forks are just above the windshield, and proceed to container location. [ Normal Travel Position ]
PenetrateContainer
Raise andLevel
Container Up
Container Dump
2-2
Level
OperationFEL - Full Eject Model
SECTION 2
DRIVING THE DIFFERENCE
2-3
Packing & Top Door
1. While driving to the next container, hit the “AutoPack” button. The packer panel normally travels alimited distance and then returns. When this cycle iscompleted, the packer panel is in the “forward or homeposition” and is ready for more refuse to be placed inthe hopper.
2. When packer panel fails to retract automatically or iftrash starts falling over the top of the packer whileextending, hit the Auto Pack 1 time. The pack panelwill stop. Hit the Auto Pack again and the pack panelwill return home.
3.The truck is full when the packer panel stops movingor is slow to pack.
4. Remove ignition key, then carefully climb onto thetop of the truck body to check for loose trash or anyobstructions that would keep the hopper lid from closing.When full, the packer can be unloaded.
5.Close the lid by operating the “Lid Switch” to the closeposition, and drive to the landfill or transfer station.
LID OPEN/CLOSE
AUTO PACK
EMERGENCY STOP BUTTON
LID FULLOPEN LIGHT
OperationFEL - Full Eject Model
SECTION 2
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2-4
Unloading
1. Check for overhead obstructions above the tailgate.Raise the tailgate by holding down the tailgate raiseand the tailgate interlock buttons. Ensure tailgate iscompletely raised.
2. Press packer extend to eject the load.
TAIL GATEOPEN/CLOSE
TAIL GATE INTERLOCKEMERGENCY STOP
LID OPEN/CLOSE
PANEL EXTEND/RETRACT
3. After the load is ejected, retrack the packer panelto home.
4. Drive to a safe place at the facility to prepare forclean-up.
OperationFEL - Full Eject Model
SECTION 2
DRIVING THE DIFFERENCE
Clean-Up
1. After driving to safe place, lower loader arms thenlower tailgate to gain access to tailgate props locatedon both sides of tailgate. Follow instructions on Decalfor Proper Use. Rest Tailgate on Tailgate Safety Props.
2. Remove the ignition key and clean the area to therear of the packer panel. Do not use your hands. Use asuitable tool such as a wooden handled garden hoe.Clean around the tailgate seal. Do not stand under anopen tailgate unless tailgate props are properly in placeand tested for steadfastness.NOTE: Keep the ignition key in your pocket for safetypurposes.
3. With loader arms down, pull “Safety Latch” toallow opening of Clean-out Trough Doors on rightand left sides. Use Hoe provided, located in end ofPivot Shaft Tube, to clean the forward trough area.Do not use your hands. Use the tool (hoe) provided.
NOTE: When Power-Washing the unit, followprescribed safety above.Also, Refer to page 1-6 ( Safety Precautions # 61 ).Do not direct high pressure wash onto the whiteelectrical component (enclosure) boxes.Doing so may result in shorting of components.
4. Close the tailgate and then open the lid and retractpacker panel. You are now ready to load more refuseor stow the truck.
Hoe and storage area.
Stow Truck
1. Park truck and shut engine off.
2. Ensure reset button on dash pops out. If resetbutton fails to pop out, report it to your maintenancedepartment immediately.
3. Open air bleeders near the hydraulic tank corner.
4. Shut down procedures are now complete.2-5
OperationFEL - Full Eject Model
SECTION 2
DRIVING THE DIFFERENCE
Proper repair and servicing is important to keep yourpacker operating at peak efficiency. Following are ef-fective methods for performing these procedures. Someof these procedures require special tools. Using im-proper tools can be dangerous to the person using them.Any modifications to equipment must be done in ac-cordance with American National Standards InstituteZ245.1-2007. Deviating from these standards couldcause damage to the user and operators.Components that exceed 4000 pounds in weight are;“Body Shell”.
Safety Precautions to be taken before performing anyservice or repair;Do not work inside, underneath, or on top of a truckbody without complying with the followingprecautionary steps.1. Shut Off Engine.2. Set Park / Emergency Brake.3. Chock front and rear of at least two tires.4. Remove Ignition Key. Keep key with you at all times.
Lock Out-Tag Out Procedure
Always wear safety glasses.
Lock out procedure! (To render safe and isolate all en-ergy sources.)
A. Shut down all power sources.
1. Turn off the truck engine, and remove the igni-tion keys and push down Emergency Stop button.
2. Turn off any auxiliary engines, and remove theignition keys.
3. Turn off the electric engine, and turn off the power
panel. Pull the 30AMP fuse by the battery or killswitch (on the 10AWG RED line). Lock out thepower panel and main breaker. Remove keys!
ALL KEYS MUST BE PLACED IN YOUR POCKET!NO OTHER KEYS SHOULD BE AVAILABLE TOANY OTHER PERSONNEL!(If more than one set of keys exists for your vehicle getall sets and place them in your pocket!)
B. Hydraulic Disengagement procedures: NOTE:Power take-off:
1. Front Mounted Pump with Electric Controls-With engine at idle, turn pump switch off. Do NotRe-Start Engine as primary pump system would re-engage causing hydraulic flow. Remove ignition keysand place in pocket!
2. Automatic Transmission with Electric Shift PTO- With ignition switch to On, and engine off or atidle, push dash control rocker switch to off position.PTO will disengage.
C. Remove all keys from engines, trucks and electricdevice switches!
3-1
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
Lock Out-Tag Out Procedure(continued)
D. Install Tag on steering wheel with non reusable fas-tener.Example of a Lockout Tag:
(DANGER)EQUIPMENT
LOCKED OUT BY:
Name: Dept: Date: Time:
E. Place Equipment in NON-Freefall Positions.
1. Raised tailgates should be lowered, either underpower or by gravity. To achieve this, operate theappropriate tailgate control in a correct manner.
F. Placing Extra Blocking Devices.Also, Refer to page 1-6 ( Safety Precautions # 61 ).
1. Raised tailgates may be blocked in raised posi-tion by first securing wheels on the road surface withwheel chocks, front and rear, on at least two wheels.This is to prevent truck movement. Whenever pos-sible, use the installed tailgate props that are installedon the tailgate by following the operation decal.When this is not possible, safely block up any tail-gate, movable assembly or part, with carefullystacked and nailed 4" x 4" lumber or 6" x 6" lumber.Check the blocking for steadfastness. Carefully lowerthe weight of the tailgate onto the beams. Test thechocks and tailgate props, or the beams for stead-fastness before placing yourself in a potentially dan-gerous situation.
G. Relieving stored hydraulic pressure in all cylindersonly when hydraulic maintenance is to be performed.
1. All telescoping hydraulic cylinders used only inconjunction with a packing panel and or ejectionpanel.
a. Secure vehicle to road surface with wheelchocks placed front and rear on at least two wheels.Test wheel chocks for steadfastness.
b. Check air tank reserve. Should have fullsystem pressure air.
c. Open all hydraulic shutoff valves incorpo-rated into your particular unit.
d. With lockout-tagout in process, turn igni-tion switch to on. Do Not Start Engine.
e. Pull up the Emergency Stop button. PushPTO Reset Button. Operate the manual packertoggle-switch in both forward and reverse directionand hold momentarily in both positions.
f. Remove ignition key and close all hydrau-lic shutoff valves incorporated into your particularunit.
g. Loosen the hydraulic fittings to the hydrau-lic telescoping cylinder at a point of attachment awayfrom the cylinder to be worked upon. Check for anyleakage of fluid under residual pressure.
h. After residual pressure has been relieved,tighten the previously loosened fittings.
i. You have now relieved the stored hydraulicpressure inside of the cylinders to be worked on!You may now proceed as normal unless power isreapplied to hydraulic system. If power is reapplied,Restart the Entire Process.
3-2
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
Lock Out-Tag Out Procedure(continued)
2. Double acting single stage cylinders which holdclose a tailgate. NOTE: These cylindersincorporate a SAFETY PILOT CHECK VALVE lo-cated underneath the body at the rear.NOTICE** The tube side port on these cylindersalways have high pressure applied!
a. Secure vehicle to road surface with wheelchocks placed front and rear on at least two wheels.Test wheel chocks for steadfastness.
b. Lower the tailgate if at all possible, by op-erating the appropriate controls.
c. If tailgate can not be lowered, safely blockup with carefully stacked and nailed 4" x 4" lumberor 6" x 6" lumber. Check the blocking for steadfast-ness.
d. After tailgate is lowered or securely sup-ported, perform the following steps.
e. Check air tank reserve. Should have fullsystem pressure air.
f. Open all hydraulic shutoff valves incorpo-rated into your particular unit.
g. With lockout-tagout in process, turn Igni-tion Switch to ON. Do Not Start Engine.
h. Push PTO Reset Button In.i. Emergency Stop Button should be in the up
position.j. Operate the Tailgate Toggle-Switch in both
Up and Down direction and hold momentarily inboth positions.
k. Remove ignition key and close all hydrau-lic shutoff valves incorporated into your particularunit.
l. DANGER** Loosen slowly and carefullythe “tubed side” port fitting to this cylinder or cylin-ders. Watch out for leakage of fluid under residualhigh pressure. Close all shut off valves incorporatedinto your particular unit.
m. After residual pressure is removed fromhose lines, tighten the loosened fittings.
n. You have now relieved the stored hydraulicpressure inside of the cylinders to be worked on!You may now proceed as normal unless power isreapplied to hydraulic system.If Power Is Reapplied, Restart The Entire Process.
3. Double acting single stage cylinders which sup-port a load or are used in conjunction with arms orforks:
a. Open all shut off valves incorporatedinto your particular unit’s hydraulic system.
b. Operate the particular valve control leverfor the appropriate cylinder. Operate in both direc-tions and hold the positions momentarily to relievepressure.
c. Secure the vehicle to the road surface withwheel chocks placed in front and behind at least twowheels. Test the wheel chocks for steadfastness.
d. Safely block up any movable assembly, orpart, with carefully stacked and nailed 4" x 4" lum-ber or 6" x 6" lumber. Check the blocking for stead-fastness.
e. Close all shutoff valves incorporated intoyour unit.
f. Loosen the hydraulic fittings to this cylin-der or cylinders at a point of attachment away fromthe cylinder to be worked on. Check for leakage offluid under residual pressure.
g. After residual pressure is removed from thehose lines, tighten the loosened fittings. Proceed towork as normal on this particular cylinder.
3-3
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-4
BOLT DESCRIPTIONQUANTITY
PER TRUCKBOLT SIZE
BOLT GRADE
WRENCH SIZE
WASHER LUBRICATION TORQUE VALUE
FORK AND ARM PIVOT PILLOW BLOCK
BEARING CAP BOLTS24 3/4-10X4.5 8 1 1/8 HEX
HARDENED FLAT
COPPER BASED ANTI-SEIZE
(k=.16)
260 FT-LBS(350 N-m)
TORQUE VALUES FOR CRITICAL BOLTS
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-5
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCEAR
M C
YLIN
DERS
EJEC
TION
PAN
ELCY
LIND
ERS
FORK
CYL
INDE
RSHO
PPER
LID
CYLI
NDER
TAIL
GATE
CYL
IDNE
RS
2000
psi
1100
psi
2450
psi
UNLO
ADER
LINE
TO
TANK
25 p
si BY
PASS
1250
psi
2450
psi
CYLINDERS
1. Inspect cylinders on a weekly basis for excessiveleakage, and check cylinder rods for scratches ornicks that may cause additional damage to thewipers, bushings, and seals. Nicks and scratchesshould be polished to prevent additional damage.(Note: Cylinder rods should be inspected in thefully extended position therefore safety precautionsneed to be in place to prevent potential harm.
Front Loader DailyMaintenance:.
1. Initiate Lockout/Tagout Procedures.
2. Inspect all safety and operational decals, makingsure they are ledgible and fully intact. In the casethat decal replacements are necessary, contact yourlocal New Way distributor or call the factory to orderfree replacements.
3. Inspect for proper operation of all lights and warningdevices, including backup and tailgate ajar alarms.Repair as necessary.
4. Perform a pre-operation inspection of the unit bywalking around it and:
Check it in accordance with the chassismanufacturer’s guidelines.
Check it in accordance with our “Refuse Packer”guidelines listed in Section 3 – “OPERATION” ofthis manual. Do not START or OPERATE anyequipment that is MALFUNCTIONING.
5. Check hydraulic system sight gage forrecommended oil level (manual shut-off valves arein open position) and inspect for leaks - withoutoperating engine or hydraulics.
6. Remove debris from under and behind ejectionpanel, and all areas around the telescoping ejectioncylinder. For this purpose, it is strongly suggestedyou use a wooden handled garden hoe or similartool.
7. Check all mounting bolts, cylinder pins, and otherfasteners for placement and tightness. Adjust orreplace as necessary with the same grade and size.
