OPERATOR’S MANUAL FOR NEW WAY SIDEWINDER AUTOMATED … · operator’s manual for new way sidewinder automated loaders scranton manufacturing co,inc. 101 state st, pobox 336 scranton,

OPERATOR’S MANUAL

FOR NEW WAY

SIDEWINDER AUTOMATED

LOADERS

SCRANTON MANUFACTURING CO,INC.

101 STATE ST, POBOX 336

SCRANTON, IOWA 51462

(712) 652-3396 OR (800) 831-1858

FAX (712) 652-3399

www.drivingthedifference.com

II

DRIVING THE DIFFERENCE

WARRANTY

SIDEWINDER AUTOMATED MODEL

Scranton Manufacturing Company, Inc. warrants its New Way Solid Waste Collection Equipment to be free

from defects in material and workmanship under normal use when properly serviced and maintained as

described in its service bulletins and operational manuals for a period of six months from the date when these

products are delivered to the fi rst purchaser.

This warranty is expressly limited to the repair or replacement of any component or part thereof, of any

such unit manufactured by the Company, that is proven to the Company’s satisfaction to have been defective

in material or workmanship. Such components or parts shall be repaired or replaced at no cost to the fi rst

purchaser for parts and labor provided such unit is returned for such repair or replacement with transportation

charges prepaid to an authorized Scranton Manufacturing Company, Inc., New Way distributor, or such other

facility as may be designated by the Company, within 30 days after discovery of the defect and within six

months of the date on which the unit was delivered to such fi rst purchaser.

The Company will furnish without charge FOB its distributor a similar part to replace any part of a product

of its manufacture which proved to be defective in material or workmanship while in normal use and service

during this period.

Normal adjustments or minor repairs, tightening of fi ttings or nuts and bolts or replacement of normally wearing

or disposable parts such as but not limited to slide blocks, seals, fi lter elements, bushing, etc., is not considered

grounds 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

inspection before the unit is placed into service, and the delivery inspection form and warranty card must be

signed by both the customer and the distributor and submitted to the Company’s Service Department within two

weeks of delivery to the fi rst purchaser of the unit.

Because the Company’s parts are engineered to work only with genuine company parts, this limited warranty

will be void and have no effect if: (a) Company parts are modifi ed other than as done at its factory or as

authorized to be done by factory in writing or (b) Parts or assemblies of any other manufacturer are used as

substitutes for genuine Company parts.

Replacement parts, components and assemblies manufactured by Scranton Manufacturing Company, Inc., are

sold under a Limited Warranty to be free from defects in workmanship or material for a period of 90 days,

providing the factory inspection reveals a material or a workmanship defect. Labor to replace or repair such

part shall be the responsibility of the customer. There is no warranty on expendable items, wear components or

used parts.

WARRANTY

III


WARRANTY


Scranton Manufacturing Company, Inc. makes no other warranty, expressed or implied, and makes no warranty

of merchantability or fi tness for any particular purpose. The company does not assume any liability for loss of

profi ts, 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 by others 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

the right to redesign and/or discontinue the manufacture of parts, components and assemblies at any time. The

Company reserves the right to make changes in the design or make additions to or improvements on its products

without imposing any obligation on itself to install them on its products previously manufactured.

IV


TABLE OF CONTENTS

SIDEWINDER AUTOMATED MODELSECTION 1- SAFETY PRECAUTIONS

General .......................................................................................1-1

Safety Decals .............................................................................1-1

Danger, Warning, And Caution Decals ......................................1-1

Prior To Start Up ........................................................................1-2

General Operation ......................................................................1-3

Pre-Operation Inspection Checklist ...........................................1-6

Hydraulics ..................................................................................1-7

House Keeping ...........................................................................1-7

Shut Down .................................................................................1-7

Decal Placement ........................................................................1-8

SECTION 2 - OPERATION

Start Up & Check Off ................................................................2-1

Requirements to Function ......................................................... 2-3

Arm Usage .................................................................................2-4

Unloading ...................................................................................2-5

Requirements for unloading.......................................................2-6

Proximity Switches and Arm Stowed Switch ............................2-7

Cleanup ......................................................................................2-8

SECTION 3 - MAINTENANCE

Sidewinder Warning Precautions ..............................................3-1

Lock Out/Tag Out Procedure .....................................................3-1

Routine Washing ........................................................................3-4

Arm Hose Location and Function ..............................................3-5

Body Valve and Pump ................................................................3-6

Body Pump and Valve Adjustment ............................................3-8

Arm Pump and Valve Adjustment ..............................................3-8

Arm Bolt Torque Specifi cations ...............................................3-12

Critical Arm Chain Adjustment ............................................. 3-13

Daily Maintenance ................. ..................................................3-16

Daily Lubrication Points ..........................................................3-17

Weekly Lubrication Points .......................................................3-19

Monthly Maintenance ..............................................................3-20

Oil Specifi cation Chart .............................................................3-21

Body Valve Schematic .............................................................3-22

Arm Valve Schematic...............................................................3-23

Layout and Pin Outs for Marlin Box .......................................3-25

SECTION 4 - ELECTRICAL

Overview of Interlocks ..............................................................4-1

Joystick Information ..................................................................4-2

Cab Console ...............................................................................4-5

Electrical Harnesses ...................................................................4-6

SECTION 5 - TROUBLE SHOOTING

Trouble Shooting Help ...............................................................5-1

Electrical Trouble Shooting Guide .............................................5-2

Pump Trouble Shooting .............................................................5-5

Torque Values And Markings For Cap Screws ..........................5-7

Valve Naming Convention .........................................................5-8

Hose And Tubing Naming Convention ......................................5-9

Fitting Naming Convention .....................................................5-10

1-1


SECTION ONE

SAFETY PRECAUTIONS


GENERAL

The New Way Sidewinder Automated Loaders were designed to work hard and withstand the rigors of daily use. The

forces used on the packer to compact refuse are accomplished with hydraulic pressure which is created and then directed

through hoses to the packer panel. Extreme care and safety practices need to be used at all times while operating the

packer. The owner is responsible to require all employees associated with this unit read this manual thoroughly 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 the opera-

tor’s responsibility to learn and follow the proper operational procedures that are in accordance with all safety codes and

requirements including the American National Standards Institute (ANSI) requirements and the Occupational Safety and

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 the safety decals, may cause DEATH or DIS-

MEMBERMENT to the operator, coworkers or bystanders.

SAFETY DECALS

Safety decals are very important and should be clearly seen and obeyed at all times. Section 1-8 describes a detailed dia-

gram of where the decals should be displayed. If any of these decals are missing or cannot be clearly read, they must be

replaced immediately with the proper decal. New decals can be ordered from New Way by calling (800)831-1858.

As you read this manual you will see the above graphics appear to alert the operator or mechanic of specifi c issues con-

cerning a particular operation. Operators and maintenance personnel shall read and comply with the instructions carefully.

Compliance and common sense are crucial for the safe operational procedures. Note: will also appear and is followed by

information that will clarify or provide emphasis to a certain point in the manual.

WARNING denotes hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION denotes hazards or unsafe practices which could result in minor personal injury or property damage.

DANGER denotes immediate hazards which WILL result in personal injury or death.

WARNING CAUTION DANGER

1-2


SECTION ONE

SAFETY PRECAUTIONS


PRIOR TO START UP

1. Scranton Manufacturing Co. Inc. Recommends that at a minimum operators wear steel toed safety shoes,

OSHA approved safety glasses, and gloves. The company also recommends that operators do not wear any

jewelry on their wrists or hands, or loose fi tting clothing that could catch on operating levers or moving com-

ponents of the packer.

2. Do not operate any machinery while under the infl uence of drugs or alcohol.

3. Before operating this refuse packer, the person(s) should be properly instructed and trained in the operation

of the equipment. He or she must also be familiar with all warning devices, hand signals, and traffi c rules.

4. Perform a pre-operation inspection of the unit by walking around it and:

*Inspect the chassis in accordance with the chassis manufacturer’s guidelines.

