UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
PROPACK REAR END LOADER MANUAL
OPERATIONS, PARTS, AND MAINTENANCE
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
100 Burland Crescent
P.O. Box 3488, Station "C"
Hamilton, Ontario L8H 7M1
Telephone: (905) 547-0161
1 877 843-1122
Fax :
(905) 547-3364
4024 - 39139 HWY 2A
Red Deer, Alberta T4N 5E1
Telephone : (403) 346-1233
Fax
: (403) 340-8720
1650 Industrial Drive
Owosso, Michigan. 48867
Telephone:
(517)725-1640
Fax:
(517) 725-1322
Edition # REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Introduction 1.0
Page
1.1 Introduction ............................................................................................................................1
1.2 Vehicle Summary...................................................................................................................2
Operations 2.0
2.1 Safety Precautions.................................................................................................................3
2.2 Pre-trip Inspection..................................................................................................................6
2.3 Rear End Loader Controls .....................................................................................................7
2.3.1 In Cab Controls ..........................................................................................................7
2.3.2 Body Controls.............................................................................................................7
2.3.3 Tailgate Controls ........................................................................................................7
2.4 General Operations Overview ...............................................................................................8
Maintenance 3.0
3.1
3.2
3.3
3.4
Maintenance Schedule ..........................................................................................................9
Body Maintenance .................................................................................................................10
Lubrication & Greasing ..........................................................................................................11
Hydraulic Maintenance ..........................................................................................................12
3.4.1 Cylinders ....................................................................................................................30
3.4.2 Hydraulic Schematics(s).............................................................................................32
3.5 Electrical Maintenance...........................................................................................................33
3.5.1 Electrical Schematic ...................................................................................................35
3.5.2 Wiring Locations.........................................................................................................36
3.6 Troubleshooting .....................................................................................................................38
Parts 4.0
4.1 Parts Ordering Summary & Contact Information ...................................................................42
4.2 Body Parts
4.2.1 Tailgate Cylinder Installation ......................................................................................43
4.2.2 Body Side Door ..........................................................................................................45
4.2.3 Locks & Rear Post......................................................................................................47
4.2.4 Body Mounting Brackets ............................................................................................49
4.2.5 Ejection Ram .............................................................................................................51
4.2.6 Ejection Cylinder Installation ......................................................................................53
4.2.7 Decal Location............................................................................................................55
4.3 Tailgate Parts
4.3.1 Valve Beam & Covers ................................................................................................57
4.3.2 Packing Blade ............................................................................................................59
4.3.3 Slide ...........................................................................................................................61
4.3.4 Packing Blade & Slide Assembly ...............................................................................63
4.3.5 Upper Slide Shoe .......................................................................................................65
4.3.6 Lower Slide Shoe .......................................................................................................67
4.3.7 Slide Cylinder Installation ...........................................................................................69
4.3.8 Packing Cylinder Installation ......................................................................................71
4.3.9 Wiper Blade Assembly ...............................................................................................73
4.3.10 Tailgate Controls ........................................................................................................75
4.3.11 Tailgate Seal .............................................................................................................77
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4.4 Electrical Parts
4.4.1 Lighting Diagram ........................................................................................................79
4.4.2 Electrical Components & Wiring.................................................................................81
4.4.3 Proximity Sensors & Components..............................................................................83
4.4.4 Body Junction Box......................................................................................................85
4.5 Hydraulic Parts
4.5.1 Body Hydraulic Lines..................................................................................................87
4.5.2 Body Valve Installation ...............................................................................................89
4.5.3 Tailgate Hydraulic Lines .............................................................................................91
4.5.4 Oil Tank ......................................................................................................................93
4.5.5 Front Mount Pump Installation ...................................................................................95
4.5.6 Pump Driveline Assembly ..........................................................................................97
4.6 Cylinder Drawings
4.6.1 Ejection Cylinder ........................................................................................................99
4.6.1.1 20 YD ..............................................................................................................100
4.6.1.2 25 YD ..............................................................................................................101
4.6.1.3 32 YD ..............................................................................................................102
4.6.2 Tailgate Lift Cylinders.................................................................................................103
4.6.3 Slide Cylinders ...........................................................................................................104
4.6.4 Packing (Sweep) Cylinders ........................................................................................105
Warranty 5.0
5.1 Warranty ................................................................................................................................106
5.2 Explanation of Terms & Conditions .......................................................................................107
Appendix 6.0
6.1
6.2
6.3
6.4
Filter Information....................................................................................................................109
Pump Information ..................................................................................................................113
Valve Information...................................................................................................................129
Cylinder Information...............................................................................................................138
Options 7.0
7.1 Pinch Point Protection System (Ontario Ministry of Labour)..................................................147
7.1.1 Schematics.................................................................................................................149
7.1.2 Controls ......................................................................................................................148
7.1.3 Junction Boxes ...........................................................................................................150
7.2 Tipper Bar ..............................................................................................................................152
7.3 Reeving Cylinder ...................................................................................................................153
7.4 Container Ears.......................................................................................................................154
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UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 1.1
INTRODUCTION
This manual has been prepared to familiarise and assist you in the safe operation of your new UHE Rear
End Loader.
In designing this vehicle every attempt has been made to make the operation and maintenance as simple
as possible. It is of absolute importance, however, that all personnel using this truck are familiar with the
operation and safety procedures outlined in the manual.
Also included in the manual are recommended maintenance and lubrication procedures. These
procedures must be followed to obtain the best performance as well as to preserve the life expectancy of
your new vehicle.
It is our aim at Universal Handling Equipment to guarantee that you remain a satisfied customer. Should
you require any replacement parts, please refer to the comprehensive spare parts list. To facilitate
identification, all the major components have detailed drawings identifying both the part and part number.
If you have a problem, which is beyond the scope of this manual, please do not hesitate to contact our
parts and service department who are available to assist you. Please provide as much information as
possible pertaining to your Rear End Loader (model, serial, part numbers, etc where applicable). This
information can be located on a sticker on the front inside cover of this manual.
In order to continually provide the best possible product, Universal Handling Equipment reserves the right
to make design changes to its products without notice.
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UHE REAR END LOADER MANUAL
SECTION 1.2
VEHICLE SUMMARY
Thank you for placing your confidence in our product. Universal Handling Equipment believes that with
proper maintenance, your Rear End Loader will be efficient and durable for many years.
The information listed below will be your guide for service information and maintenance, please keep this
manual in a safe place.
Always have your body serial number ready when calling for information and parts.
Refer to the inside cover of this manual for your vehicle information. An identification sticker similar to the
one below will provide the information required.
VEHICLE INFORMATION
Serial # of Body :
______________________
Date of Purchase :
______________________
V.I.N.:
______________________
Truck Manufacturer : ______________________
Universal Handling Equipment Co. Ltd.
100 Burland Crescent
P.O. Box 3488, Station "C"
Hamilton, Ontario
L8H 7M1
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UHE REAR END LOADER MANUAL
SECTION 2.1
SAFETY PRECAUTIONS
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READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE ATTEMPTING TO
OPERATE THIS REAR END LOADER.
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THIS EQUIPMENT USES HEAVY DUTY HYDRAULIC EQUIPMENT. IF IT IS USED
IMPROPERLY, OR, IS NOT PROPERLY MAINTAINED, IT CAN CAUSE SERIOUS INJURY OR
DEATH. PEOPLE OPERATING AND MAINTAINING THIS EQUIPMENT MUST BE FAMILIAR
WITH ITS USE AND OPERATION. ANY QUESTIONS CONCERNING OPERATION,
MAINTENANCE, SAFETY, ETC. SHOULD BE DIRECTED TO THE SERVICE DEPARTMENT AT
(905)-547-0161 or 1-877-843-1122
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ALWAYS USE EXTREME CAUTION WHEN BACKING UP. MAKE SURE NO PEOPLE OR
OBSTRUCTIONS ARE IN YOUR PATH. BE SURE THE BACK-UP ALARM INSTALLED WITH
THE REAR END LOADER WORKS PROPERLY. ADJUST YOUR TRUCK MIRRORS WHEN
ENTERING THE TRUCK CAB AND BEFORE BACKING UP. ALSO, USE A "SPOTTER" WHEN
BACKING UP TO SAFELY GUIDE YOU.
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RIDE ONLY ON THE PLATFORM DESIGNED FOR THAT PURPOSE OR IN THE TRUCK CAB.
THE RIDER'S PLATFORM IS DESIGNED FOR DISTANCES OF A BLOCK OR LESS AND
SPEEDS UNDER 16 KM/HR (10 MPH). DO NOT RIDE ON THE RIDER'S PLATFORM WHEN THE
TRUCK IS BACKING UP; USE ONLY THE HAND HOLD PROVIDED (WHEN USING THE RIDER'S
PLATFORM). DO NOT GRASP CONTROL HANDLES, CABLES, HYDRAULIC HOSES OR
TUBES.
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STAY CLEAR OF THE HOPPER WHEN THE HYDRAULICS ARE WORKING. KEEP ARMS,
HANDS, FEET, ETC. CLEAR OF ALL MOVING PARTS.
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DO NOT PRESSURIZE HYDRAULIC CYLINDERS WHEN THEY ARE REMOVED FROM THE
TRUCK. PRESSURIZING CYLINDERS WHILE THEY ARE REMOVED FROM THE TRUCK WITH
AIR, OIL, ETC. MAY CAUSE THE CYLINDERS TO FLY APART UNCONTROLLABLY.
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DO NOT WORK ON THE TRUCK, ENTER THE TRUCK BODY OR HOPPER UNLESS THE KEY IS
REMOVED FROM THE IGNITION AND A WARNING SIGN IS POSTED ON THE STEERING
WHEEL OF THE TRUCK INFORMING ANYONE GETTING INTO THE CAB THAT A PERSON IS
WORKING ON OR IN THE UNIT.
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IT IS THE OPERATORS' AND MECHANICS' RESPONSIBILITY TO LEARN TO OPERATE THE
TRUCK CORRECTLY AND SAFELY. QUESTIONS PERTAINING TO THE SAFE AND PROPER
OPERATION OF THIS EQUIPMENT SHOULD BE DIRECTED TO THE SERVICE DEPARTMENT
AT (905)-547-0161 OR 1-877-843-1122
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SAFETY WHILE WORKING WITH HYDRAULICS SHOULD BE YOUR PRIMARY CONCERN.
WEAR SAFETY GLASSES TO PROTECT YOUR EYES AND TAKE EVERY PRECAUTION TO
PREVENT INJURY TO YOURSELF OR OTHERS.
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W D A A R N N G I E N R G
WHEN REMOVING, CHANGING AND REINSTALLING PARTS AND ASSEMBLIES USE
CAUTION
TO PREVENT
INJURIES
TO
YOUR
HANDS,
FEET, RINGS)
HEAD,
ETC.
WHEN
INSTALLING
HYDRAULIC
HOSES
AND
FITTINGS,
CAUTION
SHOULD
BEMANY
USED
NOT
DO NOT
WEAR LOOSE
CLOTHING
OR JEWELLERY
(INCLUDING
WHICH
MAY GET
COMPONENTS
ARE
HEAVY
AND
MAY
REQUIRE
HOISTS,
ETC.
USE
SAFETY
GLASSES,
TO OVER-TIGHTEN
FITTINGS,
ADAPTERS
ANDSTEPS,
HOSE CONNECTIONS.
WHEN REPLACING
CAUGHT
ON MOVING
PARTS,
HAND HOLDS, ETC.
SAFETY
SHOES AND
OTHER YOU
SAFETY
EQUIPMENT
TO HELP PREVENT
INJURY TO
HOSES,
FITTINGS
AND ANY
ADAPTERS
MUST
USE COMPONENTS
WITH EQUIVALENT
OR
YOURSELF
AND
OTHERS.
HIGHER RATINGS.
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DO NOT START THE TRUCK UNTIL YOU ARE CONFIDENT THAT ALL PERSONS ARE CLEAR
OF THE BODY, HOPPER AND ANY OTHER HAZARDOUS AREAS.
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HYDRAULIC HOSES AND TUBES SHOULD BE INSPECTED ON A WEEKLY BASIS FOR
CRACKS, CUTS, ABRASION, WEAR, LEAKS, CLEARANCE AND AGING.
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NEVER USE THE VEHICLE FOR ANYTHING OTHER THAN WHICH IT WAS INTENDED FOR.