8. Check all cylinder mounting points for metal fatigueor cracked welds. Repair before use.
9. Check operation of all control levers, switches andbuttons to function properly and cause correct actionof components without problems.
10. Refer to chassis manufacturer’s manual formaintenance procedures on the chassis.
Routine Washing:
When necessary to wash interior, follow Lockout/Tagoutprocedures as specified and include a helper to be anoutside observer.
Also, Refer to page 1-6 ( Safety Precautions #61 ).
“CAUTION: Interiors may become slippery and createa hazard to the person within. An observer stationedoutside could summon help if needed.”
Suggested washing safety apparrel includes, but not lim-ited to; rainsuit, goggles, leather gloves, rubber boots.
3-6
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-7
MaintenanceFEL - Full Eject Model
SECTION 3
SLIDE ZERK
KNUCKLE ZERKS
SET SCREWS (3)BOLTS TO ENGINE (4)
Front LoaderWeekly Maintenance:
Lubricate all points on a weekly basis unless otherwisenoted. Refer to Lubrication Location Diagram on Page 3-8for location of lubrication points.1. Swab a quality grease/chassis lube to ejection panel
wear surfaces (2 channels).
2. Swab a quality grease/chassis lube to tailgate locklugs under and at sides of tailgate.
3. Grease or Oil with 30 weight oil, all cylinder pinsas shown in lubrication chart.
4. Apply 30 weight oil to all hinge, linkage or frictionpoints that are not lubricated with grease fittings.
5. PTO/pump drive line may contain (2) grease fittings(if equipped).
6. Tailgate cylinders contain (2) grease fittings each.
7. Refer to chassis manufacturer’s manual forlubrication schedule for the chassis.
Front mounted pump drive shafts should be inspected for tightness of the set screws where the shaftattaches to the pump daily. There are four bolts to the engine flywheel to check for tightnes also. Thethree grease fittings should be greased daily.
FRONT MOUNT PUMPS
DRIVING THE DIFFERENCE
Every six months the set screw should be loosened and the knuckle removed from the splined shaft.New spline lubricant (part #119732) should be applied and the assembly replaced. Ensure that thethree set screws are secure.
ThreeCylinderEnds.
OneCylinderEnd.
Decel ValveLever Shaft.
Rear PivotMount BothEnds.
Oil -Grease -LUBRICATION POINTS (weekly)
FRONT
Blade PropHinge inside.
REAR
Swab greaseto inside rails.
3-8
This page and page 3-7 reference each other.Grease Fitting Location Chart.
Front Loader MonthlyMaintenance:.
1. Check all wiring connections. Tighten or replace asnecessary.
2. Check wires for excessive wear, kinking orcrimping. Replace as necessary.
3. Check all fasteners for excessive wear and tightness.Replace or tighten as necessary.
4. Check all hydraulic hoses and pipes for damage andwear. Replace as necessary.
5. Check all air supply lines for rubbing and chafing.Replace as necessary.
6. Check all decals for readability. Replace DamagedDecals (free replacements). See pages 1-8 through1-14 in Section 1.
Oil Supply Tank
1. Hydraulic oil filter: Replace after the first 50 hoursof use and every 250 hours thereafter. (Note:Hydraulic oil filter should be changed in the caseof any major hydraulic component failure.)
2. Air Filter / Breather Cap: It must allow free air flowfor the hydraulic oil tank. Inspect daily to assurethat the cap is properly attached and free ofobstruction. Wash foam prefilter in soapy water,rinse and air dry every 3 months. Replace cartridgeelement every six months (minimum) and morefrequently in dirty conditions.
3. Hydraulic fluid: Replace after first six (6) monthsand every year thereafter. Refer to oil specificationsfor replacement oil. (Note: Oil should be drainedand replaced in the case of any major hydrauliccomponent failure.)
4. Suction strainer: Remove and clean the screen eachtime the oil is changed.
5. The optional high pressure filter should be changedat the same interval as the hydraulic oil filter.
3-9
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-10
MaintenanceFEL - Full Eject Model
SECTION 3
OIL SPECIFICATIONS:
Brand: Northland Talamar Extreme Northland Talamar All Season BLUE IN COLOR RED IN COLOR
IOS Viscosity Grade: ASTM D2422 32 46
Gravity Deg. API ASTM D278 32.0 31.1
Specific Gravity ASTM D1298 0.865 0.870
Pour Point Degree F ASTM D97 -50 -40
Flash Point Degree F ASTM D92 390 405
Viscosity: cST@40C ASTMD445 33 47
cST2100c 6.6 7.9
Viscosity: SUS@100f ASTM D2161 168
SUS@210F 48
Viscosity Index, min ASTM D2270 160 138 typical
Brookfield Viscosity ASTM D2983 1050
cP, max @-20f
Rust Test ASTM D665 pass pass
Foam Test, max. ASTM D892 10/0 10/0
20/0 20/0
10/0 10/0
Dielectric Strength, KV min. 35 35
When adding or replacing the hydraulic fluid give the above information to your supplier to provide asimilar product. The oil provided with the unit is a premium hydraulic fluid that is formulated to meetthe stringent performance requirements of refuse collection equipment exposed to broad ambientoperating temperatures.
DRIVING THE DIFFERENCE
MAIN VALVE PRESSURE ADJUSTMENTTitle: Frontloader Main Hydraulic System Valve Pressure Adjustment
Scope: This procedure applies to all New Way brand Frontloader series refusepackers manufactured after June of 1998 that utilize CommercialIntertech/Parker VA35 valves. The pressure settings affect main systempressure, hopper lid cylinder extend pressure, and ejection panel extendpressure. Reference Frontloader Hydraulic schematic, (PN 103866) forthese pressure settings.
Purpose: To provide clear and concise directions on the adjustment of the threeadjustable pressure settings.
Responsibility: All employees and representatives of Scranton Manufacturing Co shalladhere to this document, including those persons contracted to do busi-ness for Scranton Manufacturing Co. It is the responsibility of any em-ployee involved in the adjustment of these system pressures to know andunderstand this document as well as the responsibility of Scranton Manu-facturing management to ensure this document is kept current.
WARNING: Only trained personnel should conduct adjustments to the hydraulic system pressures. Hydraulicpressures set above the stated settings may cause damage to the equipment and/or personal injury.
WARNING: Only trained personnel shouldconduct adjustments to the hydraulic sys-tem pressures. Hydraulic pressures setabove the stated settings may cause dam-age to the equipment and/or personal in-jury.
3-11
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-12
1.0 Preparation – Ensure that all safety precautions are observed during this procedureincluding proper lock-out and tag-out of equipment.1.1 Tools – To perform this procedure you will need the following equipment
1.1.1 Large flat screwdriver.1.1.2 1 ½” end wrench1.1.3 ½” end wrench1.1.4 3/16” end wrench
1.2 Perform all start-up inspections.2.0 Adjustment Procedure – Main System Pressure
2.1 Retract the ejection panel cylinders by depressing the ejection panel retracttoggle until the ejection panel is fully retracted. While holding the ejectionpanel retract toggle, read the relief pressure on the gauge on the valve.
2.2 For optimum performance, safety and durability, the pressure should be 2450PSI.
2.3 If an adjustment is required, follow proper shut down and Lock-out/Tag-outprocedures before adjusting the relief cartridge on the valve.
2.4 Loosen jam-nut on main valve relief. (1 ½” end wrench) This relief is locatedon the valve and is labeled 1 on the drawing below.
2.5 Rotate the adjustment screw with a large flat screwdriver. (Clockwise to in-crease pressure)(Counterclockwise to decrease pressure)
2.6 Repeat processes 2.1 – 2.6 as required.2.7 When the pressure is properly set, tighten the jam-nut and re-check the set-
ting.3.0 Adjustment Procedure – Ejection Panel Extend Pressure
3.1 Insert a pressure gauge into pressure port 1.3.2 Open the tailgate fully.3.3 Extend the ejection panel cylinders by depressing the ejection panel extend
toggle until the panel is fully extended. While holding the ejection panel extendtoggle, read the relief pressure on the gauge on the valve.
3.4 For optimum performance, safety and durability, the pressure should set asfollows:
3.5 If an adjustment is required, follow proper shut down and Lock-out/Tag-outprocedures before adjusting the relief cartridge on the valve.
3.6 Loosen jam-nut on ejection panel relief valve. (1/2” end wrench)This relief islocated on the valve and is labeled 2 on the drawing below.
3.7 Rotate the adjustment screw with 3/16” end wrench in 1/8-turn increments.(Clockwise to increase pressure)(Counterclockwise to decrease pressure)
3.8 Repeat processes 2.1 – 2.6 as required.3.9 When the pressure is properly set, tighten the jam-nut and re-check the set-
ting.
C y lin d e r Ty p e M o d e l P re s s u re S e t t in g6 .5 " B o re Te le s c o p ic S ta n d a rd 2 0 0 0 p s i5 .5 " B o re Te le s c o p ic L ig h tw e ig h t 2 2 5 0 p s i5 .5 " B o re S in g le S ta g e H o is t B o d y 2 4 5 0 p s i
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-13
1.0 Adjustment Procedure – Hopper Door Cylinder Extend Pressure1.1 Insert a pressure gauge into pressure port 2.1.2 Extend the hopper door cylinder by depressing the hopper door extend toggle
until the hopper door cylinder is fully extended. While holding the hopper doorextend toggle, read the relief pressure on the gauge on the valve.
1.3 For optimum performance, safety and durability, the pressure should be 1500PSI.
1.4 If an adjustment is required, follow proper shut down and Lock-out/Tag-outprocedures before adjusting the relief cartridge on the valve.
1.5 Loosen jam-nut on the hopper door relief valve. (1/2” end wrench) This relief islocated on the valve and is labeled 3 on the drawing below.
1.6 Rotate the adjustment screw with a 3/16” end wrench in 1/8-turn increments.(Clockwise to increase pressure)(Counterclockwise to decrease pressure)
1.7 Repeat processes 2.1 – 2.6 as required.1.8 When the pressure is properly set, tighten the jam-nut and re-check the set-
ting.2.0 Completion - Ensure that all fasteners are fully tightened, all tools are removed, and
all oil leaks or spills are cleaned up.
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-14
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
DECELERATION VALVE ADJUSTMENTON FRONTLOADERS PRIOR TO SERIAL #8909F-01-09
The location of the deceleration valve is the lower arms pivot tube on the front drivers side of thepacker.
1.0 PREPARATION - Ensure that all safety precautions are observed during this procedureincluding proper lock-out and tag-out of equipment.
1.1 Tools - To preform this procedure you will need the following equipment1.1.1 Tape Measure1.1.2 One 1/4” size Allen Hex wrench for Cam Set Screws1.1.3 One 3/4” Combination wrench for Set Screw Jam Nut1.1.4 Two 9/16” Combination wrenches or 9/16” sockets for the Valve Mounting
Bolts1.1.5 Frontloader Operations Manual1.1.6 Lock-Out--Tag-Out Procedures
1.2 Perform all start-up inspections1.3 Rotate arms to approximately 1.5 to 2 inches from the rubber bumpers. Measure the
distance from the arm to the bumper. This measurement will be used later if furtheradjustments are required.
1.4 LOCK-OUT AND TAG-OUT THE MACHINE AT THIS TIME
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
Figure 1
2.0 ADJUSTMENT PROCEDURE (Reference Figure 1)2.1 Locate the deceleration valve actuator cam and deceleration valve2.2 Loosen deceleration valve mounting bolts. If plunger of the valve is already in line
with the cam lobe, (Reference Figure 2), move the valve towards the cam to increasedeceleration of the arms. Move valve away from cam to decrease deceleration ofarms. If plunger is not in line with the cam lobe, advance to section 2.4.
2.3 Tighten the valve mounting bolts and advance to section 2.9. Test unit persection 3.0 and repeat section 2 if needed.
2.4 Loosen set screws on cam (2) - ONLY ADJUST THE CAM IF THE PLUNGERIS NOT BEING DEPRESSED AT ALL, EVEN AFTER ADJUSTING PER 2.1-2.3.
2.5 Loosen the deceleration valve mounting bolts and slide the valve toward the cabof the truck
2.6 Rotate the cam so that the lobe is starting to depress the deceleration valve plunger.The cam lobe should be counter-clockwise from the plunger. (Reference Figure 2)
3-15
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
3-16
Figure 2
2.7 Tighten cam set screws2.8 Move the deceleration valve so that the plunger is depressed by the cam
lobe and tighten the mounting bolts.2.9 Remove all lock-outs and tag-outs
3.0 TESTING3.1 Perform all start-up inspections.3.2 Rotate the arms downward until fork pivot is above the cab or lower3.3 Rotate the arms upward, with the engine at idle, until the arms stop
against the rubber bumpers. Observe motion, velocity and acceleration/deceleration of arms as the are operating. If the arms are striking thebumpers too harshly, adjust valve distance to cam per paragraph 2/3and 2.6. With the engine at idle, the arms should come to a completestop approximately 1 inch from striking the pad.With the engine accelerated to 1600 rpm, arms should strike the padslightly and rebound off, coming to a stop about 1/2 to 1 inch from thepad. This will allow a proper stop when fully loaded with a heavycontainer.