*Inspect the packer in accordance with our “Refuse Packer” guidelines listed in Section 2 – “OPERA

TION” of this manual. DO NOT START OR OPERATE ANY EQUIPMENT THAT IS MALFUNCTION-

ING.

*Make sure all obstructions and people are clear.

*Inspect all lights, back-up and tailgate ajar alarms.

*Check all mounting bolts, cylinder pins, and other fasteners for placement and tightness.

*Adjust or replace as necessary with the same grade and size.

5. Any malfunctions should be reported to a supervisor or mechanic. Before walking away from a malfunction-

ing 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 be done with the proper tools and procedures as shown in this

service manual. Only authorized personnel should attempt the repair work. Use ONLY proper replacement

parts on the unit.

7. If the height of your unit was altered, recheck the overall height and make sure this height plus three inches is

noted on the decals.

8. Thoroughly understand the functioning of every operating control. Be aware of the function and location of

every instrument, control, gauge, and protective device.

9. Know where to get help in case of an emergency.

1-

1-3


SECTION ONE

SAFETY PRECAUTIONS


GENERAL OPERATION

1. The operator is responsible for making sure that operation of this unit is in accordance with the instructions contained

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 Wastes Management

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 qualifi ed operator(s).

They must be familiar with all danger, caution and warning decals, warning devices, hand signals, and traffi c 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 fi rst cycling of the packer panel, open the side access door and visually inspect the area behind the

ejection panel. Also inspect the internal body cavity and hopper for abnormal obstructions, equipment, 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 manu-

facturer’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 1-8).

11. Before operating the unit, put on proper safety equipment such as protective shoes, glasses, appropriate gloves 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 instruction manual.

14. Before moving the unit or operating any controls make sure coworkers can be seen and that they are in a safe position.

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 specifi ed riding platforms or steps if

vehicle speeds will exceed 10 mph or more, or if the vehicle will be travelling further that 2/10 of a mile without stop-

ping. 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 the vehicle as

1-4


SECTION ONE

SAFETY PRECAUTIONS


slowly as possible. Do not travel in reverse further than distances allowed by local ordinances. If traveling 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, fi ngers, or any limbs, etc. into a pinch point or any moving parts.- 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.

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.

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, fi rst make sure the container is fi rmly on the ground, then reach inside with

a probe or other tool – Do not use hands. Never place any part of the body between the packer body and the container.

42. Make sure there is enough overhead clearance before dumping a container.

43. Place the container on a fl at, level surface.

1-5


SECTION ONE

SAFETY PRECAUTIONS


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 suffi cient 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. Follow the main-

tenance schedule and conduct repairs as needed.

52. The following minimal lockout/tag out procedure must be completed before entering into or under any part of the

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 3-1.)

53. In the event the tailgate must be in the open position during maintenance, securely block tailgate and thoroughly test

method of blocking prior to proceeding. Tailgate Safety Props have been pre-mounted at the factory for this purpose,

and include an operation decal stating proper use procedures to obtain the required two feet of clearance.

54. All hydraulic pressure and electrical programming settings, including over-speed and accelerator

settings, are set at the factory and should not be modifi ed. Modifi cations to these settings may create

safety hazards and/or cause serious damage to the equipment. Any modifi cations 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 a transfer of

ownership the manual should be included or transferred with the equipment.

56. Scranton Manufacturing must be notifi ed of the name and address of the new owner in order to make the new owner

aware of any safety or service bulletins issued. Scranton Manufacturing can be reached at (800) 831-1858.

1-6


SECTION ONE

SAFETY PRECAUTIONS


PRE-OPERATION INSPECTION CHECK-

LIST

1. Placement and readability of decals.

2. No fl uid leaks.

3. Mounting hardware in place and fastened tightly.

4. No metal fatigue or cracks in welds.

5. Hydraulic fl uid 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.

Inspector’s Signature: ______________________________

Date of Inspection: ________________________________

OK NOT OKAY COMMENTS

1-7


SECTION ONE

SAFETY PRECAUTIONS


HYDRAULICS

1. Hydraulic fl uid fl ows through at very hot temperatures and can cause burns. To protect yourself from such burns, do

not touch cylinders, piping, or hoses.

2. When checking for hydraulic fl uid leaks never use the hands since escaping hydraulic fl uid can cause injuries.

-“High Pressure Injection Of Hydraulic Fluid Through The Skin And Into The Blood-

stream May Cause Serious Injury Or Death.”

FIRE PROTECTION

1. Always have a fi re extinguisher available and check it monthly to make sure it is fully charged and operable.

2. Never have an open fl ame around fl ammable or 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 accidentally activated.

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.

DANGER

1-8


SECTION ONE

SAFETY PRECAUTIONS


1-9


SECTION ONE

SAFETY PRECAUTIONS


1-10


SECTION ONE

SAFETY PRECAUTIONS


1

4PART # 101427

Decals

8PART # 101431

7PART # 101433

6PART # 101432

1PART # 101436

Safety Precautions — Decals

2PART # 101429

3PART # 203582

5PART # 108638

10PART # 110826

11PART # 110829

Red Re! ectors

12PART # 110827

13PART # 110828

Amber Re! ectors

1-11


SECTION ONE

SAFETY PRECAUTIONS


2

16PART # 101423


15PART # 105207

9PART # 101438

14PART # 101437

APART # 120755

BPART # 105206

CPART # 102585

DPART # 120679

Logo

White Re! ective Sheeting

Red/White Re! ective Sheeting

Serial Number Riveted


1-12


3

17PART # 101434

23PART # 105211

24PART # 101425

20PART # 105208


21PART # 112484

22PART # 105209

18PART # 101110

19PART # 101439

25PART # 112019


1-13


4 Safety Precautions — Decals

Mounting Stickers

PART # 105213

PART # 106403PART # 106214

2-1


SECTION TWO

OPERATION


THE SIDEWINDER AUTOMATED LOADER HAS BEEN CREATED TO SAFELY AND EFICIENTLY LOAD, COMPACT, TRANSPORT, AND

UNLOAD REFUSE. THE FOLLOWING TEXT AND GRAPHICS DESCRIBES HOW TO ACCOMPLISH THOSE TASKS.

START-UP INSTRUCTIONS & CHECK-OFF

1. Close air bleeders(usually found on the battery housing).

2. Start engine.

3. Do pre-trip inspection.

4. Check hydraulic reservoir oil level.

HYDRAULIC OIL GAGE

SECONDARY CONTROL PANEL

2-2


SECTION TWO

OPERATION


PRIMARY CONTROL PANELS

2-3


SECTION TWO

OPERATION


X

DECREASING

HORIZONTAL IN

“A” PORT

CYLIDER RETRACT

Y

INCREASING

VERTICAL LIFT DOWN

“A” PORT

CYLINDER RETRACT

Y

DECREASING

VERTICAL LIFT UP

“B” PORT

CYLINDER EXTEND

X

INCREASING

HORIZONTAL OUT

“B” PORT

CYLINDER EXTENDY

Y

XX

4. Upon arriving at the pickup point ensure that both E-Stop buttons on the primary control box are pulled

up.

5. Engage the pump.

6. Engage the auto pack.

REQUIREMENTS FOR PACKER TO FUNCTION

*The packer body needs to be in the full down position.

*The tailgate needs to be in the closed and locked position.

*The access door needs to be closed and latched shut.

*The crusher panel should be in the open position.

*For the arm to function the dead man switch on the joy stick must be activated. (if out side the unit

and using the secondary control the interlock switch must be activated.)

*The arm will only raise half way until the arm is fully retracted.

*The grippers will not open after going past the halfway point unless the gripper override is depressed.

*When operating in the auto pack mode the retract prox must be seen. If not seen a timer will expire

and the packer panel will retract automatically. This sequence will occur 5 consecutive times and

then the packer panel will remain in the home position until reset by turning auto pack off

and then back on again. (this occurance usually happens when the packer is full.)