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ALL DECALS MUST BE IN PLACE, INDIVIDUAL DECALS OR COMPLETE DECAL SETS ARE
AVAILABLE FROM UHE
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UHE REAR END LOADER MANUAL
SECTION 2.2
PRE-TRIP INSPECTION
Prior to operating your UHE Rear End Loader the following items should be checked as part of a pre-trip
safety inspection. The following procedures only pertain to the body aspect of the vehicle and should be
combined with the pre-trip inspection defined by the chassis supplier.
¾
Inspect all decals making sure they are in place and readable, replace any as required. For
location and a complete list of decals refer to page 64 of this manual. Replacement labels
can be purchased from Universal Handling Equipment Parts department.
¾
Check all lights and alarms and make sure they are properly working. Replacement lights and
alarms can be purchased from Universal Handling Equipment Parts department
¾
Check the oil level on the hydraulic oil tank, a sight gauge has been installed with the proper
level marked on it. The oil level must be checked with all cylinders in the retracted position.
Add clean hydraulic oil as necessary.
¾
Check all hoses and hydraulic lines for oil leaks and repair as necessary.
¾
Check and make sure that the area behind the ram is clear of debris, etc. Remove any debris
etc.
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DO NOT ENTER THE BODY WITH ENGINE RUNNING! REMOVE THE IGNITION KEY BEFORE
ENTERING THE BODY.
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UHE REAR END LOADER MANUAL
SECTION 2.3
REAR END LOADER CONTROLS
The Universal Rear End Loader is a combination electrically and hydraulically controlled compaction
vehicle. It is operated by 2 or more people using in cab, body, and rear tailgate controls. The in cab
controls control the electrical aspect of the vehicle while the tailgate controls operate the packing blade
and slide.
SECTION 2.3.1
IN CAB CONTROLS
Located on the dash of the driver’s side are all the controls necessary for the driver. One such control is a
lighted pump on/off toggle switch. This allows the driver to control the hydraulic oil flow to the system. If
the switch is turned off, oil flows through the pump to the main body valve and then back to tank. With the
pump turned off no hydraulic functions will operate. If the pump switch is turned on, the switch is
illuminated and if the right conditions are met oil flows from the pump to the main body valve. The oil then
flows through the body valve to the tailgate valve. Oil then passes through the tailgate valve and returns
to the tank. With the pump switch on, all hydraulic functions will operate. Also located on the dash are the
lighting switches. These switches will control lighting such as the hopper floodlight, tailgate side
floodlights, and the rear strobe light.
SECTION 2.3.2
BODY CONTROLS
The controls located on the main body valve are those used to control the tailgate and ejection ram. The
lever closest to the front of the body controls the ejection cylinder. Depressing this lever towards the body
causes the ejection ram to move towards the rear of the body, thus ejecting material located inside the
body. Pulling the lever out will cause the ejection ram to travel back towards the front of the body. The
lever closest to the tailgate controls the tailgate opening and closing. If this lever is pulled out from the
body the tailgate cylinders will unlock the tailgate and begin raising it. Pushing this lever towards the body
will cause the tailgate to lower and the tailgate cylinders to lock. In both cases for both the ejection ram
and tailgate controls the handles must be held in the desired direction. There is a black throttle advance
button located to the right of these controls located on the body. Pressing in this button causes the engine
to speed up if the truck’s transmission is in the neutral position. Holding down this button while operating
the function required will speed up the engine, increase oil pressure and speed up the desired function.
SECTION 2.3.3
TAILGATE CONTROLS
Located on the passenger side of the tailgate are 2 hydraulic control handles. These 2 handles control the
function of the packing blade and slide located inside the tailgate. The lever closest to the rear of the body
controls the slide. Pushing this lever towards the body will cause the slide to go up, pulling the lever
causes the slide to go down. The lever closest to the body controls the packing blade. Pushing this lever
towards the body will cause the blade to pack. Pulling this handle out will cause the packing blade to
swing back into its starting position. If the slide is up and the packing blade is in its pack position, the
packing cycle is ready to be initiated. This is also the position of the packing blade and slide for loading
the hopper. Pull both levers out and the first half of the packing cycle begins. The packing blade will
swing out to its starting position and the slide will come down. To finish the packing cycle, push both
handles in. The packing blade will swing down packing the material in the hopper, the slide will now go up
compressing the material against the ejection ram. The cycle is now complete and ready to begin loading
the hopper and restart the cycle. There is a black throttle advance to speed up the engine while it is in
neutral. However, this button is only equipped as an override, as the pushing or pulling the handles will
activate a proximity sensor in the tailgate and automatically speed up the engine. There is also a red
buzzer button equipped on the tailgate to signal the driver when the tailgate operator is ready to continue.
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UHE REAR END LOADER MANUAL
SECTION 2.4
GENERAL OPERATIONS OVERVIEW
Before operating any function on the truck you must first turn the pump switch to the “ON” position. If you
pump is equipped with a PTO, most likely it is a constant mesh PTO and does not need to be engaged.
However your truck may have a PTO switch and will need to be engaged for the pump to work.
SECTION 2.4.1
LOADING
Before loading any garbage into the truck make sure the ejection ram is at the back of the truck. To move
the ejection ram stand at the front left corner of the truck body. Push in the throttle advance button on the
body and push the ejection ram lever in. The ejection ram will move to the rear of the truck and is now
ready for packing. Note the throttle advance button will only speed up the engine if the transmission is in
neutral. The packing mechanism on the Rear End Loader is designed such that the ram will not have to
be adjusted as garbage is added to the truck. As the garbage is packed against the face of the ejection
ram by the slide, a smart valve on the ejection ram valve section senses an increase in pressure. When
the pressure reaches the pre-set pressure the ejection ram will automatically move forward towards the
front of the truck.
The controls for packing the garbage are located on the passenger side of the tailgate at the back of the
truck. There is a throttle advance button also located near the packing controls. This button, however,
only serves as a back up to the automatic throttle advance, which is activated when the packing controls
are moved. With the packing blade in the in the “pack” position and the slide in the “up” position the
packing cycle is ready to be initiated. Pull both handles out and the packing blade will swing backwards
and the slide will come down and automatically stop. Before continuing with the packing cycle make sure
everyone is well clear of the hopper area. Push both handles in and the packing blade will swing forward,
clearing the hopper of all material. The slide will then automatically move up packing the garbage against
the ejection ram. Two control handles have been provided in case the operator must move the packing
blade or slide separately in order to clear jammed material from the hopper. Repeat the packing cycle
until the ejection ram has moved to the front of the body or until the run is complete. Note that the packing
cycle can continue while the truck is in gear but the throttle advance will not speed up the engine.
SECTION 2.4.2
UNLOADING
After arriving at the dumpsite, position the truck on the most level ground possible. Go to the back of the
truck and move the slide down and the packing blade to the start position in order to reduce the pressure
that the garbage exerts on the tailgate. Make sure everyone is well clear of the tailgate before going to the
controls at the front of the body. Push in the throttle advance button and pull the tailgate control lever
away from the body. The tailgate cylinders will extend and disengage the locks. Now the tailgate will lift
up and a warning alarm will sound. Once the tailgate is fully open, release the control handle and push
the ejection ram control in towards the body. The ejection ram will move towards the back of the body and
will eject the garbage. After the ram has ejected all of the garbage, pull the ejection ram control handle
out and move the ram back to the front of the body. Do not move the ram back to the rear of the body
until you are ready to resume packing garbage as driving great distances with the telescopic ejection
cylinder extended will cause it to flex and bend.
Go to the back of the truck and clear any garbage from the bottom of the truck body and especially from
around the tailgate locks. Clearing the back of the truck will prolong the life of your tailgate seal and is
essential to ensuring the tailgate locks function properly. Make sure that everyone is well clear of the
tailgate again before going to the tailgate control at the front of the body. Push in the tailgate control
handle and the tailgate will lower, hold this lever in until the tailgate locks engage and the tailgate ajar
alarm ceases to sound. Make sure that the tailgate locks are properly engaged before packing garbage,
as pressure is exerted on the tailgate and will cause the tailgate to fly open uncontrollably.
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UHE REAR END LOADER MANUAL
SECTION 3.1
REAR END LOADER MAINTENANCE SCHEDULE
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
Description
Daily
Inspect tailgate autolock pins for wear and proper
operation
Check oil level in hydraulic tank with all cylinders
retracted
Check all functions and lights for proper operation before
starting service
Check that throttle advance will only work if the
automatic transmission is in neutral
Check ty-strap on gate valve coming from suction line of
oil tank replace if needed
Grease driveline for front mount pump
Grease slide track in tailgate and inspect slide shoes for
wear
Grease all cylinders as well as inspecting for leaks and
cylinder wear
Grease tailgate hinge and autolock and inspect for wear
Inspect return line filter an hose
Check all bolts on slide assembly
Check packing blade pivot pin
Grease ejection track inside body and check
polyethylene blocks for wear
Check all hydraulic hoses for cracks, wear and leaks
Check all hydraulic fittings for leaks
Clean, inspect and replace (if required) the suction filter,
return line filter, and filler breather cap on hydraulic oil
tank.
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Weekly
Monthly
6 Months
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UHE REAR END LOADER MANUAL
SECTION 3.2
BODY MAINTENANCE
The Universal Handling Equipment Rear End Loader should require relatively little maintenance. A
lubrication schedule has been provided on the following pages. By keeping you vehicle well lubricated
and maintained you will increase the working life of the Rear End Loader.
Cylinder bushings should be checked monthly and replaced when worn. Cylinder keepers, retaining
plates, and bolts should be checked monthly as well, replace as necessary. Also check the body and
cylinders/tubing for hydraulic oil leaks, repair as necessary.
The body hold down bracket springs should be checked to make sure they are still tight, as well as
inspecting the rear pivot plate retaining bolt.
Wear blocks / wear shoes should be inspected monthly for excessive wear. Replace worn down shoe
bearings and/or ram wear blocks as needed.
It is also important to keep you Rear End Loader clean. Regular washing will increase the life of the paint,
as well as keeping all the decals and reflectors clear and visible. Regular washing also permits a more
thorough inspection of the entire vehicle.
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UHE REAR END LOADER MANUAL
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Description
No. OF
ZERKS
LUBE
INTERVAL
RETURN LINE TO 7 MICRON FILTER
100 MESH SUCTION FILTER
OIL RESERVOIR
OIL FILLER BREATHER CAP
SLIDE TRACK – PUT GREASE IN TRACK
SLIDE CYLINDER
PACKING BLADE CYLINDERS
AUTOLOCK
TAILGATE CYLINDERS
TAILGATE HINGES
2/CYL
2/CLY.
2/LOCK
3/CYL.
VHINCE
6 MONTH
6 MONTH
6 MONTH
6 MONTH
WEEKLY
WEEKLY
WEEKLY
WEEKLY
WEEKLY
WEEKLY
PRODUCT
H 32 HYDRAULIC OIL
CLEAN
MULTI-PURPOSE GREASE GUN
MULTI-PURPOSE GREASE GUN
MULTI-PURPOSE GREASE GUN
MULTI-PURPOSE GREASE GUN
MULTI-PURPOSE GREASE GUN
MULTI-PURPOSE GREASE GUN
NOTE:
When changing filters, check the filter that you removed from the truck for metal particles.
The presence of minuet particles of brass, aluminium, or steel may indicate excessive
wear or a malfunction of one or more of the hydraulic components. Used filters and oil
must be properly disposed of.
WARNING:
Do not tighten or loosen any hydraulic or air connections while the system is under
pressure.
WARNINIG:
Check hydraulic lines and tubes for cuts, abrasions, proper clearances, leaks and ageing
on a weekly basis. Replace hoses and fittings with products of equal or better SAE
ratings.
100 Burland Crescent
P.O. Box 3488, Station "C"
Hamilton, Ontario L8H 7M1
Telephone: (905) 547-0161
1 877 843-1122
Fax :
(905) 547-3364
4024 - 39139 HWY 2A
Red Deer, Alberta T4N 5E1
Telephone : (403) 346-1233
Fax
: (403) 340-8720
11
1650 Industrial Drive
Owosso, Michigan. 48867
Telephone:
(517)725-1640
Fax:
(517) 725-1322
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
SECTION 3.4
REAR END LOADER SYSTEM HYDRAULICS
The reservoir on the side of the body holds approximately 49 gallons of hydraulic oil. The oil spec
required is AW-32. This oil is readily available in all major brands on a local basis. An oil sight gauge is
located on the reservoir and should be read when the hydraulic cylinders are in the retracted mode. If the
reservoir is filled with the cylinders extended, the reservoir may overfill when the cylinders are retracted.
