manual for new way electric over air mammoth series front...

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


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


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



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



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.


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


SECTION 1


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.


SECTION 1


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.


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.


1-6

1-7


SECTION 1


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


SECTION 1



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.


1-9


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


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


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


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)


SECTION 1

PART # 101429PART # 101434 PART # 103582

PART # 105208PART # 105211

PART # 101425

PART # 105209


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)


SECTION 1

PART # 110110f

PART # 37924


Part # 110110

KK (Qty 1)

LL (Qty 1)Part #108638

JJ(qty-1) 1-14


SECTION 1

PART # 101423



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


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


SECTION 2


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


SECTION 2


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.


SECTION 2


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


SECTION 2


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


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


SECTION 3


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


SECTION 3


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


SECTION 3


3-5


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


SECTION 3


3-7


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


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


SECTION 3


3-10


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.


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


SECTION 3


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:


3.6 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)


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


SECTION 3


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.


1.5 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)


ting.2.0 Completion - Ensure that all fasteners are fully tightened, all tools are removed, and

all oil leaks or spills are cleaned up.


SECTION 3


3-14


SECTION 3


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


SECTION 3


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


SECTION 3


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.


SECTION 3


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


SECTION 3


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


4-1

PRIOR TO SERIAL #9212F-09


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




4-3



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




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




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.




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)




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




4-9

ZELIO LOGIC CONTROLLER

PART # 117664




4-10




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




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




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




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




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




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




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


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



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:



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



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


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



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)


4-23



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



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


4-25



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



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


4-27



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



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


4-29


SECTION 5Trouble Shoot

DIGITAL MULTI-METER

LED TEST LIGHT


5-1



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.


5-2



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


5-3



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


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


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


SECTION 5


5-6


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


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.


SECTION 5


5-8


SECTION 5


5-9


SECTION 5


5-10


SECTION 5


5-11

manual for new way electric over air mammoth series front...

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