3.4 If the unit is still stricking the bumpers too harshly, perform Steps 1.0and 2.0 again. This time use 1/2” more gap than was previously measured.
4.0 COMPLETION4.1 Ensure that all the fasteners are fully tightened. Remove all tools and clean
up all oil leaks and spills.
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
DECELERATION VALVE ADJUSTMENTFRONT LOADERS SERIAL #8909F-01-09 AND LATER
The Deceleration valve has been located under the street side front section of the packer. This new location andadjustment procedure is easier and faster than the older cam version. As the arms are raised above the cab and start back,the cable attached to the pivot tube bracket will bring the stricker plate forward to depress the plunger on the Decelerationvalve. The first step in adjusting the Deceleration valve would be to check to ensure the arms over cab proximity switch is inproper adjustment and that the pivot bracket has not shifted on the pivot tube. Two technicians are required. Technician #1 will be the truck operator and technician #2 will make the adjustmentsand be able to watch the testing results. Technician #1 will need to lower the arms to the position where the fork pivot tube is just above the cab windshield asshown in FIG 1. The cam on the pivot shaft of the arms should be in the position shown in FIG 2 and the Arms Above Cab Light in thecab should be on. At this time the cable for the Deceleration valve should be slack as shown in FIG 3. If the pivot cam needs to be adjusted, technician #2 will need a 3/4” combination wrench for the jam nut and a 1/4”Allen Hex wrench for the set screw. Once the jam nut and set screw have been loosened, the pivot cam assembly can berotated into position. The Arms Over Cab light in the cab should be on. Tighten the set screw with the Allen wrench andthen tighten the jam nut to lock the set screw in place.
DECELERATION VALVE SHOWN WITH ARMS FULL BACK
3-17
MaintenanceFEL - Full Eject Model
SECTION 3
DRIVING THE DIFFERENCE
FIG 1 FIG 2
FIG 3 FIG 4
Test the setting by running the arms full back and then bring back down to the position shown in FIG #1. The camshould be in the position shown in FIG #2 and the Arms Over Cab light should be on. Once this procedure is accom-plished, the Deceleration valve can be adjusted as needed. If the arms are hitting the rubber bumpers to hard, the cable needs to be shortened. If the arms are not going back farenough for proper dumping to be achieved, the cable will need lengthened. Technician #1 will need to run the arms down to a position that will allow slack in the cable. The cable can be adjusted on both ends. Technician #2 will need two 9/16” combination wrenches to loosen the boltand lock nut on the cable clevis. Once loosened, the pin attaching the clevis to the stricker or the pivot cam will need tobe removed so that the clevis can be turned clockwise to shorten the length of the cable or turned counter clockwise tolenghten the cable. The adjusting bolt should never be lengthened beyond 1” of bolt between inside of bolt headand the outer edge of the lock nut. Half turn increments should be used between reconnecting the cable and testing thesetting. Proper adjustment will be achieved when the arms stop with a 1/2” gap between the arm and the bumpers. This allowsleeway when emptying a heavy container. To test the setting, technician #2 will stand back and observe where the arms slow down and stop. Technician #1should run the arms down to arms above cab position and the back to the full back position. When the proper setting isachieved, technician #2 will need to tighten all lock nuts to hold the position. Retest the settings.
3-18
SECTION 4Generation One PLC
FEL - Full Eject Model
DOT WIRING BAR PART #119385BLOCK, TERMINAL BLOCK
10 AMP+12v
10 AMPWORK LIGHTS
10 AMPSTROBE LIGHTS
10 AMPFOUR FRONT
PROX SWITCHES10 AMP
TAILGATE POWER
SPARE
IGNITION RELAY
GROUND POST
NEUTRALINTERLOCKRELAY
STROBELIGHTRELAY
WORKLIGHTRELAY
PROGRAMABLELOGICCONTROLLERNON REPLACEABLE
STRO
BE
RUN
RIGH
T TU
RN
LEFT
TU
RN
BRAK
E
REVE
RSE
WO
RKLI
GHT
GRO
UND
FUSE BLOCKPART# 119384
NEUTRAL
ACCELERATOR
PART # 119383 SOLINOID, 100AMP,MAIN
PART #111342RELAY SPDTBOSCH,30AMP, 12VDC
PART # 111343RELAY SOCKET12VDC 5-PIN
TERMINAL BLOCKNON REPLACEABLE
SWITCH, ROCKER, SPDT BLACKPART # 116003
SWITCH, ROCKER, DPST RED LEDPART #116002
PROXIMITY SWITCH WITH 22" LEAD 3 PINPART #117284
PANEL, CONTROL, ELECTRIC/AIR, FLPART #117664
PART NUMBERS FORMAIN CONTROL BOX IN CAB AND MISCELLANEOUS PARTS
8mm feeler gaugesfor setting proximityswitches PART #117922
DRIVING THE DIFFERENCE
4-1
PRIOR TO SERIAL #9212F-09
SECTION 4Generation One PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
8787a
30 8685
NEUT
RAL
INTE
RLOC
K
RELA
YST
ROBE
LIG
HT
RE
LAY
WORK
LIG
HT
REL
AY
8787a
30 86858787a
30 86858787a
30 8685
8787a
30 8685
8787a
30 8685
TO G
ROUN
D BO
LTTO
WIR
E PI
N #4
CAB
CONS
OLE
8-PI
N BL
ACK
PLUG
TO W
ORK
LIGH
TTE
RMIN
AL O
NDO
T ST
RIP
#2 F
USE
ON F
USE
BLOC
K
TO G
ROUN
D BO
LTTO
WIR
E PI
N #3
CAB
CONS
OLE
8-PI
N BL
ACK
PLUG
#3 F
USE
ON F
USE
BLOC
K
TO S
TROB
E L
IGHT
TERM
INAL
ON
DOT
STRI
PTO
I5 O
F PL
C
TO P
IN #
3 OF
PUM
P/OV
ERSP
EED
PLUGTO
POS
ITIV
E BA
R
TO Y
ELLO
W SE
CTIO
NOF
NEU
TRAL
JUM
PER
BAREL
ECTR
IC O
VER
AIR
CONT
ROL
BOX
RELA
Y WI
RING
8787
a30 86
85
OUTP
UT Q
5OF
PLC
TO G
ROUN
D BO
LT
TO P
UMP
FUSE
(SPA
RE)
PIN
#7 O
FPU
MP/O
VERS
PEED
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
REVI
SION
S
BYDA
TERE
ASON
NUMB
ER11
7899
06/16
/200
8
PUMP
REL
AY
4-2
Changing of Front Loader Control Box
The first step in changing this box will be to locate the 30 AMP fuse on the red 10 AWG wireconnected to either the battery post or to the shut off switch on the chassis and remove thefuse.
From there disconnect the box by unplugging the air valve plug. The 2 cab console plugs should be removed aswell as the pump over speed plug and the tail gate plug. (see Fig 1)Follow the proximity switch wires and unplug them at the plugs. These wires should be labeled or numbered orcan be marked as necessary to be able to reconnect properly.There are four proximity leads that will be plugged in. Plug #1 is for the Door Safety Prox. Plug# 2 is for the Arms Over Cab Prox. Plug # 3 is for Packer Home and # 4 is for Packer Retract.
Plug to AirValve
To cab console plug(8-Pin)To cab console plug(12-Pin)
Pump Over Speed Tailgate Plug
DOT WiringStrain Relief
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
4-3
SECTION 4Generation One PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
Replacing the Box
After mounting the new box plug in the plugs on the bottom of the box as shown in Fig. 1 above. Plug in theproximity switches and wire tie these cables securely to the unit. Feed the DOT wires through the strain reliefand tighten the strain relief. Attach the brown to run, green to right turn, red to brake, yellow to left turn andblue to reverse. Connect the black 10 AWG wire to the ground post and run a 14 AWG wire from the groundterminal to the ground post. Connect the red 10 AWG wire to the ignition relay. After completing these stepsthe 30 AMP fuse should be replaced. Test the DOT lighting as well as the work lights and strobe. If everythingchecks out as working properly the door can be fastened closed and the unit is ready to use.
The next step will be to loosen the strain relief for the DOT wiring. Open the door and remove the red 10 AWGwire from the ignition relay. Remove the black 10 AWG wire from the ground post. The DOT wiring will needremoved. The brown for run, green for right turn, red for brake, yellow for left turn and blue for reverse are thewires to remove from the terminals. These wires can now be pulled out of he box through the strain relief.The four mounting bolts can now be removed and the box can be removed from the unit.
4-4
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Neutral Interlock and Accelerator Setup
Set the Neutral Interlock first. With the truck in neutral pull the jumper in the neutral interlock position in thelower left hand corner of the box as shown in Fig 2.
NOTE: both the neutral interlock and the accelerator jumpers are in the ground position.
4-5
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Using a LED test light, connect the red lead to the hot terminal on the Ignition Relay and the black to the groundsideof the Ignition Relay (see Fig 1). The white wire shown in Fig 1 will be butt connected to #35 blue wire going intothe Pump Over Speed Plug. Probe this wire. If the red light shows in the LED test light then you will need to putthe jumper plug that you pulled in the positive position (red and yellow bar plug). If the green light shows then youwill reinsert the plug in the black and yellow position.
To use a MULTI-METER, first place the red probe to the hot side of the ignition relay and the black to the whitewire the same as with the test light. If the indicator shows 12V> (System Voltage) then there is a negative inputand the jumper will be put in the black and yellow position. Check with the black multi-meter probe on groundand the red to the white wire. If the indicator shows 12V> (System Voltage) then the input is positive and thejumper should be put in the positive or red yellow position.
The next step will be to set the accelerator. Use a jumper wire to connect to the groundside of the ignition relay.Jump to the Q3-pin#2 wire #38. If the truck revs up the jumper on the accelerator is in the right position (blackand yellow). If the truck does not rev up then using the jumper wire connected to the positive post of theignition relay, jump to the same Q3-pin#2 wire 38. If the truck revs up at this point then move the acceleratorjumper to the positive position (red and yellow).
Fig 2
4-6
4-7
OVERVIEW OF INTERLOCKS FOR THE NEW ELECTRIC OVER AIR FEL
>If the door saftey prox (iG) is not activated the main air supply (Q8) and pump (Q5) will kick out.
>Hit momentary PTO reset button (iA) to re-activate the main air supply (Q8) and pump (Q5), if emergencystop (iG) is triggered, door saftey prox (iG) is de-energized, or key is turned off.
>For engine rev-up (Q3) to work you must have a neutral signal (i5) from transmission and pump on switch(iB) must be activated.
>Tailgate can not close (QA) unless ejection panel is at home prox (i3) position.
>Unless tailgate is fully open and mercury switch is activated (i8) ejection panel cannot go past the retract prox(i4).
>If the ejection panel is not at the home prox (i3) position the arms will not raise.
>If the tailgate is not fully closed (i7) or fully open (i8) ejection panel will not extend (Q1).
>If the tailgate is not fully closed (i7) the tailgate ajar light (QB) will flash and the buzzer will go off.
>If the arms are above windshield height, the arms above cab prox is triggered (iF) and the arms above cablight (Q6) will activate.
>When the lid open switch (iE) is tripped, the lid open light (Q6) will activate.
>If the Auto-pack button (i6) is hit once the ejection panel will extend (Q1) until it hits the retract prox (i4) andthen reverse direction until the home prox (i3) is reached.
>If the Auto-pack button (i6) is depressed during the pack cycle, the ejection panel will stop. If the Auto packbutton (i6) is depressed a second time, the ejection panel will retract (Q2) until the home prox (i3) is triggered.
>During retract of the Auto-pack cycle, the one-shot (Q4) feature will activate telling the tailgate cylinders toretract (QA).
>If the main emergency stop button (iG) is depressed, the main air supply solenoid (Q8) and pump (Q5) powerwill kick out. The emergency stop button (iG) must be raised and the system reset button (iA) depressed toallow the main air supply solenoid (Q8) and pump (Q5) to be re-energized.
