Wittke StarLight User manual

STARLIGHT™ / SUPERDUTY™
MAINTENANCE MANUAL
& FEATHERWEIGHT™

STARLIGHT™ / SUPERDUTY™
& FEATHERWEIGHT™
MAINTENANCE MANUAL

Liability
Labrie Enviroquip Group assumes no liability for any incidental, consequential, or other liability that
might result from the use of the information contained in this document.
All risks and damages, incidental or otherwise, arising from the use or misuse of the information
contained herein are entirely the responsibility of the user.
Although careful precaution has been taken in the preparation of this document, Labrie Enviroquip
Group assumes no responsibility for errors or omissions.
January 2021

Liability ........................................................................................ ii
Table of Contents ......................................................................... v
Introduction ................................................................................ 1
About This Manual ........................................................................................................................................................................... 1
Topics not Included in this Manual ..................................................................................................................................... 1
About the Illustrations in this Manual ................................................................................................................................ 1
Schematics ................................................................................................................................................................................... 1
Warranty Registration Form .......................................................................................................................................................... 2
Introducing the WITTKE™ ................................................................................................................................................................ 2
Multiplexed System .................................................................................................................................................................. 2
Service and Maintenance on the WITTKE™ ............................................................................................................................... 3
Parts ................................................................................................................................................................................................ 3
Warning ......................................................................................................................................................................................... 3
WITTKE™ Basic Maintenance ................................................................................................................................................... 4
Our Office Addresses and Phone Numbers ............................................................................................................................ 7
In the U.S. ...................................................................................................................................................................................... 7
In Canada ...................................................................................................................................................................................... 7
Safety ........................................................................................... 9
Conventions ....................................................................................................................................................................................... 9
Basic Safety Notions ........................................................................................................................................................................ 9
Responsibilities ............................................................................................................................................................................... 10
Employer’s Responsibilities ................................................................................................................................................ 10
Employee’s Responsibilities ................................................................................................................................................ 10
Things to Do .................................................................................................................................................................................... 11
Things to Avoid .............................................................................................................................................................................. 11
General Precautions ...................................................................................................................................................................... 12
Fire ...................................................................................................................................................................................................... 13
Safety Kits ......................................................................................................................................................................................... 14
Safety and Informative Decals .................................................................................................................................................. 14
Safety Features ............................................................................................................................................................................... 14
Centralized Grease Block ..................................................................................................................................................... 14
Global Motion Sensors (Optional) .................................................................................................................................... 14
Back Up Alarm ......................................................................................................................................................................... 14
Service Hoist Safety Props (optional) .............................................................................................................................. 15
Tailgate Safety Prop ............................................................................................................................................................... 18
Securing Tailgate Safety Pins ............................................................................................................................................. 20
Locking Out and Tagging Out the Vehicle ............................................................................................................................ 21
Shutting Down the Vehicle ........................................................................................................................................................ 23
Prior to Start Up .............................................................................................................................................................................. 23
Lifting Components for Service ................................................................................................................................................ 25
Lifting the Arms and Forks .................................................................................................................................................. 25
Lifting the Front Section of the Body .............................................................................................................................. 25
Lifting the Entire Body .......................................................................................................................................................... 27
Safety Precautions To Be Taken When Working With Hydraulic Systems .................................................................. 28
Welding Information .................................................................................................................................................................... 29
Lubrication ................................................................................ 31
Recommended Lubricants ......................................................................................................................................................... 31
Table of Contents