The oil in the UHE hydraulic system should be changed every six months. A drain plug is located in the
bottom of the reservoir. The three filters located in the reservoir should be changed at the same time as
the oil is changed. Cleanliness is a must when servicing the hydraulic system. Carefully clean any dirt or
contaminants from the filter areas and filler cap to prevent the contaminants from entering your hydraulic
system while servicing or checking the system. Also take care in storing your hydraulic oils to prevent
moisture and contaminants from entering storage containers. If you suspect your lubricant may be
contaminated, have samples checked by your oil supplier.
The oil leaves the reservoir through a 100 mesh suction filter. To service this 100 mesh filter, drain the oil
from the reservoir and unbolt and remove the filler cap return line plate from the top of the reservoir. Take
care not to damage the rubber gasket between the plate and the reservoir. Reach into the reservoir,
unscrew the old 100 mesh filter, and dispose of it properly. This is an ideal time to wipe down the inside of
the reservoir with a clean, lint-free cloth. Clean out any sludge accumulations with a lint free cloth. Install
the new 100-mesh filter and tighten. Cleanliness is very important during this process. Also remember to
properly dispose of your used oil and filters as required by law.
The filter located on the top of the oil reservoir is a return line filter. This return line filter has a 10-micron
element, and a 25 PSI internal bypass are exposed when the top cover is removed for servicing. To
properly service this filter, first loosen the four top bolts that hold the cover down and carefully remove it.
The spring under the cover holds the 25 PSI bypass in place against the filter. Clean all of these
components thoroughly, remove the old 10 micron filter element and dispose of it properly. Save and
reuse the rubber gaskets. Clean any contaminants from the inside of the return line filter with a lint free
cloth. Place the bypass over the centre hole of the new filter element. The proper oil flow for the bypass
is that when it opens oil flows toward the reservoir. To reinstall the cover place it over the filter assembly
so the large spring is centred between the cover and bypass and the bolt heads line up in their areas.
Simply tighten back down the bolts to assemble again, do not over tighten the bolts.
The oil filler cap should also be washed out in a clean parts washer so it can breathe freely. A large
volume of air passes both directions through the fill cap as the cylinders extend and retract. A screen in
the filler which helps keep contaminants out of the reservoir while adding oil through the filler should be
inspected after the reservoir has been refilled. If contaminants are trapped in the screen and cannot easily
be removed, the filler assembly can be removed and washed in a clean parts washer. Place a clean lint
free cloth over the filter assembly opening to prevent contamination from entering the reservoir while the
filler assembly is out.
A 2" gate valve is provided to shut off the flow of oil from the reservoir while performing work on the
hydraulic tank. This valve must be completely open anytime the compactor pump is turning. If the gate
valve is closed or partially open, serious pump damage will occur if the pump is operating. A nylon strap is
put through the gate valve handle to prevent the valve from vibrating shut or being accidentally turned off.
The tie strap will have to be cut to turn the gate valve off. We recommend a new nylon tie strap be
installed after using the valve or if it is missing.
A 2" suction hose runs from the reservoir to the pump. This hose is designed for suction. It has SAE
100R4 designation. If for any reason you should have to replace this hose be sure to reinstall only hose
with a SAE 100R4 rating. A regular pressure hose may not withstand the vacuum created by the pump.
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A flow control pump provides flow to the hydraulic system. The flow control allows the pump to deliver up
to 38 GPM. If oil flow exceeds 38 GPM the pump flow control sends a signal to an unloader spool located
in the tailgate/ejection valve inlet cover. The unloader then directs the oil flow directly to the reservoir
rather than to the hydraulic system. Any flow in excess of 38 GPM is routed back to the pump inlet at the
same time.
The flow control pump is driven either by a transmission mounted PTO or directly from the front of the
engine. The engine driven pump turns anytime the engine is running. Power is transmitted from the
engine to the pump by a drive shaft. The PTO driven pump turns only when the PTO is engaged from the
truck cab. Note some PTOs’ are constant mesh and are always engaged and no on/off switch will be in
the cab. A drive shaft is used to transmit power from the PTO to the pump.
Flow from the flow control pump goes directly to the tailgate/ejection spool valve assembly. The
tailgate/ejection spool valve assembly consists of four sections: 1) Inlet Section, 2) Tailgate Section, 3)
Smart-Pak Ejection Section, and 4) Outlet Section.
The inlet section contains the unloader spool described earlier. The unloader spool diverts pump flow
from the inlet section directly to the reservoir when it receives a pressure signal or into the spool valve in
the absence of a pressure signal. Should the pump flow exceed 38 GPM the pump flow control supplies
this signal to the unloader spool and no hydraulic functions will operate. This condition would be caused
by over speeding the truck engine. The pump on/off switch in the truck cab also sends a signal to the
unloader circuit in the inlet section. This on-off switch is wired to a 12-volt coil, which is mounted onto the
"normally open" cartridge block. When no electrical current is supplied to the cartridge the oil flow can
pass through the "normally open" cartridge and flow to the unloader. When you turn on the pump switch
in the truck cab a 12-volt current is supplied to the 12-volt coil on the "normally open" cartridge. The
"normally open" cartridge then closes and stops the oil flow to the unloader. A light in the cab will indicate
when the cab pump switch is on.
A 2,750 PSI main relief valve is also located in the inlet section. This relief valve provides pressure
protection to the hydraulic circuit. Should the hydraulic pressures in the circuit reach or exceed 2,750 PSI
the main relief valve will relieve the flow back to the reservoir.
The tailgate section controls the flow to the two tailgate cylinders located on the rear of the truck. The
standard section supplies a flow of oil to a pair of double acting tailgate cylinders, which operate the
automatic tailgate. The tailgate section will have two hydraulic lines to supply oil to the pair of double
action cylinders for the automatic tailgate.
The tailgate down speed is controlled by a #55 orifice in the circuit of each tailgate cylinder. The orifices
also provide a safety circuit by allowing the tailgate to drop at a controlled speed should a hydraulic line or
circuit fail. A flow fuse is also installed on the extend line to relieve a back pressure exerted on the tailgate
cylinders by the packing process. This flow fuse acts as a safety device by bleeding off the small amount
of pressure that flows to the tailgate extend ports. This prevents the pressure from unlocking the tailgate
cylinders prematurely and prevents the tailgate from springing open. Oil flow between the tailgate section
and the tailgate cylinders is routed through 1/2" steel lines, which run along the body roof.
The ejection section controls flow to and from the telescopic ejection cylinder. The hydraulic lines run from
the ejection section to the telescopic cylinder. One line supplies hydraulic pressure to extend the
telescopic cylinder while the other line supplies the hydraulic pressure to retract the telescopic cylinder.
The Smart-Pak system responds to packing forces against the ejection panel anytime the ejection section
is in neutral (spring-loaded ejection handle centred). When the slide achieves maximum packing pressure
the Smart-Pak system senses the maximum force condition and allows the telescopic ejection cylinder to
relax just enough to accept another minimum pack on the next cycle. The Smart-Pak system delivers a
constant packing force throughout the entire load.
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The amount of force developed when extending the cylinder is controlled by the ejection force limiter block
assembly. This assembly is plumbed into the hydraulic circuit and relieves into the power beyond circuit if
the pre-set ejection hydraulic pressure is exceeded.
The outlet section of the tailgate/ejection valve assembly has a function called "power beyond". This
function limits hydraulic flow to the remaining hydraulic circuits while the tailgate/ejection spool is being
operated. This "power beyond" function protects the hydraulic circuit from developing excessive
pressures should multiple spool valve operations be attempted.
The flow of oil from the "power beyond" circuit is transmitted through a steel hydraulic tube to the rear of
the truck body. A high pressure hose connects to the steel line and routes the oil flow through the top of
the tailgate body to the rear spool valve. The high pressure hose allows the flex required when the
tailgate is raised and lowered. The rear spool valve assembly consists of up to four working sections plus
the inlet section and outlet section. The rear spool valve assembly on a standard truck contains the
packing blade section and the slide section to control those two functions. If the winch option, reeving
cylinder option, tipper bar option or other hydraulically operated functions are added to the standard truck,
spool valve sections must be added to accommodate the options. After the proper valve section to be
added is selected, it is added to the existing rear spool valve assembly by "sandwiching" it in the proper
sequence and reassembling the spool valve assembly with longer tie rods to hold the assembly together.
A new mounting hole may be required on the spool valve mounting plate. Additional linkage will have to
be installed to operate the spool valve section.
The inlet section of the rear spool valve assembly contains no cartridges or features. It serves only as an
inlet.
If the truck has the tipper bar option, the spool valve section which controls the tipper bar will be the first
working section. Two high pressure lines from this section run to the double acting tipper bar cylinders.
Should the pressure in this circuit exceed 2,750 PSI, the main relief valve in the tailgate/ejection spool
valve assembly will protect the circuit.
The packing blade section is the next section in the rear spool valve assembly. This section has two
additional accessories not installed on standard spool valve working sections. The first is a "kickout"
accessory, which returns the spool to its neutral position when hydraulic pressure in the circuit reaches
2,100 PSI. On the spool valves discussed to this point the operator must hold the spool valve control in its
working position as the spool is spring loaded to return to neutral. With the "kickout" section the spool will
stay in the working position as a detent is provided to hold it. However when the pressure in the packing
blade circuit reaches 2,100 PSI the "kickout" will return the spool to neutral position automatically. The
second accessory installed on the packing blade section is a work port relief, which protects the packing
blade circuit when the slide is moving up. If higher than desired pressures are developed in the packing
blade circuit at this time, they are relieved by the work port relief. Without the work port relief, the
pressures could be trapped in the packing blade circuit, as the spool valve would be in neutral and not in a
pressure protected circuit while the slide function is operating. Two high pressure hoses run from the
packing blade section and tee in a central location where they connect to the double acting packing blade
hydraulic cylinders. The main relief valve in the tailgate/ejection spool valve assembly also provides
protection to this circuit.
The slide section is the next section in the rear spool valve assembly. The slide section also has a
"kickout" section which returns the spool to neutral when the hydraulic pressure in the circuit reaches
2,450 PSI. The slide section also has a work port relief to protect the circuit. Two high pressure hoses
run from the slide section and tee in a central location where they connect to the double acting slide
hydraulic cylinders. The main relief valve in the tailgate/ejection spool valve assembly also provides
protection to this circuit.
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In the packing mode when the packing blade is swinging in and the slide is moving up the packing blade
cylinders and slide cylinders are pressurised on the large end to apply maximum force for packing. When
the packing blade is swinging out and the slide is moving down the small end of the packing blade
cylinders and slide cylinders are pressurised.
The fourth working section on the rear spool valve assembly operates the optional winch or reeving
cylinder when installed. Two high pressure lines run from this optional section to the winch or reeving
section. This circuit is also protected by the main relief valve in the tailgate/ejection spool valve assembly.
After the proper valve section to be added is selected, it is added to the existing rear spool valve
assembly by "sandwiching" it in the proper sequence and reassembling the spool valve assembly with
longer tie rods to hold the assembly together. A new mounting hole may be required on the spool valve
mounting plate and additional linkage will have to be installed to operate the new spool valve section.
The outlet section on the end of the rear spool valve assembly is a standard section. No "power beyond"
is required as the flow of oil leaving the rear spool valve assembly returns to the reservoir. This flow of oil
leaving the rear spool valve assembly returns to the reservoir. This flow of return oil leaves the outlet
section through a hydraulic hose and plumbs into a hydraulic return pipe. The route of this return pipe
passes by the tailgate/ejection spool valve assembly where it collects any return flow from that spool valve
assembly. The return line continues to the reservoir return line filter. Oil is filtered through the return line
filter and flows into the reservoir.
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MAINTENANCE PROCEDURE - CHECKING UNLOADER SPOOL
The unloader spool directs the flow of oil from the pump to either the reservoir or into the spool valve
sections. It is located in the inlet section of the tailgate/ejection spool. One end of the unloader spool
housing has a plug, which can be removed with an allen wrench, and the opposite end has a plug, which
has a sense line for the unloader spool. If the sense line inlet cap is removed the end of the unloader
spool is exposed. You should be able to push in on the unloader spool with finger pressure and spring
pressure will return it.