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
HOW TO START/STOP THE ZELIO LOGIC CONTROLLER
HOW TO STOP: (CONTROLLER SAYS RUN)1. Press MENU / OK key 1 time
A. The word MONITORING will flash2. Press DOWN arrow key 2 times
A. The words RUN / STOP will flash 3. Press MENU / OK key 1 time A. The words STOP PRO. & YES will flash 4. Press MENU / OK key 1 time (CONTROLLER SAYS STOP)
HOW TO START: (CONTROLLER SAYS STOP)1. Press MENU / OK key 1 time
A. The word PROGRAMMING will flash2. Press the DOWN arrow key 2 times3. Press MENU / OK key 2 times
(CONTROLLER SAYS RUN)
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
4-8
+-
i1i2
i3i4
i5i6
i7i8
i9iA
iBiC
iDiE
iFiG
-iH
iJiK
iLiP
iQiR
iN
12VD
CIN
PUTS
i1....i
A12
VDC
iB...i
GAN
ALO
G or
12V
DCIN
PUTS
iH...i
R12
VDC
MEN
U/O
K
SR3
B261
JDSR
3 XT
141J
D
OU
TPU
TSQ1
...Q8
: REL
AY 8
A AN
D Q9
...QA
: REL
AY 5
AO
UTP
UT
QB...Q
E : R
ELAY
8A
AND
QF...Q
G : R
ELAY
5A
Q1Q2
Q3Q4
Q5Q6
Q7Q8
Q9QA
QBQC
QDQE
QFQG
12
12
12
12
12
12
12
+12
*Inpu
ts H
ave
to b
e M
etBe
fore
Pum
p W
ill E
ngag
e
C
i i9
iB
IG
Q5
i1 P
ACKE
R EX
T SW
ITCH
WIR
E #
11-
PIN
#3
12-P
INRE
AR C
AB C
ONS
OLE
PLU
G
i2 P
ACKE
R RE
TRAC
T SW
ITCH
WIR
E #
12 -
PIN
#4
12-P
INRE
AR C
AB C
ONS
OLE
PLU
G
i3 P
ACKE
R HO
ME
PRO
XW
IRE
#3
2 -
PIN
#C
PLU
G #
3
i4 P
ACKE
R RE
TRAC
T PR
OX.
WIR
E #
33 -
PIN
#C
PLU
G 4
i5 N
EUTR
AL S
IGNA
L TO
ENG
INE
YELL
OW
WIR
E PI
N #
87NE
UTR
AL IN
TERL
OCK
REL
AY
i6 A
UTO
PACK
STA
RT S
WIT
CHW
IRE
#7
- PI
N #
7 8-
PIN
FRO
NT C
AB C
ONS
OLE
i7 T
AIL
GATE
CLO
SED
PRO
XW
IRE
#43
PIN
#3
12-P
INTA
IGAT
E HA
RNES
S PL
UG
i8 T
AILG
ATE
FULL
Y O
PEN
MER
C SW
ITCH
WIR
E #
44 -
PIN
#4
12-
PIN
TAIL
GATE
HARN
ESS
PLU
Gi9
OVE
RSPE
ED E
CUW
IRE
#36
- P
IN #
4 8
-PIN
PUM
POVE
RSPE
ED P
LUG
iA P
TO R
ESET
WIR
E #
14 -
PIN
#6
12-P
INRE
AR C
AB C
ONS
OLE
PLU
GiB
PU
MP
ON
SWIT
CHW
IRE
#15
- P
IN #
7 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
IC T
AILG
ATE
OPE
N SW
ITC
HW
IRE
#16
- P
IN #
8 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
iD T
AILG
ATE
CLO
SED
SWIT
CHW
IRE
#17
- P
IN #
9 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
iE L
ID F
ULL
Y O
PEN
SWIT
CHW
IRE
#45
- P
IN #
5 12
-PIN
TAIL
GATE
HAR
NESS
PLU
G
iFAR
MS
ABO
VE C
AB P
ROX
WIR
E #
31 -
PIN
#C
PLU
G #
2
iG S
AFTE
Y DO
OR
SWIT
CHW
IRE
#30
- P
IN #
C PL
UG
1
*
**
Q1 P
ACKE
R EX
T M
AC S
OL
WIR
E #
24
- PI
N #
7 12
-PIN
AIR
VALV
E PL
UG
Q2 P
ACKE
R RE
TRAC
T M
AC S
OL
WIR
E #
25 -
PIN
#8
12-P
INAI
R VA
LVE
PLU
GQ3
ACC
EL R
EV(15
00 R
PM)
WIR
E #
38 -
PIN
#6
8-PI
NPU
MP
OVE
RSPE
ED P
LUG
Q4 O
NE S
HOT
WIR
E #
23 -
PIN
#4
12-P
INAI
R VA
LVE
PLU
GQ5
PU
MP
ON
SOLE
NOID
WIR
E #
39 -
PIN
#7
8-PI
NPU
MP
OVE
RSPE
ED P
LUG
Q6 L
ID O
PEN
LIGH
TW
IRE
18 -
PIN
#10
12-
PIN
REAR
CAB
CO
NSO
LE P
LUG
Q7 A
RMS
OVE
R C
AB L
IGHT
WIR
E #
19 -
PIN
#11
12-
PIN
REAR
CAB
CO
NSO
LE P
LUG
Q8 M
AIN
AIR
SUPP
LY M
AC S
OL
WIR
E #
26 -
PIN
#9
12-P
INAI
R VA
LVE
PLU
G
Q9 T
AILG
ATE
OPE
N M
AC S
OL
WIR
E #
22 -
PIN
#3
12
-PIN
AIR
VALV
E PL
UG
QB T
AIL
GATE
AJA
R AL
ARM
AND
LIG
HTW
IRE
#9
- PI
N #
1 12
-PIN
TAIL
GATE
HAR
NESS
PLU
G
QC A
RMS
RAIS
E IN
TERL
OCK
(PAC
KER
HOM
E)W
IRE
# 2
1 -
PIN
#2
12-P
INAI
R VA
LVE
PLU
G
OU
TSID
E AC
CEL
WIR
E #
8 PI
N #
8 8-
PIN
FRO
NT C
AB C
ONS
OLE
QA T
AILG
ATE
CLO
SED
+-
i1i2
i3i4
i5i6
i7i8
i9iA
iBiC
iDiE
iFiG
-iH
iJiK
iLiP
iQiR
iN
12VD
CIN
PUTS
i1....i
A12
VDC
iB...i
GAN
ALO
G or
12V
DCIN
PUTS
iH...i
R12
VDC
MEN
U/O
K
SR3
B261
JDSR
3 X
T14
1JD
OU
TPU
TSQ1
...Q8
: REL
AY 8
A AN
D Q9
...QA
: REL
AY 5
AO
UTP
UT
QB...Q
E : R
ELAY
8A
AND
QF.
..QG
: REL
AY 5
A
Q1Q2
Q3Q4
Q5Q6
Q7Q8
Q9QA
QBQC
QDQE
QFQG
12
12
12
12
12
12
12
+12
*Inpu
ts H
ave
to b
e M
etBe
fore
Pum
p W
ill E
ngag
e
C
i i9
iB
IG
Q5
i1 P
ACKE
R EX
T SW
ITCH
WIR
E #
11-
PIN
#3
12-P
INRE
AR C
AB C
ONS
OLE
PLU
G
i2 P
ACKE
R RE
TRAC
T SW
ITCH
WIR
E #
12 -
PIN
#4
12-P
INRE
AR C
AB C
ONS
OLE
PLU
G
i3 P
ACKE
R HO
ME
PRO
XW
IRE
#3
2 -
PIN
#C
PLU
G #
3
i4 P
ACKE
R RE
TRAC
T PR
OX.
WIR
E #
33 -
PIN
#C
PLU
G 4
i5 N
EUTR
AL S
IGNA
L TO
ENG
INE
YELL
OW
WIR
E PI
N #
87NE
UTR
AL IN
TERL
OCK
REL
AY
i6 A
UTO
PACK
STA
RT S
WIT
CHW
IRE
#7
- PI
N #
7 8-
PIN
FRO
NT C
AB C
ONS
OLE
i7 T
AIL
GATE
CLO
SED
PRO
XW
IRE
#43
PIN
#3
12-P
INTA
IGAT
E HA
RNES
S PL
UG
i8 T
AILG
ATE
FULL
Y O
PEN
MER
C SW
ITCH
WIR
E #
44 -
PIN
#4
12-
PIN
TAIL
GATE
HARN
ESS
PLU
Gi9
OVE
RSPE
ED E
CUW
IRE
#36
- P
IN #
4 8
-PIN
PUM
POVE
RSPE
ED P
LUG
iA P
TO R
ESET
WIR
E #
14 -
PIN
#6
12-P
INRE
AR C
AB C
ONS
OLE
PLU
GiB
PU
MP
ON
SWIT
CHW
IRE
#15
- P
IN #
7 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
IC T
AILG
ATE
OPE
N SW
ITC
HW
IRE
#16
- P
IN #
8 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
iD T
AILG
ATE
CLO
SED
SWIT
CHW
IRE
#17
- P
IN #
9 12
-PIN
REAR
CAB
CO
NSO
LE P
LUG
iE L
ID F
ULL
Y O
PEN
SWIT
CHW
IRE
#45
- P
IN #
5 12
-PIN
TAIL
GATE
HAR
NESS
PLU
G
iFAR
MS
ABO
VE C
AB P
ROX
WIR
E #
31 -
PIN
#C
PLU
G #
2
iG S
AFTE
Y DO
OR
SWIT
CHW
IRE
#30
- P
IN #
C PL
UG
1
*
**
Q1 P
ACKE
R EX
T M
AC S
OL
WIR
E #
24
- PI
N #
7 12
-PIN
AIR
VALV
E PL
UG
Q2 P
ACKE
R RE
TRAC
T M
AC S
OL
WIR
E #
25 -
PIN
#8
12-P
INAI
R VA
LVE
PLU
GQ3
ACC
EL R
EV(15
00 R
PM)
WIR
E #
38 -
PIN
#6
8-PI
NPU
MP
OVE
RSPE
ED P
LUG
Q4 O
NE S
HOT
WIR
E #
23 -
PIN
#4
12-P
INAI
R VA
LVE
PLU
GQ5
PU
MP
ON
SOLE
NOID
WIR
E #
39 -
PIN
#7
8-PI
NPU
MP
OVE
RSPE
ED P
LUG
Q6 L
ID O
PEN
LIGH
TW
IRE
18 -
PIN
#10
12-
PIN
REAR
CAB
CO
NSO
LE P
LUG
Q7 A
RMS
OVE
R C
AB L
IGHT
WIR
E #
19 -
PIN
#11
12-
PIN
REAR
CAB
CO
NSO
LE P
LUG
Q8 M
AIN
AIR
SUPP
LY M
AC S
OL
WIR
E #
26 -
PIN
#9
12-P
INAI
R VA
LVE
PLU
G
Q9 T
AILG
ATE
OPE
N M
AC S
OL
WIR
E #
22 -
PIN
#3
12
-PIN
AIR
VALV
E PL
UG
QB T
AIL
GATE
AJA
R AL
ARM
AND
LIG
HTW
IRE
#9
- PI
N #
1 12
-PIN
TAIL
GATE
HAR
NESS
PLU
G
QC A
RMS
RAIS
E IN
TERL
OCK
(PAC
KER
HOM
E)W
IRE
# 2
1 -
PIN
#2
12-P
INAI
R VA
LVE
PLU
G
OU
TSID
E AC
CEL
WIR
E #
8 PI
N #
8 8-
PIN
FRO
NT C
AB C
ONS
OLE
QA T
AILG
ATE
CLO
SED
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
4-9
ZELIO LOGIC CONTROLLER
PART # 117664
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
4-10
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
i4 S
AFET
Y/DO
OR P
ROX
WIRE
#30
- P
IN #
C PL
UG #
1
i3 A
RMS
ABOV
E CA
B PR
OX W
IRE
#31
- PI
N #C
PLU
G #2
i1 PA
CKER
EXT
. SWI
TCH
WIRE
#11
- P
IN #
3 12
PIN
CAB
CON
SOLE
PLU
G
i2 P
ACKE
R RE
TRAC
T SW
ITCH
WIR
E #1
2 -
PIN
#4 1
2 PI
N CA
B CO
NSOL
E PL
UG
i3 P
ACKE
R HO
ME P
ROX
WIRE
# 3
2 PI
N #C
PLU
G 3
i4 P
ACKE
R RE
TRAC
T PR
OX W
IRE
#33
PIN
#C P
LUG
4
i5 N
EUTR
AL S
IGNA
L (F
ROM
ENGI
NE) Y
ELLO
W WI
RE P
IN #
87 N
EUTR
AL IN
TERL
OCK
RELA
Y
i6 A
UTOP
ACK
STAR
T SW
ITCH
WIR
E #7
- P
IN #
7 8
PIN
CAB
CONS
OLE
PLUG
i7 T
AILG
ATE
CLOS
ED P
ROX
WIRE
#43
- P
IN #
3 12
PIN
TAI
LGAT
E HA
RNES
S
i8 T
AILG
ATE
FULL
Y OP
EN M
ERC
SWIT
CH W
IRE
#44
- PI
N #4
12
PIN
TAIL
GATE
HAR
NESS
Q1 P
ACKE
R EX
S. M
AC. S
OL W
IRE
#24
- PI
N #
7 12
PIN
AIR
VAL
VE P
LUG
Q2 P
ACKE
R RE
TRAC
T MA
C SO
L WI
RE #
25 -
PIN
#8
12 P
IN A
IR V
ALVE
PLU
G
Q3 A
CCEL
(REV
1500
) RPM
WIR
E #3
8 -
PIN
#6 8
PIN
PUM
P/OV
ERSP
EED
PLUG
Q4 O
NE S
HOT
WIRE
#23
- P
IN #
4 1
2 PI
N AI
R VA
LVE
PLUG
Q4 M
AIN
AIR
SUPP
LY M
AC S
OL W
IRE
#26
- PI
N #9
12
PIN
AIR
VALV
E P
LUG
Q2 L
ID O
PEN
LIGH
T WI
RE #
18 -
PIN
#10
12
PIN
CAB
CONS
OLE
PLUG
Q3 A
RMS
ABOV
E CA
B LI
GHT
WIRE
#19
- P
IN #
11 1
2 PI
N CA
B CO
NSOL
E PL
UG
Q1 P
UMP
ON P
UMP
RELA
Y PI
N #8
5
i1 OV
ERSP
EED
ECU
WIRE
#36
- P
IN #
4 8
PIN
PUMP
/OVE
RSPE
ED P
LUG
i2 P
TO R
ESET
WIR
E #1
4 -
PIN
#6 1
2 PI
N RE
AR C
AB C
ONSO
LE P
LUG
i3 P
UMP
ON S
WITC
H WI
RE #
15 -
PIN
#7
12 P
IN R
EAR
CAB
CONS
OLE
PLUG
i4 T
AIL
GATE
OPE
N SW
ITCH
WIR
E #1
6 -
PIN
#8 1
2 PI
N CA
B CO
NSOL
E PL
UG
Q1 T
AILG
ATE
OPEN
MAC
SOL
WIR
E #2
2 -
PIN#
3 12
PIN
AIR
VAL
VE P
LUG
Q3 T
AILG
ATE
AJAR
ALA
RM &
LIG
HT W
IRE
#9 -
PIN
#1
12 P
IN T
AILG
ATE
HARN
ESS
Q2 T
AILG
ATE
CLOS
ED M
AC S
OL W
IRE
#23
- FR
OM Q
4 ON
E SH
OT
Q4 A
RMS
RAIS
E IN
TERL
OCK
(PAC
KER
HOME
) WIR
E #2
1 -
PIN
#2 1
2 PI
N AI
R VA
LVE
PLUG
i2 L
ID F
ULLY
OPE
N SW
ITCH
WIR
E #4
5 -
PIN
#5 1
2 PI
N TA
ILGA
TE H
ARNE
SS
i1 TA
ILGA
TE C
LOSE
SWI
TCH
WIRE
#17
- P
IN #
9 12
PIN
REA
R CA
B CO
NSOL
E PL
UG
11
11
222
2
1 2
1 2
1 2
1
2 1
2
222 1 1 1
i1 OU
TSID
E CO
NTRO
L AC
CELE
RATO
R WI
RE #
8 -
PIN
#8 C
AB C
ONSO
LE P
LUG
- + +-- + +-
L+ML+ML+ML+MIDEC
CON
TROL
LER
i1i2i3i4i5i6i7i8i1i2i3i4i1i2i3i4i1
ESCOK
4-11
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
DISPLAY FOR INPUTS AND OUTPUTS OF IDEC PLC
ON THE FIRST SCREEN PRESS ESC
YOUR SCREEN SHOULD LOOK LIKE:>STOPSET PROGRAMSETPRS NAME
PRESS THE ARROW DOWN KEY TWO TIMES TO THE SET POSITIONSTOPSET PROGRAM>SETPRS NAME
PRESS OK
THE SCREEN WILL CHANGE TO:>CLOCKCONTRASTSTART SCREEN
PRESS THE ARROW DOWN KEY TWO TIMES TO THE START SCREENCLOCKCONTRAST>START SCREEN
PRESS OK
PRESS THE ARROW DOWN KEY ONE TIME TO INPUT DICLOCK>INPUT DISTART SCREENCLOCK
PRESS OK FLASH POWER FOR 5 SECONDS
PRESS ESC4-12
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Problem: Everything Works Slow.
A. Check to be sure Emergency Stop button is up.B. Ensure that the pump switch is on.C. Truck needs to be running (not in Overspeed condition) .D. Ensure that side access door safety proximity switch (#1) is properly adjusted.E. Ensure the PTO reset has been pressed.F. Ensure that the Tailgate ajar prox is properly adjusted.G. Ensure that the solenoid on the front hydraulic pump is functioning.H. Check the stem that the solenoid controls for grooving or that the stem is not bent (the stem shifts so that the pump will build up pressure).