vi Table of Contents
Grease ......................................................................................................................................................................................... 31
Hydraulic Oil ............................................................................................................................................................................. 31
Engine Oil ................................................................................................................................................................................... 32
Transmission Oil ...................................................................................................................................................................... 32
Centralized Grease Block ............................................................................................................................................................. 33
Lubricating Packer Rails ............................................................................................................................................................... 35
Preventive Maintenance ........................................................... 37
Operating and Maintenance Records ..................................................................................................................................... 37
WITTKE™ Preventive Maintenance Chart ................................................................................................................................. 38
Electrical System ....................................................................... 41
Electrical Schematics .................................................................................................................................................................... 41
How the Electrical System Works ............................................................................................................................................. 41
Adjusting and Repairing Electrical Components ............................................................................................................... 43
Fuses and Circuit Breakers ................................................................................................................................................... 43
Limit and Proximity Switches ............................................................................................................................................. 45
Limit Switch Adjustment ...................................................................................................................................................... 47
Proximity Switch Adjustment ............................................................................................................................................. 47
Packer Fully Retracted Proximity Switch ........................................................................................................................ 48
Packer Fully Extended Proximity Switch ........................................................................................................................ 49
Side Access Door Proximity Switch .................................................................................................................................. 50
Top Door Fully Open Proximity Switch ........................................................................................................................... 51
Tailgate Unlocked Proximity Switch ................................................................................................................................ 52
Tailgate Fully Open Proximity Switch .............................................................................................................................. 53
Arms Partially Raised Proximity Switch ........................................................................................................................... 53
Arms and Forks Fully Retracted Proximity Switch ...................................................................................................... 55
Body Raised Limit Switch (optional) ................................................................................................................................ 58
Multiplex System-Related Interventions ............................................................................................................................... 59
IFM Program Update Process ............................................................................................................................................. 59
J1939 Baud Rate ...................................................................................................................................................................... 61
Checking Control Module (Node) Supply Voltage ..................................................................................................... 63
Pneumatic System ..................................................................... 65
How the pneumatic system works .......................................................................................................................................... 65
Air Supply ................................................................................................................................................................................... 65
Filter System ............................................................................................................................................................................. 65
Air Dryer ..................................................................................................................................................................................... 67
Controls ...................................................................................................................................................................................... 68
Auxiliary Controls (optional) ............................................................................................................................................... 69
Speed-Up Switch (optional) ................................................................................................................................................ 69
Pneumatic Valve Box and Air Valves ................................................................................................................................ 70
Air Actuators ............................................................................................................................................................................. 71
Central Air Drain Cocks (optional) ..................................................................................................................................... 72
Control System Pneumatic Pressure Switch ......................................................................................................................... 73
Auto-Dump System (optional) .................................................................................................................................................. 75
Auto-Dump Calibration Procedure .................................................................................................................................. 75
Pneumatic System Schematics ................................................................................................................................................. 76
Hydraulic System ....................................................................... 81
General Maintenance ................................................................................................................................................................... 81
Hydraulic Pump .............................................................................................................................................................................. 82
Inspecting the Pump ............................................................................................................................................................. 83
Replacing the Hydraulic Pump .......................................................................................................................................... 84

Table of Contents vii
Installing a Yoke-Locking Bolt ............................................................................................................................................ 96
Priming a New Pump ............................................................................................................................................................ 97
Hydraulic Tank ................................................................................................................................................................................ 98
Inspecting the Hydraulic Tank ........................................................................................................................................... 99
Emptying the Hydraulic Tank ........................................................................................................................................... 100
Cleaning the Strainer .......................................................................................................................................................... 101
Return Line Filter .......................................................................................................................................................................... 102
Return Line Filter Element ................................................................................................................................................. 103
Element Replacement Procedure ................................................................................................................................... 104
Hydraulic Oil .................................................................................................................................................................................. 105
Changing Hydraulic Oil ...................................................................................................................................................... 106
Hydraulic Cylinders ..................................................................................................................................................................... 107
Inspecting Hydraulic Cylinders ........................................................................................................................................ 107
Detecting Cylinder Internal Leaks .................................................................................................................................. 107
Main Valve ...................................................................................................................................................................................... 109
Pressure Relief Valve ............................................................................................................................................................ 111
Work Circuits ................................................................................................................................................................................. 111
Arms Up Deceleration Valve ............................................................................................................................................. 112
Arms Down Deceleration Valve (optional) .................................................................................................................. 113
Pack Circuit Dump Valve .................................................................................................................................................... 114
Tailgate Holding Valve ............................................................................................................................................................... 115
Service Hoist (optional) ............................................................................................................................................................. 117
Arms Down Work Section ......................................................................................................................................................... 118
Main System Pressure Adjustment ........................................................................................................................................ 118
Hydraulic Hose .............................................................................................................................................................................. 121
Pressure and Cycle Time Table ................................................................................................................................................ 121
Hydraulic System Schematics ................................................................................................................................................. 123
Packer Maintenance ................................................................ 129
Replacing Packer Wear Plates .................................................................................................................................................. 129
Replacing Body Guide Wear Plates ....................................................................................................................................... 130
Packer Removal ............................................................................................................................................................................ 131
Replacing Packer Cylinders ...................................................................................................................................................... 133
Multiplexing ............................................................................ 135
Labrie’s Multiplex System ......................................................................................................................................................... 135
Main Page ................................................................................................................................................................................ 136
Main Menu .............................................................................................................................................................................. 142
Module Locations ........................................................................................................................................................................ 151
Node 10 Module Location ................................................................................................................................................. 152
Node 30 Module Location ................................................................................................................................................. 152
Node 50/60 Module Location .......................................................................................................................................... 153
Connections and Module Condition .................................................................................................................................... 153
Warning Buzzer ..................................................................................................................................................................... 156
Plugging a Computer .......................................................................................................................................................... 156
Allison Transmission Parameters ............................................................................................................................................ 157
Programmed Parameters .................................................................................................................................................. 157
Cummins Engine Parameters .................................................................................................................................................. 159

viii Table of Contents