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

1Introduction
About This Manual
This manual contains information regarding the
correct maintenance of your WITTKE™ garbage truck.
Maintenance personnel should read and understand
this information before doing repairs and maintenance
on the vehicle. For information on how to safely and
efficiently operate the WITTKE™, please refer to the
related Operator’s Manual that is provided with your
unit.
Topics not Included in this Manual
Maintenance of the chassis
This is dealt with in the chassis manufacturer’s service
manual.
Cameras and backing-accident prevention systems
For these options, refer to the appropriate
manufacturer’s service manual.
Operating the WITTKE™
For procedures related to the operation of the
WITTKE™, please refer to the Operator’s Manual.
Parts and assemblies
For parts and assemblies that make up the WITTKE™,
and for their respective part number for ordering
purposes, please refer to the WITTKE™ Parts Manual.
About the Illustrations in this Manual
Because Labrie Enviroquip Group is constantly
updating its products, illustrations used in this manual
may differ from those of the actual product and
accessories, depending on the model or options that
come with your vehicle.
Schematics
For schematics related to body parts, refer to the
WITTKE™ Parts Manual;

2Introduction
For electrical schematics, refer to the schematics provided with your WITTKE™ unit;
For pneumatic and hydraulic schematics, refer to the schematics provided with your WITTKE™ unit.
NOTE:A number of system schematics are included in this manual.
Warranty Registration Form
Do not forget to complete the owner registration form and to send it to Labrie Enviroquip Group.
Make sure to fill out the in-service date. This date will be used as the start date of the warranty period.
If the in-service date is not indicated, the warranty period will start 30 days after the delivery date.
Introducing the WITTKE™
WITTKE™ units are front-load refuse collection vehicles used to pick up residential or commercial
dumpsters. Once the body is full, all its content is unloaded at a waste management landfill or other
appropriate site (e.g. transfer station, incinerator, recycling station). These vehicles are designed to
be operated by only one person at a time, and they use a series of hydraulic, pneumatic, mechanical,
and electrical systems to perform their work routine.
The WITTKE™ comes in three models: the SUPERDUTY™, the STARLIGHT™ and the
FEATHERWEIGHT™.
WITTKE™ units are equipped with a set of swing arms and forks to perform the collection of industrial
and commercial waste. Some trucks can be supplied with a carry can equipped with either a tipper or
an automated arm to perform residential collection.
Body’s main components are the packer, the tailgate, and the swing arms and forks.
The tailgate is the rear door that prevents refuse from exiting the body during collection. At landfill,
the tailgate is raised to allow the discharge of the refuse that has been collected.
The packer is the piece of equipment that packs refuse inside the body and pushes it out of the body
at landfill when the tailgate is raised.
Multiplexed System
Labrie has equipped your WITTKE™ unit with a CAN bus-based multiplexed system, which integrates
a monitor, a control panel, a joystick, and a set of electronic controllers. This whole system has been
designed to help you operate your unit in an efficient and easy way. Labrie’s multiplexed system is
reliable and safe and it requires less wiring harnesses to operate. It can also monitor various function
status of the body and display warning and caution messages.
Through its monitor (see Figure 1-1), Labrie’s multiplexed system informs you of any malfunctions
that may occur during the operation of the truck. Various caution and warning messages can be
displayed on the monitor, depending on the seriousness of the situation. Yellow-highlighted
messages indicate that caution should be used while red-highlighted messages indicate a warning
situation that must be dealt with quickly.

Introduction 3
Figure 1-1
Monitor
NOTE:Maintenance personnel as well as in-the-field technicians who encounter any problems with
the multiplexed system should refer to the Multiplex Diagnostic Manual (part# 153144_01) for
troubleshooting information and guidelines.
Service and Maintenance on the WITTKE™
Maintenance on the WITTKE™ is of paramount importance to ensure long-lasting durability of all its
moving parts as well as optimum performance in heavy work. Maintenance has to be done on almost
every system involved in the operation of the WITTKE™, such as the hydraulic, electrical and
mechanical systems. Some parts are subjected to more wear and tear than others. Therefore, these
parts need regular maintenance and routine check-up to prevent signs of deterioration as soon as
possible.
NOTE:Any time you have a problem with a Labrie unit, you should contact your Labrie authorized
dealer first. They should be able to provide you with the proper help that you need, whether it
is for parts or technical service.
In this manual you will find the most common maintenance and inspection procedures required for
the WITTKE™.
Parts
Labrie refuse vehicle parts are offered exclusively through LabriePlus and LabriePlus authorized
dealers. The quality and reliability of Labrie parts are second to none in the industry.
Warning
Your WITTKE™ unit MUST BE COMPLETELY LUBRICATED before its first use. Refer to the lube
chart (see Figure 1-2) on the right side of the truck to know where the lubrication points are located
on the vehicle and how often the parts should be lubricated.