Check the Main Air Supply and all air fittings on the Mac Air Valve.
Main Air Supplyon Mac Air Valve(check all fittings)
Tailgate A-jar ProximitySwitch (adjust to within8mm with no pressure onTailgate)
Access Door Saftey Proximity Switch(adjust to 8mm of touching)
Emergency StopPTO REST BUTTON
4-13
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
SOLENOID
JAM NUT If removed thereshould be resistance if pulled downward if solenoid isfunctioning properly
SOLENOID STEMStem can be replacedif damaged
If these jam nuts are removedtighten with no more torquethan 60 inch/lbs.
If there is no resistance then check to see that there is power to the solenoid.If there is no power at the pump, then go to the main box to the PLC (programmable logic controller) and checkwith either a LED test light or a MULTI meter to ensure that the input side has power to i9, iB, and iG terminals.(These input terminals as well as Q5 should be shown on the screen) All three of these inputs have to be metbefore the pump will engage. If there is no power to i9 then the wiring to the transmission control module willneed inspected. If no power to iB then the wiring going to the cab console and ensure there is +12V on the outputside of the switch. If not then the switch needs replaced. If no power to iG then check to ensure the access doorsafety switch is adjusted properly and is working. The switch may need replaced.If these three conditions have been met then check to ensure that there is power coming out of Q5 #2. If there ispower coming out of this terminal then the problem is between the PLC box and the hydraulic pump. Thewiring between the box and the pump will need checked. If there is no power at this terminal then the maincontrol box will need to be changed out. (Refer to page 5-10 & 5-11)
PROGRAMABLELOGIC CONTROLLER(PLC)
4-14
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Problem: Auto Pack extends out to the tailgate:A. Check to ensure that the retract proximity switch at the front bulkhead (#4) is aligned properly and is
functional.B. Check the Mac Air Valve to ensure air pressure at section #7.
Problem: Arms fail to lift:A. Check the panel home proximity switch on the front bulk (#3) for proper adjustment and that it is
functioning properly.B. Check the Mac Air Valve to ensure air pressure at section #2/
Problem: Panel moves but truck does not rev up:A. Check that the truck is in neutral.B. Check the neutral interlock relay and replace if needed.C. Check that the neutral interlock and accelerator jumpers are in place in the main control box. (See
Neutral interlock and Accelerator Setup on Page 5-12 & 5-13.D. With the truck running and in neutral, use a LED test light or MULTI meter to check for +12 at i5 on
the PLC in the main control box.
Problem: System functions normally during the warm up period (first ½ hour to 1 hour depending on tempera-ture) and then stops functioning:
A. Check the tailgate a-jar proximity switch to ensure that load is not pushing so hard against the tailgatethat the a-jar proximity switch is not within the 8mm range.
B. Check that the access door proximity switch (#1) is staying in adjustment when the panel is moving.
Problem: After load is ejected the tailgate does not close:A. Ensure that the panel is in the home position and that the extend proximity switch is adjusted properly.B. Check the Mac Air Valve to ensure air pressure at section #3.
Problem: Tailgate will not lift:A. Check the Mac Air Valve to ensure air pressure at section #4.B. With a LED test light or MULTI meter check for +12V at i3 on the terminal on the PLC in the main
control box.C. Ensure that the packer panel is in the home position and that the panel home proximity switch (#3) is
adjusted properly and functioning.D. Check the i4 terminal on the PLC for +12V when the retract proximity switch (#4) is met. Ensure the
proper adjustment and that the retract proximity switch is functional.
Problem: All sections function with the exception of the arms and forks:A. Check the joystick air supply (#9) on the Mac Air Valve.B. Check for air pressure at the joystick.
If there is no air at the joystick and there is pressure at #9 on the Mac Air Valve, check the airline between thevalve and the joystick.
4-15
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Problem: The complete system fails to function:A. Check for power at the battery or kill switch and ensure a good ground and power.B. Check the 30AMP fuse located at the battery or kill switch on the 10AWG wire.
Check the ignition source in the cab and that the 10AMP fuse is good.
Red 10AWG Wire connec-tioneither on battery or killswitch
Black 10AWG groundedto battery ground post orground post on frame
Problem: Lid does not open or close:A. Check the Mac Air Valve to ensure air pressure at section #5 for open and section #6 for close.B. Check the lid switch in the cab console for +12V to ensure switch is functional.
Problem: Lid open light does not come on:A. Check with a LED test light or MULTI meter that the iE input has +12 volts.B. If +12V at iE check that there is power to in the cab console (wire 18) and that the bulb is grounded
properly.C. Check to ensure bulb has not been burned out.D. No power at iE terminal:E. Check the wiring from the main control box to the cab console.F. Check the Lid Fully Open finger switch on top of packer for a broken switch or a misaligned switch.G. Check the orange wire for +12V.
4-16
DRIVING THE DIFFERENCE
SECTION 4Generation One PLC
FEL - Full Eject Model
Problem: Emergency Stop does not stop the entire system:A.Insure that when the switch is down that the only power to the main control box is to the top post of the ignition solenoid, the power side of the DOT lighting and the line side of the Emergency Stopswitch.Replace switch if power is going through the switch.
Problem: Packer will not eject the load:A. Push the PTO resetB. Ensure that the tailgate is raised to 90 degrees or more of the body. (In the case of uneven conditions at
the landfill the tailgate must be raised level or beyond level for the mercury switch to work properly.)C. Ensure that the mercury switch in the light module of the tailgate is working properly in the full open
position.D. Check the Mac Air Valve to ensure air pressure at section #7.E. Check the i8 terminal at the PLC with a LED test light or a Multi meter to ensure +12V input.
If i8 has +12V input check to ensure that i9, iB, and iG all have +12V.
4-17
SECTION 4Generation Two PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
REVI
SION
S
BYDA
TERE
ASON
NUM
BER
06/3
0/20
0911
7664
B
Q14
Q13
Q12
Q11
Q10
Q9 Q8 Q7 Q6 Q5 Q4 Q3 Q2 Q1
SPAR
E
SPAR
E
SPAR
E
SPAR
E
MAIN
AIR
SUP
PLY
MAC
SOL
PACK
ER R
ETRA
CT
PACK
ER E
XTEN
D
TAIL
GATE
CLO
SED
TAIL
GATE
OPE
N
ARM
S RA
ISE
INTE
RLOC
K
LID
OPEN
LIG
HT
TAIL
GATE
AJA
R AL
ARM
AND
LIG
HT
ARM
S OV
ER C
AB L
IGHT
PUM
P
OUTP
UTS
K8I
K8NC
K8NO
GNDACL
12V
TAILGATE CLOSED SWITCH i 1i 2
i 3i 4
i 5i 6
i 7i 8
i 9i 10
i 11i 12
i 13i 14
i 15i 16
i 17i 18
i 19i 20
P 1
TAILGATE OPEN SWITCHPUMP ON
PTO RESET
PACKER RETRACT SWITCH
PACKER EXTEND SWITCH
OVERSPEED ECU
TAILGATE CLOSED PROX
TAILGATE FULLY OPEN MERC SWITCH
LID FULL OPEN SWITCH
OUTSIDE ACCELERATOR
AUTO PACK SWITCH
PACKER RETRACT PROX
PACKER HOME PROX
ARMS ABOVE CAB PROX
SAFETY DOOR SWITCH
NEUTRAL SIGNAL
SPARE
SPARE
SPARE
GROU
ND
REVE
RSE
WORK
LIG
HT
STRO
BE
LEFT
TUR
N
STOP
RIGH
T TU
RN
RUN
SPAR
EIG
NITI
ON 1
RELA
YIG
NITI
ON 2
RELA
Y
10 AMP
10 AMP
10 AMP
10 AMP
10 AMP
10 AMP
20 AMP
20 AMP
SPARE
+12V
PROX SW 1-4
PUMP
WORK LIGHTS
STROBE LIGHT
TAILGATE POWER
REVERSE
GND
NEUT 12V
NEUT
RAL
INTE
RLOC
KRE
LAY
WORK
LIG
HTS
RELA
YST
ROBE
LIG
HTRE
LAY
REVE
RSE
REL
AY
PUM
P RE
LAY
GROU
ND -
BATT
ERY
+
1 2 V
G N D
NOTE
: CIR
CUIT
IS A
CTIV
EWH
EN L
ED IS
ON
WAGO
TER
MIN
AL IN
STRU
CTIO
NS
STRI
P WI
RE B
ACK
INSE
RT S
CREW
DRIV
ER B
LADE
IN S
QUAR
EHO
LE A
ND G
ENTL
Y AP
PLY
PRES
SURE
AGAI
NST
THE
GRAY
BLO
CK IN
THE
DIRE
CTIO
N SH
OWN
UNTI
L WI
RE IS
ABL
E TO
BE IN
SERT
ED IN
TO T
HE R
OUND
HOL
ELE
T OF
F P
RESS
URE
ON S
CREW
DRI
VER
THE
WIRE
SHO
ULD
BE H
ELD
IN P
LACE
MAIN POWER TERMINAL
SERIAL #9212 AND LATER
4-18
SECTION 4Generation Two PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
CHANGING OF FRONT LOADER CONTROL BOXFROM GENERATION ONE TO GENERATION TWO
The first step in changing the box will be to locate the 30AMP fuse on the red 10awg wire connectedto either the battery post or to the battery shut off switch on the chassis and remove the fuse.From there disconnect the box by unplugging the air valve plug. The two cab console plugs shouldbe removed as well as the pump overspeed and tailgate plugs. (see Fig 1)Follow the proximity plug wires and disconnect them at the Deutsch connectors. These wires shouldbe marked or numbered or should be marked as necessary to be able to reconnect properly with thenew box. There are four proximity leads that will be utilized in this process.