*The arm is cushioned (slows down) for the up/down or retract cycles.

2-4


SECTION TWO

OPERATION


Grasp

Container

Raise

Retract Arm

Container Dump

Stowed Position

BEFORE OPERATING THE ARM ENSURE

OVERHEAD CLEARANCE

The dead man switch on the joy stick will

need to be engaged before any function of the

arm will work.

Extend the arm with the grippers open until the

container is reached.

Grasp the container with the grippers

and raise the container from the ground. (in cold

weather ensure container is not frozen down)

The arm will need to be fully retracted and then

raised to the dumping position as shown.

Once the container has been dumped reverse the

procedure to bring container back to the postition

when fi rst grasped.

Open the grippers and return the arm

to the stowed position.

2-5


SECTION TWO

OPERATION


UNLOADING PROCEDURE

ENSURE ENOUGH OVERHEAD CLEARANCE BEFORE ATTEMPTING TO UNLOAD.

DO NOT UNLOAD ON A SIDEHILL AND DO NOT DRIVE WITH BODY RAISED OTHER THAN TO

FACILITATE UNLOADING.

DO NOT UNLOAD AGAINST A PILE OF REFUSE.

2-6


SECTION TWO

OPERATION


UNLOADING PROCEDURE continued

1. Raise tail gate to full open position.

2. Raise body hoist to fully raised postion.

3. Pull ahead VERY SLOWLY to help the load discharge.

4. When load is completely unloaded pull far enough ahead for the unit to clear the pile of refuse.

5. Lower body completely to the down position.

6. Lower tail gate to full closed position and ensure the locks are engaged.

REQUIREMENTS FOR UNLOADING THE PACKER

*The interlock switch on the secondary control must be engaged to raise the

tail gate or the body lift.

*The tail gate needs to be full open before raising the body to the full up position.

*The tail gate needs to be full open or full closed for the packer panel to move.

*The arm must be fully retracted to the stow position before that body will raise.

*The packer panel must be in the home position for the tailgate to close.

2-7


SECTION TWO

OPERATION


PROXIMITY SWITCHES AND ARM STOWED SWITCH

Hopper Access Door

Safety Switch

Body Ajar Switch

Arm Stowed Switch

Crusher Panel Switch

Packer Panel Retract & Home

Proximity Switches

Tail Gate Ajar SwitchUp Cushion Switch

Gripper Auto Close

Switch

Down Cushion Switch

Arm Cover

Removed

Horizontal In Cushion

Switch

2-8


SECTION TWO

OPERATION


Clean-Up

1. After driving to safe place, lower tailgate to gain access to tailgate

props located on both sides of tailgate. Follow instructions on Decal

for Proper Use. Rest Tailgate on Tailgate Safety Props.

2. Remove the ignition key and clean the area to the rear of the packer

panel. Do not use your hands. Use a suitable tool such as a wooden

handled garden hoe. Clean around the tailgate seal. Do not stand under

an open tailgate unless tailgate props are properly in place and tested

for steadfastness.

NOTE: Keep the ignition key in your pocket for safety purposes.

3. Pull “Safety Latch” to allow opening of Clean-out Trough Doors on

right and left sides. Do not use your hands. Use a suitable tool such as

a wooden handled garden hoe.

NOTE: When Power-Washing the unit, follow prescribed safety

above.

Do not direct high pressure wash onto the gray electrical component

(enclosure) boxes.

Doing so may result in shorting of components.

4. Close the tailgate, ensure crusher panel is full open and retract packer

panel. You are now ready to load more refuse or stow the truck.

Cleanout Door Shown

Closed

Cleanout Door Shown

Open

3-1


SECTION THREE

MAINTENANCE


WARNING

Proper repair and servicing is important to keep your packer operating at peak effi ciency. Following are effective methods

for performing these procedures. Some of these procedures require special tools. Using improper tools can be dangerous

to the person using them. Any modifi cations to equipment must be done in accordance with American National Standards

Institute Z245.1-2007. Deviating from these standards could cause damage to the user and operators.

Components that exceed 4000 pounds in weight are; “Body Shell”.

Safety Precautions to be taken before performing any service or repair;

Do not work inside, underneath, or on top of a truck body without complying with the following precautionary steps.

1. Shut Off Engine.

2. Set Park Brake or Emergency Brake.

3. Place Chocks in front and rear of at least two tires.

4. Remove Ignition Key. Keep key with you at all times.

LOCK OUT-TAG OUT PROCEDURE

Lock Out Procedure! (To Render Safe And Isolate All Energy Sources.)

Always wear safety glasses.

A. Hydraulic Disengagement procedures: NOTE: Power take-off:

1. Front Mounted Pump with Electric Controls- With engine at idle, turn pump switch off. Do Not Re-Start Engine as

primary pump system would re-engage causing hydraulic fl ow. Remove ignition keys and place in pocket!

2. Automatic Transmission with Electric Shift PTO - With ignition switch to On, and engine off or at idle, push dash

control rocker switch to off position. PTO will disengage. Remove ignition keys and place in pocket!

B. Shut down all power sources.

1. Turn off the truck engine, and remove the ignition keys and push down Emergency Stop button.

2. Turn off any auxiliary engines, and remove the ignition keys.

3. Turn off the electric engine, and turn off the power panel.

4. Pull the 30AMP fuse by the battery or kill switch (on the 10AWG RED line). Lock out the power panel and main

breaker. Remove keys!

ALL KEYS MUST BE PLACED IN YOUR POCKET!

NO OTHER KEYS SHOULD BE AVAILABLE TO ANY OTHER PERSONNEL!

3-2


SECTION THREE

MAINTENANCE


LOCK OUT-TAG OUT PROCEDURE (continued)

C. Install Tag on steering wheel with non reusable fastener.

Example of a Lockout Tag:

D. Place Equipment in a NON-Freefall Positions. Raised tailgates should be lowered, either under power or by gravity.

To achieve this, operate the appropriate tailgate control in a correct manner.

E. Raised tailgates may be blocked in raised position by fi rst securing wheels on the road surface with wheel chocks,

front and rear, on at least two wheels. This is to prevent truck movement. Whenever possible, use the installed tailgate

props that are installed on the tailgate by following the operation decal. When this is not possible, safely block up any

tailgate, movable assembly or part, with carefully stacked and nailed 4” x 4” lumber or 6” x 6” lumber. Check the block-

ing for steadfastness. Carefully lower the weight of the tailgate onto the beams. Test the chocks and tailgate props, or the

beams for steadfastness before placing yourself in a potentially dangerous situation.

F. Relieving stored hydraulic pressure in all cylinders only when hydraulic maintenance is to be performed.

1. All telescoping hydraulic cylinders used only in conjunction with a packing panel and or ejection panel.

a. Secure vehicle to road surface with wheel chocks placed front and rear on at least two wheels.

b. Check air tank reserve. Ensure full system pressure air.

c. Open all hydraulic shutoff valves incorporated into your particular unit.

d. With lockout-tag out in process, turn ignition switch to on. Do Not Start Engine.

e. Pull up the Emergency Stop button. Push PTO Reset Button. Operate the manual packer toggle-switch in both for-ward and reverse direction and hold momentarily in both positions.

f. Remove ignition key and close all hydraulic shutoff valves incorporated into your particular unit.

g. Loosen the hydraulic fi ttings to the hydraulic telescoping cylinder at a point of attachment away from the cylinder to be worked upon. Check for any leakage of fl uid under residual pressure.

h. After residual pressure has been relieved, tighten the previously loosened fi ttings.

i. You have now relieved the stored hydraulic pressure inside of the cylinders to be worked on!

You may now proceed as normal unless power is reapplied to the hydraulic system. If power is reapplied, the entire pro-

cess will need to be repeated.

EQUIPMENT

LOCKED OUT BY:

NAME:

DEPARTMENT:

DATE:

TIME:

DANGER

3-3


SECTION THREE

MAINTENANCE


LOCK OUT-TAG OUT PROCEDURE(continued)

2. Double acting single stage cylinders which hold close a tailgate. NOTE: These cylinders

incorporate a SAFETY PILOT CHECK VALVE located underneath the body at the rear.