4Introduction
Figure 1-2
Lube chart
Initial lubrication carried out by Labrie Enviroquip Group is sufficient for production and transport
purposes ONLY.
With your safety in mind, we would like to remind you that ONLY QUALIFIED PERSONNEL
should service the hydraulic, electrical, and pneumatic systems of your WITTKE™ unit. In addition,
they should also be fully knowledgeable of the operation of this unit. Please read the Operator’s
Manual carefully prior to attempting any maintenance work on your WITTKE™ unit.
IMPORTANT:WITTKE™ units must be operated by only one operator.
WITTKE™ Basic Maintenance
WITTKE™ refuse bodies require routine maintenance to ensure product longevity as well as
dependability. Various components have specific needs. A detailed portion of these items is listed
below:
1) Packer Wear Shoes and Guides
One of the most commonly overlooked wear items involves the packing system.
The packer wear strips and floor guides have a life which requires proper maintenance. Improperly
maintained packers can result in, but are not limited to: holes worn in the floor liner and/or floor
itself, binding of the packing assembly due to uneven wear against the hopper side walls, etc.
For proper packer wear diagnosis and servicing, please go to Chapter 8.
2) Lubrication
Your WITTKE™ unit MUST BE COMPLETELY LUBRICATED before its first use.
Initial lubrication carried out by Labrie Enviroquip Group is sufficient for production and transport
purposes ONLY.
All moving parts require lubrication for continued operation, longevity and dependability.
Maintenance intervals should be adjusted according to the truck’s route or duty cycle. Proper
greasing ensures the maximum life from the moving parts as it flushes out water and contaminants
from the joint.

Introduction 5
When greasing it is important to understand that providing the proper amount of grease is a delicate
balance between over greasing, which can result in seal damage as well as wasted lubricant. Only
pump enough grease until the air purges from the joint. Commonly, a “popping” sound can be heard
as the old grease begins to evacuate the seal. Equally important is to remove the excess grease from
the component you are maintaining. Leaving the excess grease will attract dirt and contaminants
which could work themselves into the joint causing potential future issues.
3) Body
The body contains grease fittings for every operating cylinder as well as all linkages.
Without proper lubrication and maintenance, these parts can become seized, galled, and/or break
resulting in equipment damage or injury.
4) Hydraulic Fluid and Filter
Hydraulic fluid is the lifeblood of the WITTKE™ refuse body. Regular maintenance of the hydraulics
will ensure long, trouble-free life.
As directed in all service training, the hydraulic filter needs to be replaced after the initial 50 hours
of new truck operation and then again every 6 months, or when the filter restriction gauge is in the
yellow. The hydraulic fluid needs to be replaced once a year along with the suction screen being
removed, inspected, cleaned and/or replaced.
5) Air Filters
All WITTKE™ trucks that utilize air-actuated MAC valves have a factory-installed air filter assembly
containing a set of water and coalescing filters.
These are typically located on the frame rail and may be found if you trace the MAC valve box supply
line back towards the chassis dry air supply tank. These filters need to be changed every 1000 hours to
ensure proper function of the pneumatic system. Failure to service these filters will result in a
contaminated and problematic air system.
Figure 1-3
Air filter assembly
5) Hardware
Hardware needs to be verified that it is present and tight. Loose or missing hardware can cause severe
damage and/or unsafe operational conditions.

6Introduction
6) Proximity and Limit Switches
Proximity and limit switches are used to limit travel of moving parts and/or to ensure conditions are
safe for operation.
If these switches are not adjusted properly, damage to the equipment may occur as well as poor or
dangerous functionality.
7) Leaks
Verify that there are not any leaking hydraulic cylinders, hoses, tubes, valves, or pumps. Leaks in the
hydraulic system are an indicator of possibly overheating hydraulics, damage to a seal, over-
pressurization, or general wear. To avoid costly and premature replacement of parts, ensure all leaks
are addressed properly and timely.
8) Cracks
Ensure that there are not any cracks forming along the hopper floor edge, body, tailgate, arms and
forks. This is an indicator that something is worn, not adjusted properly or damaged.
9) Bushings/Bearings
Check for play in any bushing or bearing. This may require the use of a pry bar or a lifting device.