If the unloader spool is binding or sticky remove it from its bore and inspect it for contamination, scoring or
scars. If the unloader spool does not want to pull out of the bore remove the plug on the opposite end with
an allen wrench and gently tap it out using a soft material punch, brass drift, etc. Use caution that the
punch does not scratch the bore or damage the spool. Contamination will be the primary cause of an
unloader spool sticking. If the spool is scored or damaged the inlet section will require replacement.
Use WD-40, LPS or an equivalent lubricating product to clean the bore and unloader spool. A small orifice
is located in each end of the unloader spool. You should be able to blow through either end of the
unloader spool and air should come out through the orifice. If necessary clean the orifices. The spool
should move freely in the bore and the spring should return the spool to the sense line end without
restriction. Remember that cleanliness is imperative while working with hydraulic systems. Contamination
too small to see can cause problems.
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MAINTENANCE PROCEDURE – CHECKING FLOW CONTROL ON P75 COMMERCIAL PUMP
1.
Remove the sense line on the pump pressure side flow control block. This will be the smaller of the
two lines located on the pump flow control block which runs to the tailgate/ejection spool inlet
section. Install a plug in this line.
2.
Install an open test line with the proper fitting into the open flow control block port to allow the port
to drain into a pail.
3.
When the truck engine idles, only a small trickle of oil should flow from the flow control block port
test line.
4.
When the truck engine RPM is increased to 1500-1600 RPM or beyond the trickle of oil from the
flow control block port test line should increase to a substantial flow.
5.
When the truck engine returns to idle the flow from the control block port test line should again
decrease to a trickle.
6.
If the flow control block test line flow is continually high or low and does not increase or decrease
with the engine RPM the flow control block on the pump may require service.
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MAINTENANCE PROCEDURE – CHECKING PUMP ON-OFF VALVE BLOCK
1.
The pump on-off valve is located in front of and toward the top of the tailgate/ejection spool valve
assembly. Two wires come from the 12-volt coil on the pump on-off valve block. One wire is
grounded and the other wire runs into the truck dash pump on-off switch. It is important that the
grounded wire has a good ground connection for proper operation.
2.
When the pump switch in the cab is in the on position the spool valves should operated normally.
When the pump switch in the cab is in the off position, the oil flow from the pump is returned directly
back to the oil reservoir without entering the work sections of the spool valves. No spool valve
functions would be operable in this condition.
3.
When the cab pump switch is turned on the red light should also light up. This red light is a warning
to the driver that the system is operable. If the light fails to come on when the cab pump switch is
turned on check the following:
1.
Verify that the bulb in the light is working.
2.
Verify that the in-line fuse in the circuit which runs from the 12-volt power source to the cab
pump switch is not blown.
4.
If bulb replacement is required reinstall part # G004-5854 dash light. The in-line fuse should be
replaced with a SFE 14 amp fuse or equivalent. Installing a larger amperage fuse may cause further
electrical problems.
5.
The pump on-off cab switch activates the 12-volt coil on the pump on-off valve. When current
passes through the 12-volt coil it becomes an electromagnet and attracts the moveable centre spool
of the cartridge. Thus, holding a non-magnetic screwdriver blade, pocket-knife blade or similar
piece of metal to the coil end of the cartridge can check the wiring circuit. If the cab pump on-off
switch is on and the circuit is complete, the coil magnetism will attract the metal of the pocket-knife
blade or metal object.
6.
When the pump switch in the cab is in the off position the valve assembly allows oil to flow through
the assembly. If the outlet line were removed from assembly, the detached line plugged and an
open test line with the proper fittings installed attached to the open valve assembly outlet port, oil
should flow from the test line when the pump switch is in the off position. When the pump switch is
in the on position the oil flow should stop. If the pump on-off valve tests OK electrically but does not
stop and start the flow of oil, the cartridge may require cleaning or replacement. The coil nut can be
removed along with the coil cover, coil and base plate. Next use a 1" socket to remove the
cartridge. This cartridge is a "normally open" cartridge meaning the flow of oil can pass through the
cartridge when it is in its normal or inactivated mode. When the coil on the cartridge is activated the
magnetism pulls the centre spool of the cartridge up against spring pressure and interrupts the oil
flow. This would be the closed position. When the coil is deactivated the spring in the cartridge
returns the centre spool to its previous normally open stage. To clean this cartridge when it is
removed from its cavity, spray it with WD-40, LPS or a similar product while working the centre
spool in and out with something soft such as a pencil eraser. Using a hard object such as a
screwdriver blade to joggle the centre spool may scratch the finely honed surfaces and destroy the
cartridge. Use caution not to let dirt or contaminants enter the cartridge cavity or cartridge. Do not
drop the cartridge. Do not rub the cartridge o-rings against the cavity threads when removing or
installing the cartridge. Do not over-tighten the cartridge or coil nut.
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MAINTENANCE PROCEDURE – SETTING THE MAIN RELIEF PRESSURE
The main relief pressure is designed into the hydraulic system to limit the upper pressure range of the
system. The relief pressure should never be tampered with. The main relief pressure should be checked
as part of regular maintenance to verify it is as originally set. To check the main relief pressure, follow the
outline below. Note that this function should be checked with the vehicle warmed up.
1.
Insert the unitest pressure gauge onto the test port located on the elbow of the main pressure line
coming from the pump.
2.
Speed up the engine using the manual throttle advance button on the body.
3.
Dead head one of the hydraulic functions other than the ejection ram, i.e. raise the tailgate as far as
it will go and then continue to hold the control. This forces oil over the relief valve.
4.
The pressure gauge should read 2750 P.S.I, plus/minus 25 P.S.I.
5.
If the pressure is out of range adjust the relief valve. Loosen the lock nut on the set screw and turn
the set screw clockwise or counter clockwise until the pressure is set. Retighten the lock nut and
confirm pressure is as set.
D
A
N
G
E
R
HIGH PRESSURE OIL CAN EASILY PUNCTURE SKIN CAUSING SERIOUS INJURY OR DEATH.
DO NOT USE FINGERS OR SKIN TO CHECK FOR LEAKS
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MAINTENANCE PROCEDURE - BLEEDING AIR FROM HYDRAULIC SYSTEM
1.
Bleed system by operating all functions several times. This will bleed air from the cylinders, spool
valves and hoses.
2.
Bleed the unloader spool sense line last.
a. Bleed the unloader sense line with 12 volt switch in "on" position and truck at high idle.
b. To bleed the unloader circuit, loosen the "tee" connection. This will allow the unloader spool to
bleed from the spool toward the tee thus eliminating air from within the spool.
3.
With pump switch in "off" position some movement of cylinders is normal due to back pressure and
leakage factors.
4.
Adjust the main relief valve to 2750 PSI.
a. A unitest fitting is provided in the fitting for a 0-5000 PSI gauge.
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MAINTENANCE PROCEDURE - ADJUSTMENT OF "KICKOUTS" ON TAILGATE VALVE
1.
Remove packing blade top rear cover for access to the rear spool valve.
2.
Put a 0-5000 PSI gauge in the barrel end (large end) tee of both the packing blade and slide
cylinder hoses. A port unitest fitting is provided in each tee for gauges.
3.
Adjust the packing spool so it kicks out at 2100 PSI.
a.
4.
Turn adjusting screw clockwise to increase kickout pressure or counter clockwise to decrease
kickout pressure.
Adjust the slide spool so it kicks out at 2450 PSI.
a.
Turn adjusting screw clockwise to increase kickout pressure or counter clockwise to decrease
kickout pressure.
5.
If the slide kickout PSI is too high it may interfere with the main relief PSI and not allow the slide
kickout to operate.
6.
If the packing kickout is too close to the slide kickout PSI the packer may kickout before cycle is
completed.
7.
Normally a minimum of 200 PSI difference is required between the packer and slide and kickout
functions.
8.
Adjust the kickouts in the rear bonnet of the spool section with a screwdriver. See below:
9.
After adjusting activate the spool and read the pressure that spool section kicks out at.
10.
Adjusting one kickout setting may affect the other kickout setting. Co-ordinate the kickouts as
required.
11.
Adjusting the kickout PSI too low will cause the load to pack too light. Increasing the kickout PSI
beyond the recommended pressures may damage the hydraulics and packer and shorten the
lifetime of the components.
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MAINTENANCE PROCEDURE – ADJUSTMENT OF FORCE LIMITER VALVE
The ejection force limiter is designed to limit the amount of force the telescopic cylinder can develop in the
extend mode. If the ejection force limiter pressure is set too high, the result may be structural damage to
the truck body and components. To test the ejection force limiter valve, follow the procedures as outlined
below.
1.
A 0-5000 PSI pressure gauge should be installed in the test port provided in the elbow of the
pressure line leading into the two-bank directional valve.
2.
Start the truck engine and turn on the pump on/off switch located on the front drivers’ side of the
dash. If the pump is P.T.O. driven, engage the P.T.O. Note that not all P.T.O.s’ will have an on/off
switch, as some P.T.O.s’ are constant mesh and are constantly engaged.
3.
Push in the throttle button located on the drivers’ side, front of the truck body. The engine should
now speed up and be at working at a higher R.P.M than before (Approximately 1200 R.P.M.).
4.
Operate the ejection cylinder to extend the telescopic cylinder until it is fully extended by pushing
the handle closest to the front of the vehicle in towards the body.
5.
Continue to hold the spool valve in this extended position, this will cause maximum pressure in the
system up to the directional valve. Read the gauge and record the pressure off of the gauge.
6.
The correct gauge settings that should be set for the ejection ram cylinders are as follows:
20 yd.
32 yd.
1500psi
1600psi
25 yd.
45 yd.
1500psi
1800psi
7.
The ejection cartridge is factory set and should not need adjustment, but if it has to be adjusted, use
the following procedure.
8.
Locate the relief cartridge in the rectangular manifold (valve to the left of the two-bank valve.) See
photo below.
9.
Slacken off the lock nut.
10.
Insert a 3/16 allen key in the valve cartridge and adjust clockwise to increase pressure while holding
the spool valve in the extended position. Once the pressure reaches the designed level, re-tighten
the lock nut and confirm that the pressure is as set by repeating steps 1-5.
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SECTION 3.4.1
MAINTENANCE INSTRUCTIONS
FOR NON TELESCOPIC CYLINDERS
1) Removal of Head Gland
Before the head is removed, the self-tapping lock screw must be removed. A hook spanner can be used
to unthread the head from the barrel. If seals are going to be removed from head, be careful not to
scratch the seal grooves as it will diminish cylinder sealability.
2) Removal of Piston From Rod Assembly
The piston is retained to the rod assembly by way of a torqued lock nut. The tailgate cylinder does not a
have a lock nut as the piston is welded to the rod. Be careful not to damage the rod with nicks or dents
when handling. The following is a list of torque ratings for the lock nut for the different cylinders.
CYLINDER DESCRIPTION
Packing (sweep) Cylinder
Slide Cylinder
Tipper
TORQUE RATING
600 FT-LBS
800 FT-LBS
160 FT-LBS
If seals are removed from the pistons, be careful not to scratch the seal grooves, as it will diminish cylinder
sealability.
3) Replacing Seals
Make sure that the seal grooves are free from nicks and scratches. When replacing seals, be careful not
to damage seals, as it will cause cylinder leakage. Make sure that the seals are installed in their proper
groove and that they are not twisted. See figures 1 and 2 for more detail.
4) Assembling Cylinders
Before putting cylinders back together, make sure that all parts are clean. Torque the lock nuts to their
proper torque as described above. Lubricating the seals with clean hydraulic oil will aid in the assembly
process. Before threading the head into the barrel, make sure that the threads are clean and free from
burrs. Screw the head into the barrel until the head butts to the front of the tube and the lock screw holes
are aligned. Replace self tapping screw to lock the head in place. Once the cylinders are completely
assembled they can be hydraulically tested at normal operating pressures.
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Piston Seal Assembly
1) Clean threads with solvent and wipe dry.
2) Put loader in proper seal groove. Make sure that the loader is not twisted.
3) Install loader on top of loader by wrapping around piston with screw driver or pick. Be careful not to
gouge or nick the seal. Check to make sure that the seal is not twisted
4) The piston seal will be stretched and will need to be resized. This is accomplished by pushing the
piston through a tapered sleeve. Re-sizing can also be done by wrapping a wear ring around the seal
while on the piston. Compress the wear ring uniformly with a hose clamp or chain vise-grip. After
holding for a few moments, the seal will have regained its original size.
Head Seal Assembly
1) Clean head with solvent and wipe dry.