The next step will be to loosen the DOT strain relief. Open the door and remove the red 10AWGwire from th ignition relay and the black 10AWG wire from the ground post. The Dot wires shouldbe removed from the DOT stip at the bottom of the box and the wiring can be pulled from the box.Mark optional strobe and work light wires if applicable.The box can now be dismounted from the packer.
4-19
Plug #1 is for the Door Safety Prox.Plug #2 is for the Arms Over Cab prox
Fig 1
Plug #3 is for Packer Home and plugPlug #4 is for Packer Retract.
DOT WIRE COLORS ARE:WHITE for groundBROWN for running lightsGREEN for right turnRED for brakeYELLOW for left turnBLUE for reverse
PROXIMITY PLUGS:
SECTION 4Generation Two PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
MOUNTING THE GENERATION TWO BOX
Measuring from the lower left bolt hole for the old box, mark a hole to be drilled 11 1/2” straightacross to the right. The upper holes will be marked and drilled 9 1/2” straight above the lower holes.
Open the cover of the new box and locate the mounting ears. Afix these to the back of hte box usingthe square insert with the bottom ones going down and the upper ones going up. (see Fig 2) Mount thebox to the bulkhead using the hardware form the old box.
Fig 2
After securing the new box to the packer, plug the plugs into the bottom of the box as marked.Reground any harness grounds to the mounting bolts. Plug in all proximity switch plugs and wire tieall the cables and harnesses securely to the packer to ensure that they do not rub and are not near anyheat sources.Use the lenght of heat shrink found in the new box and heat shrink the DOT wires in such a way as toleave enough length to work with inside the box and so that the heat shrink will insert into the strainrelief. This will ensure a good hold when the strain relief is tightend. (see Fig 2)Following the wago terminal instructions on the box layout page the DOT wires and the power har-ness can be installed using the previously mentioned wire color code.
4-20
SECTION 4Generation Two PLC
FEL - Full Eject ModelDRIVING THE DIFFERENCE
NEUTRAL INTERLOCK AND ACCELERATOR SETUPNOTE: most Allison transmissions 3000 or larger have the negative signal.The neutral interlock will be set up first. With the truck running and in neutral take the jumper wireout of the neutral interlock terminal. (strip shown in FIG 1) A LED test light or a MULTI-METERwill be needed to ensure the signal is whatis wanted.
To use an LED test light a good ground sourcewill be needed. (a mounting bolt can be used)A jumper wire will need to be attached to thepositive side of the battery or positve powercan be obtained by removing the spare fuseand placing a jumper wire under the fuse asit is being replaced. Connect the red leadof the test light to the positive source.Test the neutral wire with the probe.If the test light shows a greenlight then the signal is negative and the grayjumper wire is put in the NEUT and GNDterminals. If the test ligh shows a red lightthe signal is positve and the gray jumperwire will be put in the NEUT and 12Vterminals.
To use a MULTI-METER, first place the red probe to the source of a positive power. (the jumperwire from the battery or spare fuse) Next test the NEUT gray wire with the black probe. If the meterindicates 12V> then the signal is negative. The gray NEUT wire will be put in the GND terminal andthe NEUT terminal. If the signal is not found to be negative put the red probe to the NEUT gray wireand the black probe to ground. If the 12V> is indicated then a positive signal is present and the grayjumper goes to the NEUT terminal and the 12V terminal of the neutral strip.
Once the neutral interlock has been set the accelerator can be set. Remove the gray jumper wire fromthe GND terminal of the accelerator strip. Use a jumper wire from the positive source and test theaccel gray wire of the strip. If the truck accelerates then the signal is positive and the gray jumper canbe placed in the 12V terminal. If the truck does not accelerate test the gray accel jumper to a groundsource and if the truck accelerates the signal is negative and the jumper wire can be put back in theGND terminal.
Q14
Q13
Q12
Q11Q10Q9
Q8
Q7
Q6
Q5
Q4
Q3
Q2Q1
SPARE
SPARE
SPARE
SPARE
MAIN AIR SUPPLY MAC SOLPACKER RETRACT
PACKER EXTEND
TAILGATE CLOSED
TAILGATE OPEN
ARMS RAISE INTERLOCK
LID OPEN LIGHT
TAILGATE AJAR ALARM AND LIGHT
ARMS OVER CAB LIGHT
PUMP
OUTPUTS
K8I
K8NCK8NO
GND
ACL
12V
SPARE
10 A
MP
10 A
MP
10 A
MP
SPAR
E
+12V
PRO
X SW
1-4
GND
NEUT
12V
NEUTRALINTERLOCKRELAY
12V
GND
NEUTRAL INTERLOCK
ACCELERATORFIG 1
GRAY JUMPER WIRE
GRAY JUMPER WIRE
4-21
SECTION 4Electrical Schematics
FEL - Full Eject ModelDRIVING THE DIFFERENCE
TOP
CENT
ERLE
FT B
OTTO
M
1176
42117629
REAR
12-
PIN
FRON
T 12
-PIN
TO F
RONT
BOX
Tailg
ate
Harn
ess
Rece
ptic
al
3-PI
NTO
PRO
X
3-PI
N TA
ILGA
TEA-
JAR
PROX
BUTT
CON
NECT
ED
Body HarnessTa
ilgat
e aj
ar P
rox
1176
27
Botto
m R
ear
Top
Cent
er
12-p
in
12-p
in
12-pin
1176
39
117638
117637
TO 1
1763
9
Butt
Conn
ecte
dto
117
639
1176
40Bo
ttom
Rig
htTa
ilgat
e Li
ghts
see
draw
ing
1179
93fo
r de
tails
1176
35
8-pi
n co
nnec
tor
from
Fro
nt B
oxto
Cab
9/28
/200
7PR
OPER
TY O
F
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
1179
99
REFE
R TO
117
998
Curb
side
Rai
lHa
rnes
s
Sree
tsid
e Ra
ilHa
rnes
s
Stre
etsi
deM
id B
ody
Harn
ess
Curb
side
Mid
Bod
yHa
rnes
ssee
draw
ing
1179
93 fo
r det
ails
see
draw
ing
1179
95 fo
r det
ails
see
draw
ing
1179
96 fo
r det
ails
see
draw
ing
1179
96 fo
r det
ails
see
draw
ing
1179
95 fo
rde
tails
see
draw
ing
1179
97 fo
rde
tails
see
draw
ing
1179
96 fo
rde
tails
see
draw
ing
1179
97fo
r det
ails
RIGH
T HO
RIZO
NTAL
TUBI
NG F
OR S
IDE
LIGH
TS
LEFT
HAN
D HO
RIZO
NTAL
TUBI
NG F
OR S
IDE
LIGH
TSUN
DERS
IDE
OF P
ACKE
R
LEFT
VER
TICA
L TU
BING
RIGH
T VE
RTIC
AL T
UBIN
G
HARN
ESS
SCHE
ME
FOR
PACK
ER B
ODY
1172
84
COVE
R SH
EET
HARN
ESS
1176
42 a
nd 1
1762
7 pl
ugin
to th
is h
arne
ss
see
draw
ing
1179
94fo
r det
ails
1176
21
White White
Black Red
Red Blue
1176
41
Left
Hand
Tai
lgat
elo
wer
ligh
ts
4-22
SECTION 4Electrical Schematics
FEL - Full Eject Model
PROX
IMITY
SWI
TCH
#1DO
OR S
AFTE
Y SW
ITCH
PROX
IMIT
Y SW
ITCH
#2
ARMS
OVE
R CA
B
PROX
IMITY
SWI
TCH
#3PA
CKER
PAN
EL H
OME
PROX
IMIT
Y SW
ITCH
#4
PACK
ER R
ETRA
CT
12-PIN CONNECTORFROM 117629 BODYHARNESS
RED
10AW
G FR
OMPO
WER
SOUR
CE
BLAC
K 10
AWG
GROU
NDDO
T WI
RING
STRA
IN R
ELIEF
TAILG
ATE
PLUG
8-PIN CONNECTOR 117653TO PUMP OVERSPEED
PUMP
/OVE
RSPE
ED
TO C
AB C
ONSO
LE(12
-PIN
)
TO C
AB C
ONSO
LE(8-
PIN)
(SEE
11799
2)
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
11799
89/
28/2
007
UNDE
RSID
E OF
CON
TROL
BOX
ON F
RONT
BUL
KHEA
D OF
PAC
KER
(SEE
11766
6)
DRIVING THE DIFFERENCE
4-23
SECTION 4Electrical Schematics
FEL - Full Eject ModelDRIVING THE DIFFERENCE
28'
FRON
T PL
UG
12-P
IN6-
PIN
PLUG
REAR
PLU
G12
-PIN
3-PI
N PL
UG
12
34
56 7
89
1011
12
DEU
TSCH
LOOK
ING
FROM
THE
WIRE
SID
E
FRON
T PL
UG
1
23
45
6 78
910
1112
DEU
TSCH
REAR
PLU
GLO
OKIN
G FR
OMTH
E WI
RE S
IDE
VIEW
AVI
EW B
AB
PIN
#1 W
HITE
=GR
OUND
PIN
#2 O
RANG
E=PO
WER
PIN
#3 R
ED/W
HITE
=TAI
LGAT
E PR
OX i7
PIN
#4 Y
ELLO
W/BL
ACK=
TAIL
GATE
FUL
LY O
PEN
PIN
#5 B
LACK
/RED
=LID
FUL
LY O
PEN
PIN
#6 W
HITE
/BLO
CK=S
TROB
EPI
N #7
BRO
WN=R
UNNI
NG L
IGHT
SPI
N #8
GRE
EN=R
IGHT
TUR
NPI
N #9
RED
=BRA
KE L
IGHT
SPI
N #1
0 YE
LLOW
=LEF
T TU
RNPI
N #1
1 BL
UE=R
EVER
SE L
IGHT
SPI
N #1
2 RE
D/BL
ACK=
TAIL
GATE
A-J
AR A
LARM
GREE
N/BL
ACK=
FLAS
HERS
(SPA
RE)
PIN
#1 W
HITE
=GR
OUND
PIN
#2 O
RANG
E=PO
WER
PIN
#3 B
LANK
PIN
#4 Y
ELLO
W/BL
ACK=
TAIL
GATE
FUL
LY O
PEN
PIN
#5 B
LACK
/RED
=LID
FUL
LY O
PEN
PIN
#6 W
HITE
/BLO
CK=S
TROB
EPI
N #7
BRO
WN=R
UNNI
NG L
IGHT
SPI
N #8
GRE
EN=R
IGHT
TUR
NPI
N #9
RED
=BRA
KE L
IGHT
SPI