Introduction 7
Our Office Addresses and Phone Numbers
In the U.S.
Address: 1198 Shattuck Industrial Blvd.
LaFayette, GA 30728
Toll Free: 1-800-231-2771
Telephone: 1-706-591-8764
General Fax: 1-706-639-9275
Oshkosh General Fax: 1-706-591-8766
Parts and warranty: During business hours, 8:00 AM to 6:00 PM Eastern Standard Time
Technical Support Service: Available 24 hours
In Canada
Address: 175A Route Marie-Victorin
Levis, QC G7A 2T3
Toll Free: 1-877-831-8250
Telephone: 1-418-831-8250
Service Fax: 1-418-831-1673
Parts Fax: 1-418-831-7561
Parts and warranty: During business hours, 8:00 AM to 5:00 PM Eastern Standard Time
Technical Support Service: Available 24 hours
Website: www.labriegroup.com
E-mail: sales@labriegroup.com
IMPORTANT:For technical support and parts ordering, the serial number of your vehicle is required. Therefore,
Labrie Enviroquip Group recommends to keep record of the information found on the VIN plate,
which is located in the cab.

8Introduction

2Safety
Safety is always of prime importance when servicing
any type of equipment. All maintenance personnel
working on the WITTKE™ front-loader garbage truck
must be aware of the safety practices and features
detailed in this chapter.
Conventions
Basic Safety Notions
The following safety notions are related to the
maintenance of the WITTKE™. It is important to point
out that the safe servicing of the vehicle remains the
mechanic’s responsibility. He must heed all safety
notions explained in this manual as well as warning
decals placed on the truck.
Danger! Indicates a hazardous situation which, if
not avoided, will result in serious injury or
death.
Warning! Indicates a hazardous situation which, if
not avoided, could result in serious injury
or death.
Caution! Indicates a hazardous situation which, if
not avoided, may result in minor or
moderate injury.
Danger! Always be aware of the vehicle’s
surroundings to make sure that no
pedestrians, passersby, bystanders, or
other people or vehicles are in any way
exposed to any danger caused by the
use of the WITTKE™.

10 Safety
Responsibilities
Safety is everybody’s responsibility. Both the employer and the employees must play their part to
ensure their work environment is safe for everyone.
Employer’s Responsibilities
It is the responsibility of the employer:
To ensure the WITTKE™ is operated and serviced in accordance with all safety requirements and
codes, including all applicable regulations.
To ensure employees are qualified for operating and servicing the vehicle and its equipment, and
they all take safety measures before working on or around them.
To properly maintain all mobile equipment to meet all provincial/state and federal safety
standards.
To supply maintenance personnel with adequate knowledge and skills to operate the vehicle and
its equipment safely.
To keep the vehicle maintained and properly adjusted to meet the manufacturer’s standards and
recommendations. For help or for more information, please contact the manufacturer or any of its
authorized representatives.
To keep records of all vehicle breakdowns and malfunctions, as well as any inspection and
maintenance.
To ensure that all failures or malfunctions that may be affecting the safe use of the vehicle are
repaired before the vehicle is put back into operation.
To make sure that the backup alarm works properly when the vehicle is in reverse.
To take necessary measures to correct any damage or malfunction reported by an employee.
To establish a “lockout/tagout” procedure and ensure its application any time inspection, repair
or maintenance is performed on the vehicle, regardless of whether it takes place on the road or in
the garage.
Employee’s Responsibilities
It is the responsibility of the employee:
To enforce all safety measures to meet the requirements established by the employer.
To operate the WITTKE™ only after having received proper instructions and training.
To perform routine daily unit inspections.
To make sure that nobody is near the vehicle before activating any of the controls, and to be
prepared to stop at any indication of possible danger.
Danger! Never get in the hopper area when the engine is running.
Only authorized personnel may do so following a lockout/tagout procedure (see Locking
Out and Tagging Out the Vehicle on page 21).
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