2) Install rod seal, rod wiper, o-ring and back up as shown in figure 2. It is important that the rod seal is
installed in the proper direction and that the back up is on the proper side of the o-ring.
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SECTION 3.5
ELECTRICAL COMPONENTS AND MAINTENANCE
The Universal Handling Equipment Rear End Loader contains many electrical components in addition to
the hydraulic components. These systems must also be properly maintained in order to ensure a long life
of the vehicle. All lighting and alarms must be checked everyday in order to make sure proper warning
lights and alarms are functioning properly. Signal lights and working lights should be functioning at all
times for the safety of workers and others around the vehicle. Replacement lights and alarms can be
ordered from our parts department and a detailed parts list can be found in section 4 of this manual.
Tailgate proximity sensors are responsible for the engine speed up when the packing control handles are
pushed in or pulled out. There is also a proximity sensor located on the drivers’ side of the tailgate locks
to activate the tailgate alarm. These sensors can vibrate out of alignment and need to be adjusted. If the
tailgate hinge proximity sensor comes out of alignment the tailgate alarm will either not come on at all or
will not shut off. With the tailgate closed, loosen the adjusting nut on the sensor and move it away from
the sensing plate, the alarm will now sound. Adjust the sensor forward to the sensing plate until the alarm
turns off and tighten the adjusting nuts down. Test the sensor by opening the tailgate. As the locks open
the plate will pull away from the sensor and the alarm will begin to sound. The alarm should continue
sounding until the locks are fully engaged. The proximity sensors for the packing controls are located up
inside the tailgate on the linkage bars that connect the handles to the tailgate valve. Here there will be two
U shaped sensing blocks facing towards each other. The proximity sensor will be located just above these
two blocks centred between them (see Figure 3). This is how the 3 components should line up, if the
handles are pushed or pulled the sensing block leg moves under the proximity sensor and the engine
speeds up. To adjust the sight blocks or sensor someone must enter the inside of the tailgate. To adjust
the sensing blocks loosen the setscrews and slide the block along the rod. To move the sensor up or
down loosen the adjusting nut and move accordingly. When all 3 components are in place tighten the
adjusting nuts and set screws. To test the proximity sensors turn on the vehicle and pull or push the
handles, the engine should speed up. Note the engine should speed up for both directions that the
handles are pushed. If the engine does not speed up for both positions on both handles the sensor needs
to be adjusted again.
It is also important to check the wiring located on the body of the Rear End Loader for worn or broken
wires. Wire joints are connected using heat shrink butt connectors and weather sealed with a piece of heat
shrink tube. There should not be any bare wire showing anywhere on the body of the vehicle. Bare wires
should be properly covered or frayed or broken wires should be replaced with same gauge of wire.
Lighting should also be properly connected. Some lights on the Rear End Loader are grounded to the
body of the vehicle itself and should be screwed down tight at all times. Tail lights and signal lights are
plugged into a main harness and should be fully plugged in at all times.
33
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UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
There is an interlock device located on the body access door that is wired into the 12-volt solenoid valve
discussed earlier. This interlock prevents any hydraulic function from working if the side door is open. If
the side door is open during an operation that function will cease to operate until the door is closed and
the interlock is back together. For the pump solenoid, and interlock schematic see page 43 of this manual.
34
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
SECTION 3.6
TROUBLE SHOOTING GUIDE
No hydraulic functions work:
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Diagnostic number
Check if oil level low
Check if the 100 mesh suction filter is clogged
Check if the 2” gate valve is closed
Check if the suction hose has internally collapsed
Check if the pump is working
Check if the pump on/off switch is functioning properly
Check if the unloader spool is sticking
Check if the relief valve is stuck open
See if the vehicle engine is operating at too high of an R.P.M.
Check and see if the solenoid valve is functioning properly
1
2
3
4
5,6,17
7
8
9,15
10
11
Ejection cylinder will not move automatically or will not hold packing load:
1)
2)
3)
4)
Check if Smart-Pak cartridge is adjusted properly
Check if the spool valve is leaking
Check if the ejection force limiter is leaking
Check if the ejection ram cylinder is leaking
12
13,19,20
32
14
System pressure is low:
1)
2)
3)
4)
5)
6)
7)
8)
9)
Check system relief valve
Check if pump is worn or damaged
Check pump flow control
Check unloader spool
Check solenoid valve for leaks
Check if oil level is low
Check if the100 mesh suction filter is clogged
Check if the 2” gate valve is closed
See if the vehicle engine is operating at too high of an R.P.M.
9,15
16
17
4
7
1
2
3
10
Packer/slide kickout does not work properly:
1)
2)
3)
4)
5)
6)
Packer/slide kicks out too soon
Packer /slide does not kick out
Check for internal leakage in rear spool
Check return pressure (too high)
Check main relief pressure (too low)
Check control linkage for binding
18
18
19,20
22
9,15
23
Cylinder problems:
1)
2)
3)
4)
No response when spool valve is activated
Cylinder binds
Cylinder leaks hydraulic oil
Excessive play in bushings
See “No hydraulic functions work”
27,28
30
31
This Trouble shooting section is to act as a guide for common problems found. If there is a problem
beyond the scope of this manual please feel free to contact our parts and service departments at (905)
547-0161 or at 1-800-843-1122.
38
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UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
HYDRAULIC TROUBLE SHOOTING DIAGNOSTICS
1.
Fill oil level to sight gauge line with cylinders retracted. Do not overfill.
2.
The top cover on the reservoir must be removed to change the100 mesh filter. When the old 100
mesh filter is removed clean inside of the reservoir with a lint-free cloth. Do not over tighten the
new 100 mesh filter. Examine the top cover gasket and replace if required. Do not over tighten the
top cover bolts or gasket may be damaged. See section titled, "Compactor System Hydraulics" for
details.
3.
Nylon tie strap should be reinstalled to prevent vibration from closing gate valve or inadvertent
closing of gate valve. See section titled, "Compactor System Hydraulics" for details.
4.
SAE Spec 100R4 hose must be used in this application to prevent suction from internally collapsing
hose. See section titled, "Compactor System Hydraulics" for details.
5.
See section titled "Procedure - Check Flow Control on P75 Commercial Pump." See Step #17.
6.
Inlet vacuum should not exceed 5" mercury when oil temperature is warm. If vacuum exceed 5"
mercury, check the 100 mesh filter and the suction hose for restriction.
7.
See section titled "Procedure - Check Pump On-Off Valve Block."
8.
See section titled "Procedure - Check Unloader Spool."
9.
The relief valve can be cleaned with WD-40 or an equivalent product. The fitting in the inlet section
on the tailgate/ejection spool valve assembly is drilled for a 0-5000 PSI gauge. The relief valve
should be set for 2750 PSI. Call UHE for assistance on setting the relief valve pressure. Also see
Step #15.
10.
If the truck engine RPM is increased enough to allow the pump flow to exceed 38 GPM the pump
flow control will send a signal to the unloader in the tailgate/ejection inlet and direct the oil flow to
the reservoir rather than through the spool valve system. Lowering the engine RPM allows the
system to resume normal functions.
11.
The pump solenoid valve sends a signal to the unloader valve to direct oil flow back to the reservoir.
To test if the solenoid valve is malfunctioning, remove the hose going from the solenoid to the
tailgate/ejection valve at the tailgate/ejection valve and plug it. If hydraulic function resumes, the
solenoid valve is faulty and needs to be replaced.
12.
The Smart-Pak section has a cartridge which can be adjusted. This cartridge adjustment will
determine density of the load. If the cartridge is adjusted too low the load will be less dense and
maximum pack will not be achieved. If the cartridge is adjusted too high the telescopic cylinder will
not move back automatically as you pack the load. No gauges are required to adjust this cartridge.
To achieve maximum packing force on the system, make the following adjustments while packing.
Simply loosen the cartridge locknut and use an allen wrench to turn the adjustment screw clockwise
1/8 turn. This will increase the amount of force required to move the telescopic cylinder back
automatically as you pack. Continue to turn the adjustment screw in 1/8 turn increments until the
telescopic cylinder refuses to move back automatically. At this point you have hydraulically locked
up the telescopic cylinder and should now turn the adjustment screw counter-clockwise 1/8 of a
turn. The telescopic cylinder should move back automatically as you pack. Should the cylinder be
reluctant to move, turn the adjusting screw counter-clockwise and additional 1/8 turn. Please feel
free to call UHE at any time should you have questions or require assistance.
39
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
13.
Spool valve external leakage should be visible. Leakage can cause the spool valve to malfunction
through external or internal leakage. Seals can stop the leakage in some instances. However,
leakage caused by wear will require replacement of the spool valve section. Also see steps #19
and #20.
14.
If ejection cylinder leaks are external determine the source of the leak to determine if it can be
repaired. Complete seal kits are available for the ejection cylinder. If you require assistance please
contact UHE.
15.
The main relief valve (MRV) is located in the inlet section of the tailgate/ejection spool valve. It is
adjusted to relieve pressure at 2750 PSI. If the MRV becomes contaminated it may stick open or
fail to open. Normally the MRV cartridge can be removed and cleaned. If necessary the MRV
cartridge can be replaced. To adjust the MRV a 0-5000 PSI gauge should be installed in the tap
provided in the inlet fitting on the high pressure line coming from the pump going into the spool
valve. Start with the MRV adjusted fully counter clockwise. Hold the ejection valve in the retract
position with the ejection fully retracted. This will cause maximum PSI in the system up to the MRV
setting. Turn the MRV adjusting screw clockwise until the gauge reads 2750 PSI and tighten the
locknut. Caution: do not run oil past the MRV for over 10-15 seconds at one time as damage
to the system may result.
16.
The pump is designed to deliver the required working pressures on a continuous basis. To test the
performance of the gear pump, a 0-5000 PSI gauge and adjustable needle valve capable of the
same pressures and adequate flow is required. The gauge should be tee'd into the system on the
outlet flow side of the pump and the adjustable needle valve should be plumbed in series
immediately following the gauge. The needle valve should be in the full open position. Let the truck
engine idle, engage the pump and slowly close the needle valve until the gauge reads 2750 PSI.
Never exceed 2750 PSI as the pump may be damaged. If the pump is not capable of reaching
2750 PSI it may have excessive internal leakage due to wear or damage. Please feel free to
contact UHE if you have nay questions. Caution: all components installed for test purposes
must be able to withstand 5000 PSI. Serious person injury could result if the incorrect
components are used for testing.
17.
The flow control section located on the outlet side of the pump can be entirely removed from the
hydraulic system for troubleshooting purposes. The two small hoses on both sides of the flow
control section will have to be blocked off and shorter bolts used to fasten the slit flange on the
outlet hose directly to the pump body outlet port. Also read the section titled, "Procedure - Check
Flow Control on P75 Commercial Pump." The flow control may be contaminated if it fails to work
and may simply require cleaning. After the flow control is removed from the pump, it can be
disassembled by carefully removing the snap ring on the inlet port end. the spacer, spool, spring
and components can be removed at this point. Carefully clean and examine the bore in the housing
and the internal components for damage and wear. If the components are serviceable, lubricate
them and reinstall them in the housing. After installation push the flow control spool back and forth
against the spring. It should move freely and not bind. Also see step #5.
18.
The packer and inside kickout adjustments must be properly adjusted and co-ordinated to function
properly. Should readjustment of the kickouts be required, follow the procedure titled, "Adjustment
of Kickouts on Rear Spool Valve." Please call UHE for assistance if required.
19.
Internal leakage between spool sections will require removal and disassembly of the spool valve.
New seals and components will be required to reassemble the assembly. We suggest you contact
UHE for information before disassembling the spool valve assemblies. Also see steps #13 and #20.
40
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
20.
Excess leakage between the spool and bore will require the entire section to be replaced. The
spools and bores on the spool valves are matched when they are initially manufactured and are not
normally interchangeable. We suggest you contact UHE for information before disassembling the
spool valve assemblies. Also see steps #13 and #19.
21.
The 10 Micron return line filter assembly is located in the oil reservoir cover. See the section titled,
"Compactor System Hydraulics" which discusses servicing this filter.
22.
Any obstruction in the return line system will cause return line pressures to increase. Check for
damage to hoses and pipes. Be sure the proper fittings are installed. Remember to use the correct
specification hoses and pipe, the same as the hose removed.
23.
If the linkage is binding the kickouts may not be able to overcome the resistance caused by the
binding. If this happens, the linkage will require disassembly, cleaning, lubrication and reassembly.
For adjustments, see step #24.
24.