N #1
0 YE
LLOW
=LEF
T TU
RNPI
N #1
1 BL
UE=R
EVER
SE L
IGHT
SPI
N #1
2 RE
D/BL
ACK=
TAIL
GATE
A-J
AR A
LARM
GREE
N/BL
ACK=
FLAS
HERS
(SPA
RE)
C
D
12
3 4
56
DEUT
SCH
REAR
6-P
IN P
LUG
LOOK
ING
FROM
THE
WIRE
SID
EVI
EW C
PIN
#1 W
HITE
=GRO
UND
PIN
#2 B
ROWN
=RUN
NING
LIG
HTS
PIN
#3 G
REEN
=RIG
HT T
URN
PIN
#4 Y
ELLO
W=LE
FT T
URN
PIN
#5 B
LUE=
REVE
RSE
PIN
#6 B
LANK
AB
C
TO T
AILG
ATE
A-JA
RPR
OXIM
ITY
SWIT
CHVI
EW D
PIN
A OR
ANGE
=POW
ERPI
N B
WHIT
E=GR
OUND
PIN
C RE
D/WH
ITE=
TAIL
GATE
PRO
X TR
IGGE
R
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
1179
9710
/01/
2007
1
1762
9BO
DY H
ARNE
SS
PROX
IMIT
Y SW
ITCH
3-PI
N PL
UG
DTO4
-12P
DTO6
-12S
1162
5611
6242
MAI
N BO
DY H
ARNE
SSU
NDER
PAC
KER
1172
84
4-24
SECTION 4Electrical Schematics
FEL - Full Eject Model
20'
12
34
56 7
89
1011
12
DEU
TSCH
1176
27CU
RBSI
DE R
AIL
HARN
ESS
PIN
#1
14AW
G W
HITE
=GRO
UND
PIN
#2
18AW
G OR
ANGE
=POW
ERPI
N #
3 BL
ANK
PIN
#4
18AW
G YE
LLOW
/BLA
CK=T
AILG
ATE
FULL
Y OP
ENPI
N #
5 18
AWG
BLAC
K/RE
D=LI
D FU
LLY
OPEN
PIN
#6
14AW
G W
HITE
/BLA
CK=S
TROB
EPI
N #
7 14
AWG
BROW
N=RU
NNIN
G LI
GHTS
PIN
#8
14AW
G GR
EEN=
RIGH
T TU
RNPI
N #
9 14
AWG
RED=
BRAK
ESPI
N #
10 1
4AW
G YE
LLOW
=LEF
T TU
RNPI
N #
11 1
4AW
G BL
UE=
REVE
RSE
PIN#
12
14AW
G RE
D/BL
ACK=
TAIL
GATE
A-J
AR A
LARM
14AW
G GR
EEN/
BLAC
K=FL
ASHE
R (S
PARE
)
WIR
E CO
NFIG
URA
TION
S AR
E TH
E SA
ME
ON B
OTH
ENDS
12
34 5
67
8
LOOK
ING
FRO
MTH
E WI
RE S
IDE
LOOK
ING
FROM
THE
WIRE
SID
E
14'
1176
42ST
REET
SIDE
RAI
LHA
RNES
S
PIN
# 1
WHI
TE=G
ROU
NDPI
N #
2 BR
OWN=
RUNN
ING
LIGH
TSPI
N #
3 YE
LLOW
=LEF
T TU
RNPI
N #
4 GR
EEN=
RIGH
T TU
RNPI
N #
5 RE
D=BR
AKES
PIN
#6
BLU
E=RE
VERS
EPI
N #
7 W
HITE
/BLA
CK=S
TROB
EPI
N #
8 GR
EEN/
BLAC
K=FL
ASHE
RS
12"
PLU
G FO
R SI
DE L
IGHT
SAN
D TU
RN
12
3 4
56
DEU
TSCH
DT06
-6S
LOOK
ING
FROM
WIR
E SI
DE
PIN
#1
WHI
TE=G
ROU
NDPI
N #
2 BR
OWN=
RUNN
ING
LIGH
TSPI
N #
3 GR
EEN=
RIGH
T TU
RNPI
N #
4 YE
LLOW
=LEF
T TU
RNPI
N #
5 BL
UE=
REVE
RSE
PIN
#6
BLAN
K
10/0
1/20
0711
7996
PROP
ERTY
OF
SCRA
NTON
MAN
UFA
CTU
RING
NEW
WAY
DRAW
N BY
DATE
LDE
1162
65
1162
60
1162
56
RIGH
T VE
RTIC
AL R
AIL
HARN
ESS
LEFT
VER
TICA
L RA
IL H
ARNE
SSSI
DE L
IGHT
CON
NECT
ION
DRIVING THE DIFFERENCE
4-25
SECTION 4Electrical Schematics
FEL - Full Eject ModelDRIVING THE DIFFERENCE
4-26
BUTT
SPL
ICE
BUTT
SPL
ICE
BUTT
SPL
ICE
Gree
n 1
4AW
G
Brow
n 14
AWG
Whi
te
14AW
GW
hite
14
AWG
Blac
kRe
d
17'
Blue
14A
WG
1176
37
CU
RBSI
DE M
ID B
ODY
HAR
NESS
WHI
TE=G
ROU
NDBR
OW
N=RU
NNIN
G LI
GHTS
GREE
N=RI
GHT
TURN
BLU
E=RE
VERS
E
1176
37
Blac
k
Whi
teRe
d
PLU
G EN
D FO
RSI
DE L
IGHT
GRO
TE P
ART
#6
700
2-3
Whi
te
DEU
TSC
H 2
-PIN
CO
NNEC
TORS
DT0
6-0
2S
PLU
GW
2S
W
EDGE
04
62-2
09-1
614
1
S
OC
KETS
PRO
PERT
Y O
F
SCRA
NTO
N M
ANU
FAC
TURI
NGNE
WW
AY
DRAW
N BY
DATE
LDE
07/0
8/20
09
BUTT SPLIC
EBU
TT SPLICE
BUTT SPLIC
E
Brow
n 1
4AW
GW
hite
14A
WG
Whi
te 1
4AW
G
Blac
kRe
d
17'
Yello
w
14AW
G
1176
38
STRE
ETSI
DE M
ID B
ODY
HAR
NESS
BLU
E 1
4AW
G
Whi
te
DEU
TSCH
2-P
IN C
ONN
ECTO
RSDT
06-0
2S
PLU
GW
2S
W
EDGE
04
62-2
09-
1614
1
S
OC
KETS
1176
38
&
WHI
TE=G
ROU
NDBR
OW
N=RU
NNIN
G LI
GHTS
YELL
OW
=LEF
T TU
RNBL
UE=
REVE
RSE
SECTION 4Electrical Schematics
FEL - Full Eject Model
WHIT
EWH
ITE
BLAC
KBL
ACK
RED
RED
BROW
NBR
OWN
YELL
OWGR
EEN
GRAY
GRAY
RED
RED
YELL
OW/B
LACK
ORAN
GE
ORANGE TO LID SWITCH
MER
CURY
SWIT
CH
BLACK/RED TO LID SWITCH
WHITE/BLACK TO STROBE
RED/BLACK TO BACKUP ALARMBLUE TO BACKUP ALARM
WHITE TO BACKUPALARM AND STROBE
12-P
IN P
LUG
GREEN/BLACK(SPARE FOR FLASHERS)
8-PI
N PL
UG
1
23
45
6 78
910
1112
DEU
TSCH
1
23
4 56
78
DEUT
SCH
LOOK
ING
FROM
THE
WIRE
SID
E
LOOK
ING
FROM
THE
PIN
SIDE
PIN
#1 1
4AWG
WHI
TE=G
ROUN
DPI
N #2
18A
WG O
RANG
E=PO
WER
PIN
#3 B
LANK
PIN
#4 1
8AWG
YEL
LOW/
BLAC
K=TA
ILGA
TEFU
LLY
OPEN
PIN
#5 1
8AWG
BLA
CK/R
ED=L
ID F
ULL
Y OP
ENPI
N #6
14A
WG W
HITE
/BLA
CK=S
TROB
EPI
N #7
14A
WG B
ROWN
=RUN
NING
LIG
HTS
PIN
#8 1
4AWG
GRE
EN=R
IGHT
TUR
NPI
N #9
14A
WG R
ED=B
RAKE
SPI
N #1
0 14
AWG
YELL
OW=L
EFT
TURN
PIN
#11
14AW
G BL
UE=R
EVER
SEPI
N #1
2 14
AWG
RED/
BLAC
K=TA
ILGA
TE A
-JAR
ALA
RM
RED
WHIT
E
BLAC
K
PART
#11
1267
X 3
RED=
BRAK
E LI
GHTS
BLAC
K=RU
NNIN
G LI
GHTS
WHIT
E=GR
OUND
PIN
#1 1
4AWG
WHI
TE=G
ROU
NDPI
N #2
14A
WG B
ROWN
=RUN
NING
LIG
HTS
PIN
#3 1
4AWG
YEL
LOW=
LEFT
TUR
NPI
N #4
14A
WG G
REEN
=RIG
HT T
URN
PIN
#5 1
4AWG
RED
=BRA
KEPI
N #6
14A
WG B
LUE=
REVE
RSE
PIN
#7 1
4AWG
WHI
TE/B
LACK
=STR
OBE
PIN
#8 1
4AWG
GEE
N/BL
ACK=
FLAS
HERS
(SPA
RE)
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
1179
9410
/02/
2007
1162
6211
6258
1010
5210
1052
UPPE
R LI
GHT
MOD
ULE
HARN
ESS
CONF
IGUR
ATIO
N
DRIVING THE DIFFERENCE
4-27
SECTION 4Electrical Schematics
FEL - Full Eject ModelDRIVING THE DIFFERENCE
14AW
G WH
ITE
12"
BUTT
SPL
ICE
14AW
G WH
ITE
18"
TO W
ORKL
IGHT
S18
AWG
WHI
TE
14AW
G BL
ACK/
WHIT
E18
" TO
WORK
LIGH
TS8-
PIN
CONN
ECTO
R
34'
PIN#
1 14A
WG W
HITE
=GRO
UND
PIN#
2 BL
ANK
PIN#
3 18
AWG
BLAC
K/WH
ITE=
NEUT
RAL
INTE
RLOC
KPI
N#4
18AW
G GR
EEN=
OVER
SPEE
D BA
CKPIN
#5 18
AWG
RED=
POWE
R TO
ECU
PIN#
6 18
AWG
VIOL
ET=A
CCEL
ERAT
ORPI
N#7
18AW
G BL
ACK=
PUMP
POW
ERPI
N#8
14AW
G BL
ACK/
WHIT
E=WO
RKLI
GHTS
12
34 5
67
8
LOOK
ING
FROM
THE
WIRE
SID
E
DEUTSCH
1176
35
White
Black
WhiteRed
Red
Blue
BUTT
SPL
ICE
Brow
n
Red Blue
White
Red=
Reve
rse
(But
t Spl
iced
to B
lue)
BUTT
SPL
ICE
White
=Gro
und
Red=
Brak
eWh
ite=G
roun
dBl
ack=
Runn
ing
PART
# 11
1267
3-WI
RE P
LUG
4 US
ED
PART
#11
268
2-WI
RE P
LUG
2 US
ED
White WhiteBlack Re
d
Red Blue
THES
E HA
RNES
SES
WILL
BE
BUTT
CON
NECT
EDTO
GETH
ER A
LONG
WIT
H 11
7637
,11
7638
& 11
7639
1179
9310
/02/
2007
1162
60
PUMP
/OVE
RSPE
ED A
ND B
OTTO
MRE
AR L
IGHT
MOD
ULE
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
REVI
SION
S
BYDA
TERE
ASON
NUMB
ER
1DL
04/2
0/20
09CH
ANGE
D LE
NGTH
ON
1176
35
PART
#11
7641
PART
#11
7640
4-28
SECTION 4Electrical Schematics
FEL - Full Eject Model
12-P
IN C
ONNE
CTOR
12-P
IN C
ONNE
CTOR
8-PI
N CO
NNEC
TOR
8-PI
N CO
NNEC
TOR
1176
66 27'
12
34
56 7
89
1011
12DE
UTSC
H
12
34 5
67
8
LOOK
ING
FROM
THE
WIRE
SID
E
DEUT
SCH
LOOK
ING
FROM
THE
WIRE
SID
E
19
Q-1
12
10"r
ever
se" p
ost o
n te
rmin
al b
lock
311
I-14
12I-2
5op
enPl
ug6
14I-1
07
15I-1
18
16I-1
29
17I-1
310
18Q
-611
19Q
-712
open
Plug
PIN
WIR
E NO
:CO
NNEC
TS T
O:
WIRE
CON
FIGU
RATI
ONS
ARE
THE
SAM
E ON
BOT
H EN
DS
12
34 5
67
8
LOOK
ING
FROM
THE
WIRE
SID
E
DEUT
SCH
WIRE
CON
FIGU
RATI
ONS
ARE
THE
SAM
E ON
BOT
H EN
DS
PROP
ERTY
OF
SCRA
NTON
MAN
UFAC
TURI
NGNE
WWAY
DRAW
N BY
DATE
LDE
1176
6610
/04/
2007
HARN
ESS
FROM
CON
TROL
BOX
ON F
RONT
BUL
KHEA
D ON
PAC
KER
TO C
AB C
ONSO
LE B
OX
PIN
WIR
E N
O:C
ON
NEC
TS T
O:
11
BLAC
K 18
GA
TO G
RO
UN
D2
2R
ED 1
8 G
A TO
CO
IL P
OST
OF
POW
ER S
OLE
NO
ID3
3ST
RO
BE L
IGH
T R
ELAY
BLA
CK
WIR
E4
4W
OR
K LI
GH
T R
ELAY
BLA
CK
WIR
E5
5IN
TER
CO
NN
ECTE
D T
O A
IR V
ALVE
DEU
TSC
H
PIN
66
6In
terc
onne
ct to
Air
Valv
e D
euts
ch P
in 5
77
1-6
88
iH
DRIVING THE DIFFERENCE
4-29
FEL - Full Eject Model
SECTION 5Trouble Shoot
DIGITAL MULTI-METER
LED TEST LIGHT
DRIVING THE DIFFERENCE
5-1
FEL - Full Eject Model
SECTION 5Trouble Shoot
ELECTRICAL TROUBLE SHOOTING GUIDE LINESElectrical trouble shooting will be less intimidating if remembering that all electric circuits areelectricity passing from the battery through the wires, fuses, switches and relays to the component orcomponents and to ground,from which it is passed back to the battery. Any electrical problem is aninterruption of the flow of electricity to and from the battery.The two instruments on the opposite page are the main tools that are used in trouble shooting this 12volt, negative ground, alternator charged system. NOTE: For trouble shooting purposes the batterywill need to be connected but when servicing any components remove the ground cable and the30amp inline fuse located at the power source.