NOTE: The tube side port on these cylinders is always under high pressure!

a. Secure vehicle to road surface with wheel chocks placed front and rear on at least two wheels. Test wheel chocks

for steadfastness.

b. Lower the tailgate if at all possible, by operating the appropriate controls.

c. If tailgate cannot be lowered, safely block up with carefully stacked and nailed 4” x 4” lumber or 6” x 6” lumber.

Check the blocking for steadfastness.

d. After tailgate is lowered or securely supported, perform the following steps.

e. Check air tank reserve. Ensure full system air pressure.

f. Open all hydraulic shutoff valves incorporated into your particular unit.

g. With lockout-tag out in process, turn Ignition Switch to ON. Do Not Start Engine.

h. Push the 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 in both positions.

k. Remove ignition key and close all hydraulic shutoff valves incorporated into your particular unit.

l. Loosen slowly and carefully the port fi tting on the tube side of the cylinder or cylinders

to be worked on. Watch out for leakage of fl uid under residual high pressure. All shut off valves incorporated in your

unit will need closed.

m. After residual pressure is removed from hose lines, tighten the loosened fi ttings.

n. You have now relieved the stored hydraulic pressure inside of the cylinders to be worked on! You may now pro-

ceed as normal unless power is reapplied to hydraulic system.

If power is reapplied, the entire process will have to be repeated.

3. Double acting single stage cylinders which support a load or are used in conjunction with arms or forks:

a. Open all shut off valves incorporated into your particular unit’s hydraulic system.

b. Operate the particular valve control lever for the appropriate cylinder. Operate in both directions and hold the

positions momentarily to relieve pressure.

DANGER

3-4


SECTION THREE

MAINTENANCE


LOCK OUT-TAG OUT PROCEDURES(continued)

c. Secure the vehicle to the road surface with wheel chocks placed in front and behind at least two wheels. Test the

wheel chocks for steadfastness.

d. Safely block up any movable assembly with carefully stacked and nailed 4” x 4” lumber or 6” x 6” lumber. Check

the blocking for steadfastness.

e. Close all shutoff valves incorporated into your unit.

f. Loosen the hydraulic fi ttings to this cylinder or cylinders at a point of attachment away from the cylinder to be

worked on. Check for leakage of fl uid under residual pressure.

g. After residual pressure is removed from the hose lines, tighten the loosened fi ttings. Proceed to work as normal

on the cylinder or cylinders.

ROUTINE WASHING

The washing of the interior of the packer body requires Lock Out-Tag Out procedures to be followed. It is strongly sug-

gested that an observer be staioned on the outside of the unit should help be needed.

The interior of the unit will be very slippery and could become hazardous to the person inside.

It is suggested that at a minimum, safety gear should include a rainsuit, goggles, leather gloves and rubber boots.

CAUTION

3-5


SECTION THREE

MAINTENANCE


HOSE # FUNCTION

1 GRIPPER EXTEND

2 GRIPPER RETRACT

3 VERTICAL EXTEND

4 VERTICAL RERACT

5 HORIZONTAL EXTEND

6 HORIZONTAL RETRACT

ARMS HOSE MANIFOLD

HOSE # FUNCTION


2 HORIZONTAL EXTEND

3 VERTICAL RETRACT

4 VERTICAL EXTEND

5 GRIPPER RETRACT

6 GRIPPER EXTEND

ARM VALVE

3-6


SECTION THREE

MAINTENANCE


BODY VALVE

FRONT MOUNT PUMP

3-7


SECTION THREE

MAINTENANCE


B0DY PUMP AND VALVE ADJUSTMENT

Only trained personnel should conduct adjustments to the hydraulic system pressures. Hydraulic

pressures set above the stated settings may cause damage to the equipment and/or personal injury.

WARNING

1.0 PREPERATION (NOTE: ENSURE THAT ALL SAFETY PRECAUTIONS ARE OBSERVED DUR-

ING THE PROCEDURE INCLUDING LOCK-OUT /TAG-OUT OF EQUIPMENT)

1.1 Tools required to perform this procedure

1.1.1 Large fl at tip screwdriver

1.1.2 7/16” end wrench

1.1.3 9/64” allen wrench

1.1.4 15/16” end wrench

1.1.5 1 1/2” end wrench

1.2 Preform all start up inspections

2.0 ADJUSTMENT PROCEDURE (NOTE: TAILGATE AND PACKER PANEL PRESSURE ARE CON-

TROLLED BY THE SYTEM PRESSURE OF 2450PSI)

2.1 Set pump pressure

2.1.1 Extend and hold the packer panel in the extend position

2.1.1.1 Using the 7/16” wrench loosen the lock nut on the pump body relief

2.1.1.2 Using the 9/64” allen wrench adjust the pump body pressure to 2600 PSI

(clockwise to increase and counter clockwise to decrease)

2.1.1.3 Tighten the jam nut while holding the adjustment screw at the proper setting

2.2 Body valve pressure adjustment

2.2.1 With the packer panel still being held in the extend position

2.2.1.1 Using the 1 1/2 inch wrench loosen the lock nut on the body valve relief

2.2.1.2 Using the large fl at tip screwdriver adjust the body valve relief pressure to

2450 PSI (clockwise to increase and counter clockwise to decrease)

2.2.1.3 Tighten the jam nut while holding the adjustment screw at proper setting

2.3 Body lift relief adjustment

2.3.1 Raise the body to the full up dump position and hold in dump position

2.3.1.1 Using the 15/16” wrench loosen the lock nut on the body lift relief

2.3.1.2 Using the large fl at tip screwdriver adjust the body lift relief pressure to



3-8


SECTION THREE

MAINTENANCE


2.4 Crusher panel relief adjustment

2.4.1 Extend the crusher panel and hold in extended postition

2.4.1.1 Using the 15/16” wrench loosen the lock nut on the crusher panel relief

2.4.1.2 Using the large fl at tip screwdriver adjust the crusher panel relief pressure to



ARM PUMP AND VALVE ADJUSTMENT

Only trained personnel should conduct adjustments to the hydraulic system pressures. Hydraulic pressures

set above the stated settings may cause damage to the equipment and/or personal injury.

WARNING

DANGER

EXTREME CAUTION MUST BE USED WHEN USING THE MANUAL OVERRIDE TO ADJUST PRES-

SURE SETTINGS ON THE ARM VALVE. STAY CLEAR OF ALL ARM MOVEMENTS. PERSONAL

INJURY OR DEATH MAY RESULT FROM PINCH POINTS AND FAST MOVEMENTS OF THE ARM

ASSEMBLY.

ARM VALVE LOCATION

HOSE # FUNCTION


2 HORIZONTAL EXTEND

3 VERTICAL RETRACT

4 VERTICAL EXTEND

5 GRIPPER RETRACT

6 GRIPPER EXTEND

3-9


SECTION THREE

MAINTENANCE


Front Mount Pump

Arm Valve Shown

Before Assembly

For Clarity

3-10


SECTION THREE

MAINTENANCE


ARM PUMP AND VALVE ADJUSTMENT Cont.

1.0 PREPERATION (NOTE: ENSURE THAT ALL SAFETY PRECAUTIONS ARE OBSERVED

DURING THE PROCEDURE INCLUDING LOCK-OUT /TAG-OUT OF EQUIPMENT)

1.1 Tools required to perform this procedure


1.1.2 7/16” end wrench


1.1.4 10mm end wrench

1.1.5 3mm allen wrench

1.2 Preform all start up inspections

1.3 Turn adjustment for arm valve pressure clockwise 1 turn from factory setting using the 5/32” allen

wrench. This will allow pump pressure to be set.