The linkage is adjusted so the spool valve has full travel in both directions. Adjustment is made by
loosening the locknuts on the control rods, adjusting the clevis and retightening the locknut. Check
the linkage for free operation without binding. See step #23.
25.
The winch motor must be properly installed. A pre-load on the bearing is required. See the winch
section for details.
26.
Winch disassembly and reassembly instructions are included in the winch section. Should you
have further questions or need parts, call UHE.
27.
If the cylinder binds the rod may be bent. Sometimes the bend is so slight it is difficult to see.
Removing the cylinder from the packer and moving the rod in and out manually may detect the
bend.
28.
If the improper seal kit is installed in a cylinder it may leak or cause the cylinder to bind. Proper seal
kits for cylinders can be found in the parts section of this manual.
29.
If the tipper mechanism is damaged, it may cause binding. Check for damage or worn lubrication
points.
30.
If a cylinder leaks externally or internally, it should be removed from the packer, disassemble,
cleaned and inspected for wear and damage. If no excessive wear or damage is evident a new
seal kit should solve the leakage problem. Any cylinder with excess wear or damage should be
replaced.
31.
The bushings on the ends of the cylinder can be replace by driving out the old bushing and installing
a new bushing.
32.
The ejection force limiter is plumbed into the hose which runs between the spool valve and the
telescopic ejection cylinder. If the cartridge is suspect, thoroughly clean the area around the
cartridge and remove it from the block. Inspect the O-rings and seals for damage, replace as
necessary. The cartridge can be cleaned with WD-40 or an equivalent product, the centre spool
should move freely. Reinstall the cartridge and recheck the system. See the section on
“Adjustment of force limiter valve”
41
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
SECTION 4.1
PARTS ORDERING
When ordering parts, please collect all of the information indicated at the bottom of this page. Part
numbers and the proper part names can be found in the following sections of this manual. The serial
number of the vehicle is stamped on an aluminium plate located on the compaction body on the driver’s
side. This information can also be found on page 2 of this manual. Once you have accumulated all of the
necessary information, parts can be ordered through Universal Handling Equipment’s service department
at (905) 547-0161 or 1-877-843-1122. Parts can also be ordered online by email by contacting
Parts@UHECL.com.
Vehicle Information
Serial number:
Approximate date truck was received:
Part Information
Part number:
Part name:
Quantity required:
42
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.1
Tailgate Cylinder and Tailgate Installation
Drawing RA-53
Bubble No.
Part No.
1
601237A
Tailgate Hinge Pin
2
2
601260C
Tailgate Hinge Keeper
2
3
F004-5216
Lock Washer
2
4
F004-5328
Hex Head Bolt
2
5
RA-53-5
Tailgate Shim Inner
2
6
RA-53-6
Tailgate Shim Outer
2
7
RA-53-7
Flat Washer
2
8
F004-5216
Lock Washer
2
9
F002-5328
Hex Head Bolt
2
10
RP-18-16A
Cylinder Pivot Pin
2
11
F003-4262
Hex Head Bolt
2
12
M610-4000
Tailgate Cylinder
2
Part Description
43
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.2
Side Door Assembly
Drawing RA-54
Bubble No.
Part No.
1
RA-54-1
2
Part Description
Quantity
Side Door
1
F005-5620
Side Door Hinge
2
3
F001-4103
Hex Head Bolt
1
4
RA-54-4
Door Handle
1
5
F004-4835
Hex Nut
1
6
K001-5416
Spring
1
7
45
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.3
Tailgate Lock Assembly
Drawing RA-52
Bubble No.
Part No.
1
RA-25
Pin Assembly
1
2
F005-5556
Retaining Ring
2
3
RA-23
Shaft Assembly
1
4
RA-52-4
Pin Housing Assembly
1
5
RP-18-15
Bellcrank Mount Eye Pin
1
6
F002-5303
Hex Head Bolt
1
7
PA-141
Bellcrank Pin retainer
1
8
RP-18-14
Bellcrank Mount Eye*
2
9
RP-18-17
Autolatch Bellcrank
1
10
RP-18-27
Bronze Bushing
1
11
RP-18-18
Autolatch Linkage Pin
2
12
F003-4262
Hex Head Bolt
1
13
RP-18-16
Autolatch Cylinder Pivot Pin
1
14
M610-4000
Tailgate Cylinder
1
15
RA-52-15
Tongue Assembly
1
16
604-U401B
Autolatch tailgate Lock Assembly
1
17
F004-4871
Hex Nut
1
18
F004-5054
Lock Nut
1
Part Description
Quantity
* NOTE quantity is PER Tailgate Rear Post Assembly
47
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.4
Body Mounting
Drawing RA-55
Bubble No.
Part No.
1
F002-5384
2
RA-55-2
3
F004-4866
4
RA-55-4
5
Part Description
Quantity
Hex Head Bolt
2
Rear Pivot Plate
2
Lock Nut
8*
Heavy Flat Washer
8*
F002-5332
Hex Head Bolt
16*
6
MP-52-8C
Upper Spring Bracket **
4*
7
F001-5402
Spring
8*
8
F002-5340
Hex Head Bolt
8*
9
F004-4866
Hex Nut
16*
10
F004-5216
Lock Washer
16*
11
MP-52-8C
Lower Spring Bracket
4*
12
F004-5219
Flat Washer
2
13
F004-4869
Hex Head Nut
2
*NOTE Drawing Reflects Layout for 25 or 32 Yard Body For 20 Yard There are Only 2 Total Spring
Brackets
**NO holes drilled in top bracket
49
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.5
Ejection ram Assembly
Drawing RA-42
Bubble No.
Part No.
1
RP-18-9
2
Part Description
Quantity
Nylon Shoe
8
RA-17
Lower Shoe Spacer
2
3
RA-18
Upper Shoe Spacer
2
4
RP-18-8
Shoe Retainer
4
5
F001-4134
5/8” Hex Head Bolt
8
6
RP-18-7
Ram Mount block
8
7
F004-5188
Lock Washer
8
51
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.6
Ejection Cylinder Installation
Drawing RA-46
Bubble No.
Part No.
1
RA-46-1
2
Part Description
Quantity
Ejection Cylinder Mounting Assembly
1
F002-5321
Hex Head Bolt
1
3
RP-18-23
Ejection Cylinder Pin (Floor Mount)
1
4
* See Below
Telescopic Ram Cylinder *
1
5
F002-5321
Hex Head Bolt
1
6
F004-5214
Lock Washer
2
7
RP-18-12A
Ejection Cylinder Pin (Ram Mount)
1
8
F004-4865
Hex Nut
2
Body Size
Cylinder Part Number
20 Yard
D002-6413
25 Yard
D002-6411
32 Yard
D002-6414
53
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.2.7
Rear End Loader Decals
RL-29A
Bubble No.
Part No.
1
WO11-7743
Hydraulic Oil Only
1
2
WO11-7744
Aluminium UHE Sign
2
3
WO11-7801
Slide and Packing Control Arrows
1
4
WO11-7814
Ejection and Tailgate Control Levers
1
5
WO11-7815
Danger: Stand Clear When Blade Is In Motion
2
6
WO11-7816
Danger: Stand Clear When Tailgate Is In Motion
4
7
WO11-7818
Caution: Do Not Use As Riding Step
4
8
WO11-7821
Caution: Stand Clear When Packer Is In Motion
4
9
WO11-7874
Danger: Do Not Enter Unless Body Is Empty
2
10
WO11-7823
Throttle Advance
2
11
WO11-7827
Warning: Rotating Shafts
2
12
WO11-7829
13
WO11-7830
14
WO11-7831
Check Reservoir Oil Level Only
1
15
WO11-7832
Warning: Do Dot Fill The Refuse Body
1
16
WO11-7834
Lubrication Chart
1
17
R002-2705
Red Handle Covers
2
18
G001-5711
Red Reflectors
4
19
G001-5712
Amber Reflectors
2
20
W011-7889
Buzzer Stickers
Part Description
Engine Cannot Be Operated Without Proper
Hydraulic Fluid Level
Warning: Do Not Operate Or Service This
Machine Until You Have Read And Understood
The Operation Manual Supplied With This
Equipment
55
Quantity
1
1
1(2)
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.1
Valve Beam and Covers Assembly
Drawing RA-50
Bubble No.
Part No.
1
F001-4053
Hex Head Bolt
7
2
F004-5108
Flat Washer
7
3
F005-5561
Self Tapping Bolts
33
4
PA-637C
Middle Tailgate Cover
1
5
RP-7-2
Top Tailgate Cover
1
6
F004-5110
Flat Washer
8
7
F004-5214
Lock Washer
4
8
F004-4865
Hex Nut
4
9
F005-5561
Self Tapping Bolts
16
10
RP-7-5
Bottom Tailgate Cover
1
11
V005-0208
2 Spool Valve
1
12
F004-4865
Hex Nut
4
13
F004-5214
Lock Washer
4
14
F004-5110
Flat Washer
4
15
F002-5306
Hex Head Bolt
16
F004-4833
Hex Nut
7
17
F004-5184
Lock Washer
7
Part Description
57
Quantity
4(8)
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.2
Packing Blade Assembly
Drawing RA-40
Bubble No.
Part No.
1
RP-18-35
Packing Cylinder Rod Pin
2
2
RA-40-2
Packing Blade Weldment
1
3
RP-18-40
Packing Blade Bushing
2
4
W007-7736
NPT Grease Fitting
2
5
RP-18-36
Slide and Packing Cylinder Thrust Washer
4
6
RP-18-37
Pin Retainer
2
7
F004-5214
Lock Washer
16
8
F002-5305
Hex Head Bolt
4
Part Description
59
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.3
Slide Assembly
Drawing RA-44
Bubble No.
Part No.
1
RA-34
2
RA-44-2
3
RA-35
4
Part Description
Quantity
Lower Slide Shoe (Assembled)
2
Slide Weldment
1
Upper Slide Shoe (Assembled)
2
F004-5218
Lock Washer
22
5
F002-5352
Hex Head Bolt
22
6
F004-4880
Jam Nut
8
7*
F003-4266
Square Head Bolt * (Lower Shoe)
4
7*
F003-4267
Square Head Bolt* (Upper Shoe)
4
8
F001-4051
Hex Head Bolt
4
9
F004-5184
Lock Washer
4
10
RP-18-30
Slide Access Cover
2
* Square head bolts for the UPPER SHOE are longer than the Lower Shoe bolts
61
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UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.4
Packing Blade and Slide Assembly
Drawing RA-43
Bubble No.
Part No.
1
F002-5354
Hex Head Bolt
6
2
F004-5218
Lock Washer
6
3
RP-18-32
Packing Blade Pin
2
4
RA-44
Slide Assembly
1
5
RP-18-57
Packer Pin retainer
2
6
F004-5218
Lock Washer
4
7
F002-5351
Hex Head Bolt
4
8
RP-18-34
Packer Thrust Washer Inside
2
9
RP-18-33
Packer Thrust Washer Outside
2
Part Description
63
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.5
Upper Slide Shoe Assembly
Drawing RA-37
Bubble No.
Part No.
1
F003-4540
Brass Hex Head Screw
4
2
RP-18-49
Slide Shoe Brass Bearing
1
3
RA-37-3
Upper Slide Shoe Weldment
1
4
RA-37-4
Wear Pad Plate
1
5
R002-2732
Polyethylene Wear block
1
6
F003-5071
Brass Lock Nut
8
7
F003-4320
Steel Hex Head Screw
4
8
RP-18-50
Slide Shoe Composite Bearing
1
Part Description
Quantity
* Note Quantity is PER Upper slide shoe
* 2 Upper slide shoes required per REL
65
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.6
Lower Slide Shoe Assembly
Drawing RA-38
Bubble No.
Part No.
1
F003-4540
Brass Hex Head Screw
4
2
RP-18-49
Slide Shoe Brass Bearing
1
3
RA-38-3
Lower Slide Shoe Weldment
1
4
RA-38-4
Wear Pad Plate
1
5
R002-2732
Polyethylene Wear Block
1
6
F003-5071
Brass Lock Nut
8
7
F003-4320
Steel Hex Head Screw
4
8
RP-18-50
Slide Shoe Composite Bearing
1
Part Description
Quantity
* Note Quantity is PER Upper slide shoe
* 2 Upper slide shoes required per REL
67
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.7
Slide Cylinder Installation
Drawing RA-47
Bubble No.
Part No.