GENERAL INFORMATION:The previous chapter holds the various electrical schematics for the packer unit and a chassis topacker wiring schematic is sent along with the the truck. Refer to the individual schematics for theproblem being investigated. Page 4-3 is the harness scheme for the packer body and should give agood understanding of tracing problems related to the packer body.This chapter is designed to help with most problems encountered and the diagnostic steps in solvingthose problems.
CHECKING FOR VOLTAGE
Electrical problems generally are attributed to blown fuses, loose or corroded connections or a failedrelay. Check these things as a first step in trouble shooting. When changing a blown fuse always usethe same amperage rating as the circuits require this amount of protection. Using a larger fuse valuecould cause serious damage. If the new fuse blows soon after replacement do not replace until theproblem is found and corrected.Starting at a point closest to the power source and following it along the path of the circuit having aproblem is usually the fastest way to find the problem. Pay special attention to points where connec-tions are made as these can be the trouble areas. Connector cases hide oxidation and misaligned orloose wires. Often this will be the case if intermitent problems are being experienced.The truck ignition may need to be in the on position to have voltage to most of the circuits.
CHECKING FOR GROUND
To determine if a component is grounded, disconnect the ground from the battery and having set themultimeter to the ohms scale connect one lead of the multimeter to a good ground. Connect the otherlead to the ground wire of connection being tested. The resistance should be 5 ohms or less if theground is good.
DRIVING THE DIFFERENCE
5-2
FEL - Full Eject Model
SECTION 5Trouble Shoot
RELAY CIRCUITS
The first step in trouble shooting a circuit controled by a relay is to understand how a relay works.When power is applied across the 85 and 86 terminals (control circuits) current passes through thecoil which builds a magnetic field in the bar it is wrapped around. This pulls the steel plate to it andthat is the audible snap heard when power is applied. The spring attached to the steel plate pulls theplate away from the bar when power is removed. The relay uses a low current circuit (control circuit)to open and close the high current circuit (power circuit).If a failed relay is suspected, while being close enough to hear, have the switch to the component inquestion turn on. Remember you must have the ignition key on. When the switch is turned on anaudible snap should be heard. Continuity between 30 and 87 should be found at this point. With theswitch in the off position continuity should be between 30 and 87a. If not then you have a failedrelay that needs replaced.It is important to remember that relays can be wired to have power energize the circuit or can bewired to have ground energize the circuit. On the following page are examples of each.
87
87A
86 85
30
STEEL PLATE
ELECTROMAGNET
COIL
SPRING
BRAIDED WIRE SWITCHCONTACTS
POWER CIRCUITS
CONTROL CIRCUITS
DRIVING THE DIFFERENCE
5-3
FEL - Full Eject Model
SECTION 5Trouble Shoot
5d
BATTERY
8787a30
86 85
BATTERY
POWER USED TO ENERGIZESWITCH OFF
ON WITH SWITCH OFF
OFF WITH SWITCH OFF
GROUND
GROUND
GROUND
GROUND
8787a30
86 85
SWITCH OFF
GROUND
GROUND
ON WITH SWITCH OFF
OFF WITH SWITCH OFF
GROUND USED TO ENERGIZE
GROUND
GROUND
INLINEFUSE
10 AMP
INLIN EFU
SE30AM
P
WITHIN 6"
OF SO
URC
E
INLINEFUSE
10 AMP
INLINEFU
SE30AM
P
WITHIN 6"
OF S O
URCE
DRIVING THE DIFFERENCE
5-4
3
5
8
6
7
8
9
5
4
3
2
4 6 7
2
CLOSE
TAILGATE
OPEN
LID
CLOSE
OPEN
DOWN
UP
FORKS
EXTEND
RETRACT UP
DOWN
ARMSPACKER
GRAYJOYSTICKSUPPLY
PACKERRETRACT
PACKEREXTEND
LIDCLOSE
LIDOPEN
TAILGATEOPEN
TAILGATECLOSE
RED - ARMSUP TO VALVE
CLEAR - MAIN AIR SU
PPLY
RED - ARMS UPINTERLOCKVALVEAIR IN EXHAUST
MAC AIR VALVE
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-5
PUMP TROUBLE SHOOTING
Problem:Excessive noise in pumpA. insufficient fluid
Replenish fluid to proper level,with proper gradeB. Fluid is too heavy
Drain system and refill with the specified grade offluid
C. Oil filter is dirtyReplace with new filter
D. Clogged oil lineClean line thoroughly
E. Pump overspeedingCheck pump maximum speed; slow down the pumpdriver; or install a larger pump
F. Air vent on fluid reservoir cloggedReplace breather on reservoir
G. Air bubbles in fluidDrain system and refill with non-foaming hydraulicfluid
H. Coupling misalignmentRealign flexable coupling between pump and driver
I. Air leaks at pump intake, pump shaftpacking, or inlet pipeDrip oil over suspected joint: listen for a change in thesound of pump; tighten joints
J. Worn or broken pump partsReplace parts as necessary
Problem:Foaming fluidA. Improper fluid
Drain system and refill with proper grade of non-foaming hydraulic fluid
B. Inadequate baffling in tankReplace with correct baffle
C. Air leaking into suction line betweenresevoir and pumpTighten all connections
Problem:Oil level in tank continues to dropA. Oil level in tank drops
Indicates a broken pipe line or a pipe left out betweena bulkhead coupling and the bottom of the tank aftercleaning tank. Replace pipe
B. Pump rotating in wrong directionIMMEDIATELY STOP PUMP DRIVER TO PRE-VENT DAMAGE TO THE PUMP. REVERSEDIRECTION OF PUMP ROTATION
C. Pump fails to prime itself Indicates an air leak in suction line, oil is too heavyor system is not in Neutral. Tighten all joints, replacehydraulic fluid with proper grade,open valve onpressure side of pump, or install a bleed valve.
Problem:System lacks any pressure with pumprunning
A. Relief valve not set correctlyuse pressure gauge and reset valve to specifiedpressure
B. Relief valve leakingReplace valve
C. Broken relief valve springRepalce spring and reset relief valve
D. Flow to tank is unrestrictedCheck for control valve in “Neutral” or for openreturn valve
E. Internal leakage in control valve or powercylinderRepair or replace parts as necessary
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-6
FEL - Full Eject ModelTrouble Shoot
Problem:Excessive wear in pumpA. Abrasive contaminants in fluid
Drain and flush entire syatem. Install a new filter. Fillsystem with new oil of the proper grade. Operatepump for 1 hour. Drain the system again and refillwith new oil and a new filter.
B. Sustained pressure above pump maximumrating.Check and reset relief valve pressure using a pressuregauge.
C. Sustained excessive speed at pressureabove pump maximum ratingRecheck the rated speed of the pump. Slow pumpdriver to rated speed.
D. Drive misalignment or weight of pumpsupported by its drive shaft.Check the pump/driver coupling or belt alignment.Install adequate support for the pump
E. Entrapped air in hydraulic systemBleed air from the system
Problem:Fluid overheatsA. Fluid is to heavy or to light
Drain and replace fluid with proper grade of non-foaming fluid
B. Dirty fluidDrain and flush system. Replace with new fluid andchange the filter element
C. Dirt or a chip caught between the plungerand seat of the relief valve.Disassemble the relief valve and remove the contami-nant. Check condition th the filter to prevent arecurrence
D. Incorrect setting on relief valveReset relief valve using a pressure gauge
E.Worn pump permits oil to bypass internallyRepair worn parts or replace pump
F. Excessive friction caused by pump compo-nents being overtorquedRepair or replace pump
G. Undersized hoses or valves in the systemReplace hoses or valves with proper sizes.
H. Restrictions from exsesive bends in thelinesReplumb the system to eliminate restrictions.
I. Inadequate reservoir prevents adequatecooling of fluidInstall a larger reservoir or add fluid radiator
Problem:Pump is not efficientA. Worn pump parts reduce efficiency
Repair or repalce pumpB. Air in the system
Bleed the air from the system and check line connec-tions for air leaks
C. Internal leak in control valve or cylinderRepair or replace control valve. Replace cylinderpacking. Check cylinder walls for scoring and replaceif necessary
D. Erratic pump performanceIf pump runs slow on startup, and speeds up afterfluid is warm the fluid grade is to heavyIf the pump slows down after fluid is warmed up thefluid is to lightDrain system and refill with proper grade of non-foaming oil
SECTION 5
DRIVING THE DIFFERENCE
5-7
CAPSCREW MARKING AND TORQUE VALUES
USAGE MUCH USED USED AT TIMESUSED AT TIMES
CAP SCREW DIAMETER& MINIMUM TENSILESTRENGTH PSI
TO 3/4 - 120,000TO 1 - 115000
TO 5/8 - 140,000TO 3/4 - 133,000
150,000
QUALITY OF MATERIAL MIN. COMMERCIAL MEDIUM. COMMERCIAL BEST COMMERCIAL
SAE GRADE NUMBER 5 6 OR 7 8
CAPSCREW HEAD MARKINGSMANUFACTURES MARKS MAY VARYTHESE ARE ALL SAE GRADE 5 (3 LINES)
CAPSCREW BODY SIZE(INCHES) - (THREAD)
TORQUEFT-LB (KG)
TORQUEFT-LB (KG)
TORQUEFT-LB (KG)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
- 20- 28- 18- 24- 16- 24- 14- 20- 13- 20- 12- 18- 11- 18- 10- 16- 9- 14- 8- 14
8 (1.11) 10 (1.38) 17 (2.35) 19 (2.63) 31 (4.29) 35 (4.84) 49 (6.78) 55 (7.61) 75 (10.37) 85 (11.76)110 (15.21)120 (16.60)150 (20.75)170 (23.51)270 (37.34)295 (40.80395 (54.63)435 (60.16)590 (81.60)660 (91.28)
10 (1.38)
19 (2.63)
34 (4.70)
55 (7.61)
85 (11.76)
120 (16.60)
167 (23.10)
280 (38.72)
440 (60.85)
660 (91.28)
12 (1.66) 14 (1.94) 24 (3.32) 27 (3.73) 44 (6.09) 49 (6.78) 70 (9.68) 78 (10.79)105 (14.52)120 (16.60)155 (21.44)170 (23.51)210 (29.04)240 (33.19)375 (51.86)420 (58.09)605 (83.67)675 (93.35)910 (125.85)990 (136.92)
NOTES
1. ALWAYS USE THE TORQUE VALUES LISTED ABOVE WHEN SPECIFIC TORQUE VALUES ARE NOT AVAILABLE.2. THE ABOVE IS BASED ON USE OF CLEAN, DRY THREADS.3. REDUCE TORQUE BY 10% WHEN ENGINE OIL IS USED AS A LUBRICANT.4. REDUCE TORQUE BY 20% IF NEW PLATED CAPSCREWS ARE USED.5 GENERAL FORMULA FOR CALCULATING TORQUES IS AS FOLLOWS: TORQUE IN INCH LBS. = .2 X NOMINAL DIAMETER OF SCREW X LOADS IN LBS., WHERE LOAD = 80% OF YEILD STRENGTH, EXPRESSED IN LBS., NOT POUNDS PER SQUARE INCH.
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-8
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-9
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-10
FEL - Full Eject ModelTrouble Shoot
SECTION 5
DRIVING THE DIFFERENCE
5-11
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