2.0 ADJUSTMENT PROCEDURE (NOTE: HORIZONTAL PRESSURE IS CONTROLLED BY

THE SYTEM PRESSURE OF 2000PSI)

2.1 Set pump pressure

2.1.1 Extend and hold the arm in the extend position

2.1.1.1 Using the 7/16” wrench loosen the lock nut on the arm pump relief

2.1.1.2 Using the 9/64” allen wrench adjust the arm pump pressure to 2150 PSI


2.1.1.3 Tighten the jam nut while holding the adjustment screw at the proper setting

2.2 Arm valve pressure adjustment

2.2.1 With the arm still being held in the extend position

2.2.1.1 Using the 5/32”allen wrench adjust the main valve pressure to 2000 PSI


3-11


SECTION THREE

MAINTENANCE


2.3 Vertical function adjustment

2.3.1 With the gripper head held in the extend position or up position

2.3.1.1 Using the 5/32” allen wrench set the extend pressure to 1500 PSI


2.3.2 With the gripper head held in the retract position or down position

2.3.2.1 Using the 5/32” allen wrench set the retract pressure to 1500 PSI


2.4 Gripper valve pressure adjustment

2.4.1 With the gripper held in the open (retract) position

2.4.1.1 Using the 5/32” allen wrench set the retract to 1900 PSI


2.4.2 With the gripper held in the closed (extend) position

2.4.2.1 Using the 5/32” allen wrench set the extend pressure to 675 PSI


3.0 NOTE: ALTHOUGH FACTORY SETTINGS ARE RECOMMENDED THE SPEED OF THE GRIPPERS

CAN BE CHANGED BY USING THE 10mm WRENCH TO LOOSEN THE NUT ON THE LIMIT ADJUST-

ING SCREW AND USING THE 3mm ALLEN WRENCH TO ADJUST THE SPEED. (clockwise to slow down

and counterclockwise to speed up)

3-12


SECTION THREE

MAINTENANCE


ARM BOLT TORQUE SPECIFICATIONS

3-13


SECTION THREE

MAINTENANCE


CRITICAL ADJUSTMENT OF ARM CHAIN

FIG 1 Shows the arm chains out of adjustment. A visual inspection of the lift arms should be

done daily as this is a critical adjustment. Failure to keep these chains properly adjusted

will cause excessive wear on the lift arms and improper functioning of the arm and

grabber.

3-14


SECTION THREE

MAINTENANCE


ADJUSTMENT OF ARM CHAIN PROCEDUREInitiate Lockout/Tagout Procedures.

1.0 Retract (lower) the vertical cylinder (arm raise or lower) completely.

2.0 Loosen the two top chain adjustment nuts one turn.(see FIG 2 for location)

FIG 2

3.0 Adjust the gripper head IN or OUT using

the bottom adjustment nuts until the gripper

head is fl ush with the front vertical support

plate. (see FIG 2 for lower chain adjustment

nuts)(see FIG 3 for proper alignment)

FIG 3

3-15


SECTION THREE

MAINTENANCE


FIG 4FIG 4 shows the lift arm when adjustment is correct.

4.0 When both conditions shown in FIG 3 and FIG 4 have been met torque upper adjusting nuts to 40 ft lbs

3-16


SECTION THREE

MAINTENANCE


SIDEWINDER DAILY MAINTENANCE

1. Lockout-Tag Out procedures should be followed.

2. Inspect all safety and operational decals. Ensure that all are ledgible and intact. If replacements are

neccesary, contact your local New Way distributor or call the factory for replacement decals.

3. Inspect all lights and ensure they are functioning properly.

4. Ensure that the back up alarm and tailgate ajar alarm are working properly.

5. Inspect the chassis in accordance with the chassis manufacturer’s guide lines.

6. Check the hydraulic tank sight gauge with the engine off and the manual shut off in the open position to

ensure recommended oil level.

7. Inspect all hoses and fi ttings for leakage. Repair or replace as neccesary.

8. Inspect all mounting bolts, cylinder pins and other fasteners for placement and tightness. Adjust and replace

as neccesary using the same grade and size fasteners.

9. Inspect all cylinder mounting points for metal fatigue or cracked welds.

10. Ensure all switches, control levers and buttons are functioning correctly.

11. Using the wooden handled garden hoe provided (replace if neccesary), remove all debris from under and

behind ejection panel and the area around the telescoping ejection cylinders.

FRONT MOUNT PUMPS

Front mount pump drive shafts should be inspected daily for tightness of the set screws where the shaft attaches

to the pump. There are four bolts to the engine fl ywheel to check for tightness also. The three grease fi ttings

should be greased daily. 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.

BOLTS TO

ENGINE (4)

SLIDE

ZERK

SET

SCREWS

(3)

KNUCKLE ZERKS

3-17


SECTION THREE

MAINTENANCE


DAILY LUBRICATION POINTS

(LIFT ARM 29 GREASE ZERK LOCATIONS)

STREET SIDE LUBE POINTS ON ARMWith the arm in the stowed postion, the roller bearing blocks (4 places) can be greased on the street side of the

unit. There are also roller bearing blocks (2 places) on the curb side of the unit (not shown) that can be greased

when the arm is extended. The two horizontal cylinders (2 places) can be greased with the arm in the stowed

postition for the street side cylinder ends. The curb side horizontal cylinder ends can be greased (2 places not

shown) when the arm is extended.

VERTICAL CYLINDER TOP LUBE POINT (BETWEEN CHAINS)

VERTICAL CYLINDER BOTTOM LUBE POINTS (2 POINTS)

The vertical cylinder located in the center of the arm above the

grippers has two places on the bottom of the cylinder and one

place on the top between the lift chains.

GRIPPER PIVOT POINT AND

CYLINDER LUBE POINTS

The gripper pivot pins can be greased

(4 places) with the grippers in the open

position. The gripper cylinders can be

greased with the arm slightly extended.

(2 places on each end of cylider)

3-18


SECTION THREE

MAINTENANCE


ARM LIFT MECHANISM LUBE

POINTS (6 POINTS)

The arm lift outer mechanism has two places on the bottom of

the mechanism and two places on the top as shown. The inner

mechanism has the two places as shown on the bottom .

LOWER RAIL ROLLERS

LUBE POINTS (2 POINTS)

RIGHT AND LEFT LOWER

RAIL ON CURB SIDE

There are two rollers on the shaft under the rails that the arm

extend ride on. There is one place to grease on each roller

PACKER PANEL CYLINDER

INNER CYLINDER HEAD

GREASE POINTS (2 POINTS)

PACKER PANEL CYLINDER

OUTER CYLINDER HEAD

GREASE POINTS(1 POINT

EACH CYLINDER)

CURB SIDE STREET SIDE

3-19


SECTION THREE

MAINTENANCE


SIDEWINDER WEEKLY MAINTENANCE

TAIL GATE CYLINDERS

(2 POINTS) 1 CYLINDER ON

EACH SIDE OF THE TAIL

GATE

Lubricate all friction points that do not have grease zerks, such as the hopper access

door and the clean out door hinges with a quality 30 weight oil. The following grease

points will need to be greased weekly.

TAIL GATE LOCKING MECHANISM

(2 POINTS) ONE POINT ON EACH

SIDE ON THE BLOCK

BODY PIVOT LUBE

LOCATIONS

STREET SIDE SHOWN

(6 POINTS) 3 ON EACH

SIDE

OF THE PIVOT POINT

(CENTER POINT NOT

SHOWN)

BASE OF BODY LIFT

CYLINDER

(5 POINTS) 2 ON EACH

SIDE OF

CYLYNDER AND 1 IN THE

CENTER

ON THE COLLAR

3-20


SECTION THREE

MAINTENANCE


1. Check all wiring connections. Tighten or replace as necessary.

2. Check wires for excessive wear, kinking or crimping. 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 and wear. Replace as necessary.

5. Check all air supply lines for rubbing and chafi ng. Replace as necessary.

6. Check all decals for readability. Replace Damaged Decals (free replacements). See pages 1-8 through 1-14 in

Section 1.