1
RP-18-29
Slide and Packing Cylinder Pin
4
2
RP-18-37
Pin Retainer
4
3
F004-5214
Lock Washer
8
4
F002-5305
Hex Head Bolt
8
5
RP-18-36
Slide and Packing Cylinder Thrust Washer
16
6
M612-8000
Slide Cylinder
2
Part Description
69
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.8
Packing (Sweep) Cylinder Installation
Drawing RA-45
Bubble No.
Part No.
1
RP-18-37
Pin Retainer
4
2
F004-5214
Lock Washer
8
3
F002-5305
Hex Head Bolt
8
4
RP-18-29
Slide and Packing Cylinder Pin
4
5
RP-18-36
Slide and Packing Cylinder Thrust Washer
16
6
M612-7000
Packing Cylinder
2
7
RP-18-35
Packing Cylinder Rod Pin
2
Part Description
71
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.9
Wiper Panel Assembly
Drawing RA-48
Bubble No.
Part No.
1
F004-4835
Hex Nut
10
2
F004-5110
Flat Washer
30
3
604185
Wiper Panel Blade
1
4
K001-5424
Spring
10
5
F001-4109
Hex Head Bolt
10
6
604205
Wiper Panel Weldment
1
Part Description
73
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.10
Tailgate Controls Installation
Drawing RA-51
Bubble No.
Part No.
1
F005-5636
Clevis Pin
2
2
G004-5816
Clevis Yoke
2
3
F005-5634
Clevis Pin
2
4
G004-5813
Clevis Yoke
2
5
601664A
Inside Link Bar
2
6
F002-5313
Hex Head Bolt
4
7
RA-51-7
Bracket
2
8
602267
Valve Control Outside Link
2
9
D002-4839
Bearing
4
10
F004-5110
Flat Washer
24
11
F004-4865
Hex Nut
8
12
RA-51-12
Control Cover
1
13
601935
Controls Bearing Housing
2
14
602263 (S)
602261 (L)
Bottom Spacer *
2*
15
602275
Handle
2
16
F005-5522
Spring Pin
2
Part Description
75
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.3.11
Tailgate Seal Installation
Drawing RA-49
Bubble No.
Part No.
1
R002-2776
Rubber “P” Gasket
1
2
F005-5585
Self Tapping Bolts
39
3
RA-49-3
Flat Bar Retainer – Short
2
4
PA-142
Flat Bar Retainer – Curved
2
5
RA-49-5
Flat Bar Retainer – Long
1
Part Description
77
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.4.1
Lighting Layout for R.E.L.
Drawing no. RS-15
Bubble No.
Part No.
1
G001-5715
Front Amber Clearance Light
2
2
G003-5761
Licence Plate Light
1
3
G001-5714
3-In-Row Marker Light
3
4
G001-5712
Amber Reflector
2
5
R001-2654
Side Marker Reflective Tape – 70” Long
4
6
G002-6282
Midway Turn Signal Lights
2
7
G001-5714
Rear Side Red Marker Light
2
8
G001-5711
Red Reflector
4
9
G001-5813
Reverse Light
2
10
G001-5721
Rear Stop and Turn Lights
4
11
G002-5719
Amber Strobe Light
1
12
G002-5750
Spot Lamp(s) (optional)
13
G001-5764
Spot Lamp in Hopper (optional)
1
14
G003-5817
7” Amber Flashing Light (optional)
2
15
G001-5721
Rear Turn Signal Above Hopper Cover (optional)
2
16
G003-5817
Front 7” Amber Flashing Lights (optional)
2
Part Description
79
Quantity
1 (2)
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.4.2
Electrical Components & Wiring
Drawing no. RS-16
Bubble No.
Part No.
1
G001-5736
Tailgate Throttle Button
1
2
See Note 1
MOL Button #3 (optional)
2
3
G001-5736
Cab Buzzer Passenger Side (driver side
optional)
1
4
E001-2081
4 Wire MOL* Button (optional)
1
5
G001-5738
Round MOL* Junction Box (optional)
1
6
G002-5747
Alternating Flasher (optional)
1
7
E003-2210
Electrical Junction Box (optional)
1
8
E001-2063
6 Wire MOL* Junction Box to Cab (optional)
1
9
N/A
Chassis Wire
1
10
E001-2064
8 Wire Junction Box to Cab
1
11
G003-5815
Back-up Alarm
1
12
E001-2063
6 Wire Lighting (Flashers, Clearance Lights,
Spots, Strobe)
1
13
E001-2061
4 Wire Buzzer & Throttle
1
14
A
7 Wire Main Harness tail lights & Signals
1
15
G003-6003
3 Wire Mid Body to Chassis Wire
1
16
See Note 1
MOL Button #2 (optional)
1
NOTE 1
Part Description
Quantity
MOL button consists of components E009-0108 (Button), (E009-0161& E009-0171
Contacts)
81
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.4.3
REL Proximity Sensors and Electrical Components
Drawing RA-58
Bubble No.
Part No.
1
G003-6003
Cabtire to Throttle Advance Button
1
2
G003-6003
Cabtire to Pump Solenoid and Interlock
1
3
V005-0248
Pump Solenoid
1
4
G001-5736
Throttle Advance Button
1
5
E003-2280
Side Door Interlock
1
6
V005-0243
MOL* Proximity Sensor
1
7
602597A
8
9
Part Description
Quantity
Sensing Block
2(3)
F003-4422
Set Screw
4(6)
V005-0243
Packing Blade and Slide Proximity Sensor
83
1
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.4.4
Electrical Junction Box
Drawing RA-56
Bubble No.
Part No.
1
RA-56-1
2
Part Description
Quantity
Base Plate
1
F003-4568
Screw
4
3
G003-5830
Terminal Strip
2
4
G003-5830
Flat Washer
48
5
G003-5830
Star Washer
48
6
G003-5830
Nut
48
7
E001-2246
Seal Ring
7
8
E001-2355
Cabtire Connector
2
9
E001-2333
Lock Nut
7
10
E001-2353
Cabtire Connector
2
11
E001-2354
Cabtire Connector
1
12
E001-2355
Cabtire Connector
2
13
E003-2210
Junction Box
1
85
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.1
Body Hydraulic Lines Assembly
Drawing no. RA-59
Bubble No.
Part No.
1
RA-58-1
Elbow
1
2
RA-58-2
Pipe Clamp
5
3
RA-58-3
Pipe Clamp
6
4
RA-58-4
Pipe Clamp
12
5
RA-58-5
Power Beyond Line Assembly (Upper)
1
6
RA-58-6
Tailgate Line Assembly
2
7
H007-3231
Pipe Fitting
1
8
H007-3226
Pipe Fitting
2
9
RA-58-9
Return Line Assembly (Lower)
1
10
RA-58-10
Power Beyond Line Assembly (Lower)
1
11
RA-58-11
Return Line Assembly (Roof)
1
12
RA-58-12
Power Beyond Line Assembly (Roof)
1
13
RA-58-13
Ejection Cylinder Extend Hose
1
14
RA-58-14
Ejection Cylinder Retract Hose
1
15
RA-58-15
Extend Hose
1
16
RA-58-16
Retract Hose
1
Part Description
87
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.2
Body Valve Hydraulics
Drawing no. RA-60
Bubble No.
Part No.
1
RA-60-1
Ejection Extend Hose
1
2
RA-60-2
Ejection Retract Hose
1
3
RA-60-3
Tailgate Extend Hose
1
4
RA-60-4
Tailgate Retract Hose
1
5
V002-0041
Valve Block
1
6
V003-0072
Force Limiter Valve
1
7
V005-0113
Ejection Ram Handle
1
8
V0050115
Tailgate Handle
1
9
RA-60-9
Smart Pak
1
10
V003-0046
Body Valve
1
11
RA-60-11
Solenoid Signal to Valve Line
1
12
V005-0248
Solenoid Valve
1
13
RA-60-13
Pressure Line From Pump
1
14
RA-60-14
Return Line to Filter
1
15
RA-60-15
Suction Line to Pump
1
16
V001-0028
Gate Valve
1
17
N002-3845
Pipe Elbow
Part Description
89
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.3
Tailgate Hydraulics
Drawing no. RA-61
Bubble No.
Part No.
1
RA-61-1
Tailgate Retract Hose
1
2
RA-61-2
Power Beyond Hose
1
3
RA-61-3
Tailgate Extend Hose
1
4
RA-61-4
Oil Return Hose
1
5
RA-61-5
To Packing Cylinder Extend Hose
2
6
RA-61-6
Packing Cylinder Extend Hose
1
7
RA-61-7
To Packing Cylinder Retract Hose
2
8
RA-61-8
Packing Cylinder Retract Hose
1
9
RA-61-9
To Slide Cylinder Extend Hose
2
10
RA-61-10
Slide Cylinder Extend Hose
1
11
RA-61-11
To Slide Cylinder Retract Hose
2
12
RA-61-12
Slide Cylinder Retract Hose
1
13
RA-61-13
Tailgate Cylinder lines
2
14
V005-0208
Tailgate Valve
1
Part Description
91
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.4
Oil Tank Assembly
Drawing RA-39
Bubble No.
Part No.
1
L003-5246
“Schroeder” Return Line filter
1
2
L003-5272
Filler Breather Gasket
1
3
L003-5272
Filler Breather Basket
1
4
L003-5272
Filler Breather Cap
1
5
F001-4022
1/4” Hex Head Bolt
15
6
RA-39-6
Oil Tank Weldment
1
7
F004-4886
5/8” Hex Nut
2
8
F004-5216
5/8” Lock Washer
2
9
F002-5328
5/8” Hex Head Bolt
2
10
L003-5216
Sight Level Gauge
1
11
L003-5216
Sight Gauge Screws
2
12
N001-3785
Pipe Nipple
1
13
L003-5208
Suction Strainer
1
14
N002-4080
Drain
1
Part Description
93
Quantity
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.5
Front Mount Pump Installation
Drawing no. RA-62
Bubble No.
Part No.
1
RA-63
2
F002-5303
3
Part Description
Quantity
Pump Driveshaft
1
Bolt
4
PA-501
Pump Mounting bracket
1
4
RA-62-4
Channel
1
5
F004-5214
Lock Washer
4
6
F004-4884
Nut
4
7
P002-2955
Suction block
1
8
H006-4030 90q
H006-4025 45q
Pipe Elbow
1
9
RA-62-9
Suction Line From Tank
1
10
RA-62-10
Overspeed Line
1
11
P001-2810
Pump
1
12
P002-2956
Flow Control Block
1
13
H006-4027 90q
H006-4028 45q
Pipe Elbow
1
14
RA-62-14
Pressure Line to Body Valve
1
15
RA-62-15
Signal Line to Solenoid Valve
1
95
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.5.6
Pump Driveline Assembly
Drawing no. RA-63
Bubble No.
Part No.
1
G004-5803
Flange Yoke
1
2
F004-5212
Lock Washer
4
3
F002-5230
Bolt
4
4
G004-5801
Universal Joint
2
5
G004-5804
Slip Yoke
1
6
G004-5808
Slip Tube Shaft
1
7
RA-63-7
Pipe*
1
8
G004-5807
End Yoke
1
9
G004-5805
Pump End Yoke
1
10
G004-5825
Square Head Bolt
1
Part Description
Quantity
*Note Pipe dimension changes for different truck chassis and pump locations.
97
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 4.6
Cylinder Drawings
Ejection Cylinders
20 Yd ................................................................................................D002-6413
25 Yd ................................................................................................D002-6411
32 Yd ................................................................................................D002-6414
Tailgate Lift Cylinders
...................................................................................................M610-4000
Slide Cylinders
...................................................................................................M612-8000
Packing (sweep) cylinders
...................................................................................................M612-7000
99
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
Section 6.0
Appendix
108
REL01-09A
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
6.1 FILTER INFORMATION
BEWARE OF IMITATION SCHROEDER FILTER ELEMENTS
If you are a hydraulic system designer, you know the filtration process specifications parameters involved
in maintaining a certain level of fluid cleanliness. The nominal micron rating of a filter means very little. A
more useful concept is the percentage of contaminant particles of a certain size that are removed with
each pass through the filter. This concept is called EFFICIENCY. The efficiency, along with the rate at
which particles are generated or ingested by the system, determines the level of cleanliness maintained.
Obviously, hydraulic filtration system design requires close co-operation of filter supplier with the system
designer. The designer’s work is in vain if the filter element is replaced with one that doesn’t perform to
the specifications the designer used.