SIDEWINDER MONTHLY MAINTENANCE

NOTE: Low pressure spin

on fi lters Part #119238 (2

required)

High pressure internal

elements Part #111472 (2

required)

Breather fi lter Part #106207

1. Hydraulic oil fi lters: Replace after the fi rst 50 hours of use and every 250 hours thereafter. (Note: Hydraulic

oil fi lter should be changed in the case of any major hydraulic component failure.)

2. Air Filter / Breather Cap: It must allow free air fl ow for the hydraulic oil tank. Inspect daily to assure that

the cap is properly attached and free of obstruction. Wash foam prefi lter in soapy water, rinse and air dry

every 3 months. Replace cartridge element every six months (minimum) and more frequently in dirty condi-

tions.

3. Hydraulic fl uid: Replace after fi rst six (6) months and every year thereafter. Refer to oil specifi cations for

replacement oil. (Note: Oil should be drained and replaced in the case of any major hydraulic component

failure.)

4. Suction strainer: Remove and clean the screen each time the oil is changed.

5. The optional high pressure fi lters should be changed at the same interval as the hydraulic oil fi lter.

OIL SUPPLY TANK

3-21


SECTION THREE

MAINTENANCE


OIL SPECIFICATION CHARTBRAND NORTHLAND TALAMAR NORTHLAND TALAMAR

EXTREME (BLUE IN COLOR) ALL SEASON (RED IN COLOR)

IOS Viscosity Grade ASTM D2422 32 46

Gravity Def.API ASTM D278 32.0 31.1

Specifi c 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

cST2100c

ASTM D445 33

6.6

47

7.9

Viscosity: SUS@100f

SUS@210F

ASTM D2161 168

48

Viscosity Index: min ASTM D2270 160 138 typical

Brookfi eld Viscosity

cP,max@-20f

ASTM D2983 1050

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

NOTE: When adding or replacing the hydraulic fl uid, give the above information to you supplier to provide a

similar product. The oil provided with the unit is a premium hydraulic fl uid that is formulated to meet the stringent

performance requirements of refuse collection equipment exposed to broad ambient operating temperatures.

3-22


SECTION THREE

MAINTENANCE


3-23


SECTION THREE

MAINTENANCE


3-24


SECTION THREE

MAINTENANCE


MAC AIR VALVE

DENISON T6DC FRONT MOUNT PUMP

PART #122553

3-25


SECTION THREE

MAINTENANCE


4-1


SECTION FOUR

ELECTRICAL


OVERVIEW OF INTERLOCKS

>If the door saftey prox (i16) is not activated the main air supply (Q10) and pump (Q1) will kick out.

>Hit momentary PTO reset button (i4) to re-activate the main air supply (Q10) and pump (Q1), door saftey prox

(i16) is not triggered, door saftey prox (i16) is de-energized, or key is turned off.

>Tailgate can not close (Q7) unless ejection panel is at home prox (i14) position.

>Unless tailgate is fully open and mercury switch is activated (i9) ejection panel cannot go past the retract prox

(i13).

>If the tailgate is not fully closed (i8) or fully open (i9) ejection panel will not extend (Q8).

>If the tailgate is not fully closed (i8) the tailgate ajar light (Q3) will fl ash and the buzzer will go off.

>When the crusher panel prox (i10) is tripped, the crusher panel open light (Q4) will activate.

>During retract of the Auto-pack cycle, the one-shot (Q4) feature will activate telling the tailgate cylinders to

retract (Q7).

>If the safety door switch (i16) is deactivated, the main air supply solenoid (Q10) and pump (Q1) power will

kick out. The safety door switch (i16) must be activated to allow the main air supply solenoid (Q10) and pump

(Q1) to be re-energized.

>If autopack on switch (i12) is activated the ejection panel will continue to cycle. There is a 1/2 second delay

on the extend and retract to eliminate hydraulic shock. NOTE: If the panel does not reach the retract prox switch

within 22 seconds it will automatically retract. It will do this cycle 5 times and then shut down. The autopack

switch will need to be turned of and then turned back on to reset. When the auto pack switch is turned off the

panel will return to the home position.

>If the arm stowed switch (i15) is not activated the body raise (Q13) will not function.

>If the body ajar prox (i18) is not activated the body ajar light (Q12) will illuminate.

OF

4-2


SECTION FOUR

ELECTRICAL


4-3


SECTION FOUR

ELECTRICAL


1. Revisions

2. Software Specification

Module NODE

#

HWD

Version

Baud

Rate

Program Number

10100900 3 10101468v240 250K SA3877105

3. Description of Operation

Joystick functions X and Y are both controlling PVEA sections. X-Axis -X decreasing

-horizontal mast in -controls b-port on valve -cyl retract port

-X increasing -horizontal mast out -controls a-port on valve -cyl extend port Y-Axis -Y decreasing -vertical lift up -controls a-port on valve -cyl extend port -Y increasing -vertical lift down -controls b-port on valve -cyl retract port 1.Controller must have input from the deadman switch to activate any of the valve functions. 2. Inputs at pin #’s 6 and 7 are the input commands which control the PVEO section. -Input 6 (grip open) controls the A port on the valve. Output disabled if “Grip auto close prox” is on.

LEVEL DESCRIPTION – ECO NUMBER DATE BY

104 CREATED 7/10/09 CSS

105 Added two manual switches to allow operator to

operate from outside the cab at 50% speed. In/Out

and Up/Dwn

3/10/10 CSS

4-4


SECTION FOUR

ELECTRICAL


-Input 7 (grip close) controls the B port on the valve. Output disabled if “Disable grip close SW” is seen.

-If the controller sees “grip auto close prox”, Grip close (B port on the PVEO section) needs to be activated for a duration of 2sec., Even if it continues to see the input. Timer will be reset once it goes away.

3. If “arm in cushion prox” is present the output to the B-port on the valve controlled by the X axis (X decreasing) needs to be ramped down to X%(needs to be adjustable from 0-100% of the output commanded). This is to act as a cushion for the horizontal mast in. 4. If “Arm up cushion prox” is present the output to the A-port on the valve controlled by the Y axis (Y decreasing) needs to be ramped down to X%(needs to be adjustable from 0-100% of the output commanded). This is to act as a cushion for the Vertical lift up. 5. If “Arm down cushion prox” is present the output to the B-port on the valve controlled by the Y axis (Y increasing) needs to be ramped down to X%(needs to be adjustable from 0-100% of the output commanded). This is to act as a cushion for the Vertical lift down. 6. If “Body ajar prox” is present Arm up (vertical lift up, a-port on valve) is to be disabled. 7. If “Hopper door open prox” is NOT present, Arm up (vertical lift up, a-port on valve) is to be disabled. 8. If “Gripper auto close prox” and NOT “Arm in prox” (vertical lift up, a-port on valve) is to be disabled to prevent garbage being dumped prematurely. 9. If “E-stop” is NOT present nothing works. -In order for the system to operate either by flashing power to the controller, or releasing the E-Stop, the controller needs to see a momentary “reset button” input to resume normal operation. 10. There are ramp and deceleration rates for the X and Y axis outputs.

Blink Codes:

Blink Code Reason for Fault Corrective Action 21 Sensor power Fault Sensor power shorted to ground or too high.

22 Grip close output Output coil open or short detected, check

wiring, or replace coil.

23 Grip open output Output coil open or short detected, check


24 In/Out Enable coil Output coil open or short detected, check


25 X-axis out of range Shorted, open circuit or bad joystick.

26 Y-axis out of range Shorted, open circuit or bad joystick.

27 Up/Down Enable Output coil open or short detected, check


28 X-axis compare Sensors on X axis out of range, replace

joystick.

29 Y-axis compare Sensors on Y axis out of range, replace

joystick.

4-5


SECTION FOUR

ELECTRICAL


4-6


SECTION FOUR

ELECTRICAL


4-7


SECTION FOUR

ELECTRICAL


4-8


SECTION FOUR

ELECTRICAL


4-9


SECTION FOUR

ELECTRICAL


4-10


SECTION FOUR

ELECTRICAL


4-11


SECTION FOUR

ELECTRICAL


4-12


SECTION FOUR

ELECTRICAL


4-13


SECTION FOUR

ELECTRICAL


4-14


SECTION FOUR

ELECTRICAL


4-15


SECTION FOUR

ELECTRICAL


4-16


SECTION FOUR

ELECTRICAL


4-17


SECTION FOUR

ELECTRICAL


4-18


SECTION FOUR

ELECTRICAL


5-1


SECTION FIVE

TROUBLE SHOOT


LED TEST LIGHT

DIGITAL MULTI METER

5-2


SECTION FIVE

TROUBLE SHOOT


ELECTRICAL TROUBLE SHOOTING GUIDE LINES

Electrical trouble shooting will be less intimidating if remembering that all electric circuits are electricity

passing from the battery through the wires, fuses, switches and relays to the component or components and to

ground, from which it is passed back to the battery. Any electrical problem is an interruption of the fl ow of

electricity to and from the battery.

The two instruments on the previous page are the main tools that are used in trouble shooting this 12 volt, nega-

tive ground, and alternator charged system. NOTE: For trouble shooting purposes the battery will need to be

connected but when servicing any components remove the ground cable and the 30amp inline fuse located at

the power source.

GENERAL INFORMATION:

The previous chapter holds the various electrical schematics for the packer unit and a chassis to packer wiring schematic

is sent along with the truck. Refer to the individual schematics for the problem being investigated. Page 4-3 is the harness

scheme for the packer body and should give a good understanding of tracing problems related to the packer body.

This chapter is designed to help with most problems encountered and the diagnostic steps in solving those problems.

CHECKING FOR VOLTAGE

Electrical problems generally are attributed to blown fuses, loose or corroded connections or a failed relay. Check these

things as a fi rst step in trouble shooting. When changing a blown fuse always use the same amperage rating as the circuits

require this amount of protection. Using a larger fuse value could cause serious damage. If the new fuse blows soon after

replacement do not replace until the problem is found and corrected.

Starting at a point closest to the power source and following it along the path of the circuit having a problem is usually

the fastest way to fi nd the problem. Pay special attention to points where connections are made as these can be the trouble

areas. Connector cases hide oxidation and misaligned or loose wires. Often this will be the case if intermittent problems

are being experienced.

NOTE: 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 the multi meter

to the ohms scale connect one lead of the multi meter to a good ground. Connect the other lead to the ground

wire of connection being tested. The resistance should be 5 ohms or less if the ground is good.

5-3


SECTION FIVE

TROUBLE SHOOT


The fi rst step in trouble shooting a circuit controlled 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 the coil which builds a magnetic fi eld in the bar

it is wrapped around. This pulls the steel plate to it and that is the audible snap heard when power is applied. The spring

attached to the steel plate pulls the plate 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 in question turn on.

Remember you must have the ignition key on. When the switch is turned on an audible snap should be heard. Continuity

between 30 and 87 should be found at this point. With the switch in the off position continuity should be between 30 and

87a. If not then you have a failed relay that needs replaced.

It is important to remember that relays can be wired to have power energize the circuit or can be wired to have ground

energize the circuit. On the following page are examples of each.

STEEL PLATE

ELECTROMAGNET

COIL

SPRING

BRAIDED WIRE SWITCHCONTACTS

POWER CIRCUITS

CONTROL CIRCUITS

87A

85

87

86

30

5-4


SECTION FIVE

TROUBLE SHOOT


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

INLINEFU

SE30AM

P

WITHIN 6"

OF SOURCE

INLINEFUSE

10 AMP

INLINEFU

SE30AM

P

WITHIN 6"

OF SOURCE

5-5


SECTION FIVE

TROUBLE SHOOT


Problem: Excessive noise in pump

A. insuffi cient fl uid

Replenish fl uid to proper level,with proper grade

B. Fluid is too heavy

Drain system and refi ll with the specifi ed grade of fl uid

C. Oil fi lter is dirty

Replace with new fi lter

D. Clogged oil line

Clean line thoroughly

E. Pump overspeeding

Check pump maximum speed; slow down the pump driver; or install a larger pump

F. Air vent on fl uid reservoir clogged

Replace breather on reservoir

G. Air bubbles in fl uid

Drain system and refi ll with non-foaming hydraulic fl uid

H. Coupling misalignment

Realign fl exable coupling between pump and driver

I. Air leaks at pump intake, pump shaft packing, or inlet pipe

Drip oil over suspected joint: listen for a change in the sound of pump; tighten joints

J. Worn or broken pump parts

Replace parts as necessary

Problem:Foaming fl uid

A. Improper fl uid

Drain system and refi ll with proper grade of non-foaming hydraulic fl uid

B. Inadequate baffl ing in tank

Replace with correct baffl e

C. Air leaking into suction line between resevoir and pump

Tighten all connections

Problem:Oil level in tank continues to drop

A. Oil level in tank drops

Indicates a broken pipe line or a pipe left out between a bulkhead coupling and the bottom of the tank after

cleaning tank. Replace pipe

B. Pump rotating in wrong direction

IMMEDIATELY STOP PUMP DRIVER TO PREVENT DAMAGE TO THE PUMP. REVERSE DIRECTION

OF PUMP ROTATION

C. Pump fails to prime itself

Indicates an air leak in suction line, oil is too heavy or system is not in Neutral. Tighten all joints, replace

hydraulic fl uid with proper grade,open valve on pressure side of pump, or install a bleed valve.

PUMP TROUBLE SHOOTING

5-6


SECTION FIVE

TROUBLE SHOOT


Problem:Excessive wear in pump

A. Abrasive contaminants in fl uid

Drain and fl ush entire syatem. Install a new fi lter. Fill system with new oil of the proper grade. Operate pump

for 1 hour. Drain the system again and refi ll with new oil and a new fi lter.

B. Sustained pressure above pump maximum rating.

Check and reset relief valve pressure using a pressure gauge.

C. Sustained excessive speed at pressure above pump maximum rating

Recheck the rated speed of the pump. Slow pump driver to rated speed.

D. Drive misalignment or weight of pump supported by its drive shaft.

Check the pump/driver coupling or belt alignment. Install adequate support for the pump

E. Entrapped air in hydraulic system

Bleed air from the system

Problem:Fluid overheats

A. Fluid is to heavy or to light

Drain and replace fl uid with proper grade of non-foaming fl uid

B. Dirty fl uid

Drain and fl ush system. Replace with new fl uid and change the fi lter element

C. Dirt or a chip caught between the plunger and seat of the relief valve.

Disassemble the relief valve and remove the contaminant. Check condition th the fi lter to prevent a recurrence

D. Incorrect setting on relief valve

Reset relief valve using a pressure gauge

E.Worn pump permits oil to bypass internally

Repair worn parts or replace pump

F. Excessive friction caused by pump components being overtorqued

Repair or replace pump

G. Undersized hoses or valves in the system

Replace hoses or valves with proper sizes.

H. Restrictions from exsesive bends in the lines

Replumb the system to eliminate restrictions.

I. Inadequate reservoir prevents adequate cooling of fl uid

Install a larger reservoir or add fl uid radiator

Problem:Pump is not effi cient

A. Worn pump parts reduce effi ciency

Repair or repalce pump

B. Air in the system

Bleed the air from the system and check line connections for air leaks

C. Internal leak in control valve or cylinder

Repair or replace control valve. Replace cylinder packing. Check cylinder walls for scoring and replace if necessary

D. Erratic pump performance

If pump runs slow on startup, and speeds up after fl uid is warm the fl uid grade is to heavy

If the pump slows down after fl uid is warmed up the fl uid is to light

Drain system and refi ll with proper grade of non-foaming oil

5-7


SECTION FIVE

TROUBLE SHOOT


CAPSCREW MARKING AND TORQUE VALUES

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.

USAGE MUCH USED USED AT TIMES USED AT TIMES

5-8


SECTION FIVE

TROUBLE SHOOT


VALVE NAMING CONVENTION

Valve or Cartridge

X

VALVE TYPEV - ValveC - Cartridge

Valve GeneralDesription

XX X

VALVE FLUID TYPEH - HydraulicP - Pneumatic

VALVE TYPEC - Directional ControlF - Flow ControlK - Check-Direct ActingV - Divider/CombinerN - Non-Directional ControlP - Pilot Operated CheckB - Counter BalanceD - DumpR - ReliefS - Shuttle

CENTER TYPEO - Open CenterC - Closed CenterT - Tandom CenterN - Not ApplicableP - Normally OpenL - Normally Closed

X

RELIEF TYPEN - Non ReliefS - Standard-Non AdjustableA - Standard-AdjustableP - Differential Poppet-Non AdjustableD - Differential Poppet-Adjustable

##

RELIEF SETTING

2 Didgit (00 for No Relief)- Pressure in hundred-psi forHydraulics

# # XX X

Main Relief Sections 1,2,3,.... For repeated sections can enclosedescription in parenthesis and precede withnumber of repeated sections. i.e. "3(SM63N)"

Repeat for continuing sections

OutletSection

RETURN

S - SpringM - ManualD - Spring w/DetentN - Static

OPERATIONM - Manual/MechanicalS - Pilot Operated Electric SolenoidP _ Pneumatic PressureH - Hydraulic PressureN - Static

PORTS2 - Two Way3 - Three Way4 - Four Way5 - Five Way6 - Six Way

POSITIONS

1 - Single Position/Static2 - Two Position3 - Three Position4 - Four Position

FEATURESA - Anti-CavitationN - No Special FeaturesW - Work Port ReliefC - Anti-Cavitation/ReliefR - Activated Restricted FlowF - Needle Valve Flow ControlH - Activated Check with Full Reverse FlowL - Lock Out Pilot Operated Check ValveM - Activated Check with Metered Reverse Flow

OUTLETT - Tank DumpP - Power Beyond

X

EXAMPLE:

VHCO-S24-SM63N-DM63C-DM63N-T: Hydraulic Valve, Direction Control with Open Center System, Non-Adjustable Reliefset at 2400 psi, 3 sections: Section 1: Spring Returned-Manual Operated 6 way-3 position section; Section 2: DetentSpring return-Manual Operated 6 way-3 position section with Anti-Cavitation and Work Port Relief; Section 3: DetentSpring return-Manual Operated 6 way-3 position section, Tank Dump

To be Used as Description, use only Descriptors that are Necessary

5-9


SECTION FIVE

TROUBLE SHOOT


X XXX X ### #X X#### ## ### #

DESCRIPTION OF PART

FITTING SIZE

HOSE PRESSURE RATING

HOSE/TUBE SIZE - NOMINAL

FITTING ANGLE

FITTING REACH

HOSE LENGTHIN INCHES

HOSE LENGTH FRACTIONALCOMPONENT I 1/4 INCH INCREMENT

EXAMPLE:

H - Hydraulic HoseP - Pneumatic HoseT - Hydraulic Tubing

Pressure in Hundred psi for Hydraulic (30 for 3000psi)Pressure in Ten psi for Pneumatic (25 for 250 psi)

TUBING WALL THICKNESSThickness in Thousandths for t < 0.100Thickness in Hundredths for t > 0.100

04 - 1/4 inch06 - 3/8 inch08 - 1/2 inch10 - 5/8 inch12 - 3/4 inch16 - 1 inch20 - 1.25 inch24 - 1.5 inch32 - 2 inch

04 - 1/4 inch06 - 3/8 inch08 - 1/2 inch10 - 5/8 inch12 - 3/4 inch16 - 1 inch20 - 1.25 inch24 - 1.5 inch32 - 2 inch

0

0FITTING STYLE

FJ - Female 37 FlaredFX - Female 37 Flared SwivelMJ - Male 37 FlaredMP - Male NPTFP - Female NPTMO - Male SAE O-RingFO - Female SAE O-Ring61 - Code 61 Flange62 - Code 61 Flange

0

0

0

N - NormalS - ShortL - LongX - Extra LongY - Extra Extra Long

0 - Straight3 - 304 - 456 - 609 - 90

0

0

0 - Even Inch Length1 - 1/4 inch2 - 1/2 inch3 - 3/4 inch

H3006-06FX0N-06MJ9L-078-23/8" Hydraulic Hose Comprised of 3000 psi rated hose, #6 Female 37 Flared Swivel Straight fitting on one end, #6 Male JIC Long 90Fitting on the other end, 78.5 inches long from center.

00

HOSE AND TUBING NAMING CONVENTIONTo be Used as Description

5-10


SECTION FIVE

TROUBLE SHOOT


0

FTG, XXX ## XX ## XX ## XX X X, XXXXXX

If Req'd

END SIZE

FITTING CONFIGURATION

FITTING TYPE

ADDITIONAL DESCRIPTORS(seperated with comma)

END STYLE

EXAMPLE:

01 - 1/16 inch 10 - 5/8 inch02 - 1/8 inch 12 - 3/4 inch03 - 3/16 inch 16 - 1 inch53 - 5/32 inch 20 - 1.25 inch04 - 1/4 inch 24 - 1.5 inch05 - 5/16 inch 32 - 2 inch06 - 3/8 inch

HYD - Hydraulic (Steel)HOSE - Hose-crimp on or slip fitPNU - PneumaticBLP - Black PipeBRS - BrassSS - Stainless Steel

If Req'd

If Req'd

0 - Straight3 - 304 - 456 - 609 - 90P - PlugC - CapB - Breather VentR - Run TeeT - TeeX - 4-way CrossY - Y SplitD - Double Y Split

FITTING REACHN - NormalS - ShortL - LongX - Extra LongY - Extra Extra Long

HH - Hex HeadSH - Hex Socket KeySSQ - Square Socket KeySQ - Square HeadLN - Lockenut IncludedFORG - High Pressure ForgedCR - Chrome PlatedZN - Zinc Plated§=§§§§§§§§§§§§§§§§MAG - Magnetic

If Req'd If Req'd

FJ - Female 37 FlareFX - Female 37 Flare SwivelMJ - Male 37 FlareMP - Male NPTFP - Female NPTMO - Male SAE O-RingFO - Female SAE O-RingFW - Female SAE O-Ring Swivel61 - Code 61 Flange62 - Code 62 FlangeHB - Hose BarbHY - Hose (crimp on)

TU - Air Brake TubeBM - Male British PipeBF - Female Brithish PipeHD - Hose Bead - Push OnTN - Air Brake Tube NutTI - Air Brake InsertBN - Bulkhead Nut

00

00

0

0

0

FTG, HYD, 8MO-6MJ-9LFTG, BLP, 12MP-PN,SHFTG, HYD, 16MO-16HB-0NFTG, HYD, 12MO-8MJ-8MJ-TN

Hydraulic Fitting, #8 Male O-Ring Boss to #6 Male 37 Flare 90 Long ElbowBlack Pipe Plug, 3/4 NPT, Socket Hex Head

Hydraulic Fitting, #16 Male O-Ring Boss to 1 inch Hose BarbHydraulic Fitting, #12 Male O-Ring Boss to #8 Male 37 Flare Tee

0 0

0

FITTING NAMING CONVENTIONTo be Used as Description. Use Only Desciptors that are Necessary

OM - Male O-Ring Face SealOF - Female O- Ring Face Seal SwivelPO - Push on Hose BarbBH - Bulkhead Male 37 FlareBW - Hose (crimp on) larger size-high pressureQF - Quick Coupler Female - CheckQX - Quick Coupler Female - No CheckQM - Quick Coupler Male - CheckQY - Quick Coupler Male - No CheckPX - Female Pipe SwivelTS - Air Brake Tube SleevePL - Push Lock (air Fitting)

Documents

OPERATOR’S MANUAL FOR NEW WAY SIDEWINDER AUTOMATED … · operator’s manual for new way sidewinder automated loaders scranton manufacturing co,inc. 101 state st, pobox 336 scranton,