There are two possible problems with changing filter elements. First, the substitute element may have
inferior efficiency. This will result in a lower level of system cleanliness, and probably in shorter
component lives. Secondly, problems may arise when the element exhibits the required efficiency but
holds only a small quantity of dirt before the pressure drop becomes excessive. This will lead to early
replacement, meaning a loss of hoped-for savings. In fact, Schroeder’s test of other manufacturer’s
elements made to fit Schroeder housings, have so far, shown that if the price is lower, the performance is
also lower.
What if a replacement filter costs more and performs better? An increased level of cleanliness will be
attained. This increased cleanliness doesn’t necessarily translate into increased component life. That’s
because the relationship between cleanliness level and component life is non-linear. Hydraulic
components typically have a “threshold” level of contamination tolerance. Increases in contamination from
this level will result in dramatic decrease in component life. Greater cleanliness, however, will not
increase component life. This is because the life-limiting factor will be something other than wear, such
as, fatigue. The designer specifies the filters to maintain the cleanliness required by the components in
the system. Spending more to make the system cleaner makes no useful purpose.
Before you consider using imitation element in Schroeder housings, ask the supplier to furnish efficiency
and dirt holding tests results. Schroeder will be happy to provide Schroeder element test results for
comparison.
109
REL01-09A
RT Tank-Mounted Filter
100 gpm
380 L/min
100 psi
7 bar
OPTIONAL DIRT ALARM
OR ELECTRIC SWITCH
OPTIONAL
INLET
PORT
4.31
(110)
6.25 MAX.
(159)
IN
.12 (3) THICK
GASKET
SEE CHART
CTO TANK TOP
5.06 (129) Ø
HOLE IN TANK
FOR INSTALLATION
1K = 8.81 (224)
2K = 18.00 (457)
3K = 27.31 (694)
45° TYP.
.44 (11) Ø ON A
6.25 (159) Ø B.C.
(4) MOUNTING HOLES
SEE CHART
PORT TO PORT
7.00 Ø
(178)
11⁄2” Ports
11⁄4”, 11⁄2”
Standard Ports 4-Bolt Flange Only
Port to Port
6.38”
7.12”
CL to Casting Base
CL to Tank Top
1.56”
1.88”
1.75”
2.06”
2” Ports
4.50
Ø
(114)
7.56” (P, S, B)
7.38” (F)
1.81”
2.12”
2.59
(66)
OPTIONAL
CHECK VALVE
.88
(22)
Optional mounting ring available to weld to tank.
OUT
Metric dimensions in ( ).
Model No. of filter in photograph is RT1K10S24NP16CY2.
Filter
Housing
Specifications
Flow Rating:
Max. Operating Pressure:
Min. Yield Pressure:
Rated Fatigue Pressure:
Temp. Range:
Bypass Setting:
Porting Head & Cap:
Element Case:
Weight of RT-1K:
Weight of RT-2K:
Element Change Clearance:
Element
Performance
Information
Element
K3
Up to 100 gpm (380 L/min) for 150 SUS (32 cSt) fluids
100 psi (7 bar)
400 psi (28 bar)
90 psi (6 bar), per NFPA T2.6.1-1974
-20°F to 225°F (-29°C to 107°C)
Cracking: 25 psi (1.7 bar)
Full Flow: 48 psi (3.3 bar)
Die Cast Aluminum
Steel
11.4 lbs. (5.2 kg)
14.5 lbs. (6.6 kg)
8.0” (205 mm)
Absolute Rating Per ISO 4572 / NFPA T3.10.8.8
Abs. Rating wrt ISO 16889
Using automated particle counter (APC) calibrated per ISO 4402
Using APC calibrated per ISO 11171
ßx ≥ 75
ßx ≥ 100
ßx ≥ 200
ßx(c) ≥ 200
ßx(c) ≥ 1000
Dirt Holding
Capacity gm
6.8
7.5
10.0
N/A
N/A
54
K10
15.5
16.2
18.0
N/A
N/A
44
KZ1
<1.0
<1.0
<1.0
<4.0
4.2
112
KZ3
<1.0
<1.0
<2.0
4.7
5.8
115
KZ5
2.5
3.0
4.0
6.5
7.5
86
KZ10
7.4
8.2
10.0
10.0
12.7
108
KZ25
18.0
20.0
22.5
19.0
24.0
93
Element Collapse Rating:
Flow Direction:
Element Nominal Dimensions:
Fluid
Compatibility
Type Fluid
Petroleum Based Fluids
High Water Content
Invert Emulsions
Water Glycols
Phosphate Esters
Skydrol
150 psid (10 bar)
See RTI, page 114 for inside out flow version.
Outside In
4.0” (100 mm) O.D. x 9.0” (230 mm) long
Appropriate Schroeder Media
All Paper (E) and Synthetic (Z) Media
Z1, Z3, Z5, Z10, Z25
Z10, Z25
Z3, Z5, Z10, Z25
All Z Media with EPR Seals, K3H and K10H E Media
Z3H.5, Z5H.5, Z10H.5, Z25H.5 and WH.5
Note: Contact factory regarding use of E Media in High Water Content, Invert Emulsion and
Water Glycol Applications.
110 SCHROEDER INDUSTRIES
For more
information, refer to
Fluid Compatibility:
Fire Resistant Fluids,
pages 19 and 20.
Tank-Mounted Filter RT
Meets HF4 automotive standard. Top, side or bottom mounting. Optional check valve prevents reservoir
siphoning. Up to 3 inlet ports available. RTW model allows filter to be welded to tank instead of bolted.
Element
Series Part No.
K3
E
K10
Media
K25
KZ1
KZ3
Z
KZ5
Media
KZ10
KZ25
Pressure
Return
Line
-TankMounted
Flow
Element selections are predicated on the use of 150 SUS (32 cSt)
petroleum based fluid and a 25 psi (1.7 bar) bypass valve.
1K3
2K3
3K3
1K10
2K10
1K25
2K25
1KZ1
2KZ1
1KZ3
2KZ3
1KZ5
2KZ5
1KZ10
1KZ25
gpm
0
(L/min)
0
40
50
60
80
150
250
Features
ST
SKB Housings
MTA
Element
Selection
MTB
Based on
Flow Rate
GT
ZT
RT
RTD
RTI
100
KFT
380
LRT
Shown above are the elements most commonly used in this housing.
ΔPfilter = ΔPhousing + ΔPelement
Exercise:
Determine ΔP at 80 gpm (300 L/min) for
RT1KZ10P24NN using 200 SUS (44 cSt)
fluid.
BFT
ΔPhousing
ΔPelement
RT ΔPhousing for fluids with sp gr = 0.86:
ΔPelement = flow x element ΔP factor
x viscosity factor
Flow (L/min)
El. ΔP factors @ 150 SUS (32 cSt):
(50)
10
(150)
(250)
(350)
Solution:
8
ΔPhousing = 3.0 psi [.20 bar]
ΔPtotal
= 3.0 + 5.3 = 8.3 psi
or
ΔPelement = [.20 + .38 = .58 bar]
6
4
(0.25)
2
0
0
20
40
60
80
100
Flow gpm
ΔP (bar)
ΔP psi
(0.50)
ΔPelement = 80 x .05 x (200÷150) = 5.3 psi
or
ΔPelement = [300 x (.05÷54.9) x (44÷32) =
.38 bar]
K3
K10
K25
KZ1
KZ3
KZ5
KZ10
KZ25
1K
2K
.25
.09
.02
.20
.10
.08
.05
.04
.12
.05
.01
.10
.05
.04
.03
.02
Pressure
Drop
Information
Based on
Flow Rate
Air Breathers
and Viscosity
Filler Strainer
Assemblies
Magnetic Suction
Separators
If working in units of bars & L/min,
divide above factor by 54.9.
Suction Strainers
PAF1
Viscosity factor:
sp gr = specific gravity
Divide viscosity by 150 SUS (32 cSt).
Sizing of elements should be based on element flow information provided in the Element Selection chart above.
Filter No. of
Element
Series Elements† Part No.
RT
1
2
3
RTW
Seal
Material
K3
K10
K25**
KZ1
KZ3
KZ5
KZ10
KZ25
KM60
KW
Accessories
for TankMounted
Filters
(Omit)
= Buna N
H = EPR*
Inlet Porting Location
Dirt Alarm
Inlet Porting Options–Identify All Ports
Outlet Porting (See Appendix A for
complete list of options)
Port A
Port B
Port C
Options
P16
P20
P24
P32
S16
S20
S24
S32
F20
F24
F32
B24
W = Buna N*
P16
P20
P24
P32
S16
S20
S24
S32
F20
F24
F32
B24
N=None
P2
P16
S16
N = None
If using Port B, Port A & B must always
be the same type and size.
Example:
(A) P20 (B) P20 (C) P16
P=NPTF, S = SAE Straight, F = SAE J518
4-Bolt Flange Code 61, B = BSPP
2= 1⁄8”, 16=1”, 20=11⁄4”, 24=11⁄2”, 32 = 2”
(Omit)
= 11⁄2” NPT
Male
C = Check
Valve
D = Diffuser
CD = Check
Valve &
Diffuser
T = 13” Tube
Extension
A = Nonthreaded
Outlet
Located @ Port D:
(Omit) = None
Y2 = Tri-color Gauge
ES = Electric Switch
ES1 = Electric Switch
with Conduit
Connector
Located in Cap:
Y2C = Bottom
Mounted
Gauge
Located @ Port C:
Y2R = Back
Mounted
Gauge
ESR = Electric Switch
ES1R = Electric
Switch with
Conduit
Connector
MAF1
Filter
Model
Number
Selection
MF2
TF1
TF3
KF3
WKF3
LF1
LF1—2"
MLF1
SRLT
™
STAND-ALONE DISPOSABLE ELEMENT
SRLT
TRLT
RLT
1
S32=2 ⁄2”-12 SAE Straight
™
STAND-ALONE DISPOSABLE ELEMENT
**When “H” or “W” seals are ordered all aluminum filter parts are anodized.
**Not available with EPR seals.
WRLT
†Double and triple stacking of elements can be replaced by single KK and 27K elements, respectively.
Note: RTW allows filter to be welded to tank instead of bolted.
G501 = Rubber gasket
G547 = Two 1⁄8” gauge ports
G820 = Stamped cap
N = No-element indicator
M = Metric thread for SAE 4-bolt
flange mounting holes (specify
after each F port designation)
See also “Accessories for Tank-Mounted Filters” section.
See Appendix B for
additional information
on these options and
instructions on how
to order.
RLT
KF8
Other
Available
Options
QF5
MQF5
QFD2
4QFD2
Filtration Carts
SCHROEDER INDUSTRIES 111
UNIVERSAL HANDLING EQUIPMENT COMPANY LIMITED
UHE REAR END LOADER MANUAL
SERVICE BULLETIN
It is estimated, by fluid power component manufacturers, that ½ - ¾ of component failures are caused by
particulate contamination (dirt) in the oil.
This “dirt” is constantly entering, through breathers and past rod wipers, and being generated within the
system.
We have installed high-quality hydraulic oil filters to remove this dirt to assure the long, reliable service
inherent in a properly designed, well maintained hydraulic system and we highly recommend servicing our
machines with original-equipment filter elements.
CAUTION:
There are many brands of after-market filter elements available. They all wi11 fit in the
fi1ter housing for which they are supplied but many have been found to have seriously
inferior effectiveness in removing contamination.
If Schroeder replacement elements are not used in this filter, element life, efficiency and dirt holding
capacity may be reduced and warranty voided.
A)
Before using filter elements: other than the original, make sure their efficiency equals or exceeds
that of the original, otherwise your system may operate with high levels of contamination and
damage may result.
B)
Be certain the dirt holding capacity equals or exceeds that of the original, as elements with a lower
capacity for dirt may cease functioning before the next service interval.
C)
Verify that the element's minimum collapse pressure equals or exceeds that of the original. Some
after-market elements have been found to be so poorly constructed that they have collapsed in
service, resulting in dirt, plus pieces of element, being dumped into the system.
D)
Make sure the elements have radial seals, such as grommets or O-rings. Some after-market
replacement elements have only flat gaskets on the ends and these will not seal properly in the
housing.
Following are efficiency ratings, dirt holding capacities* and minimum collapse pressures**
for the elements supplied on our machines.
P/ N
Beta * 10
“Abso1ute
Rating”***
Dirt
Capacity *
Min.
Collapse **
KS7 (UHE
Supplied)
70
56 Grams
100 PSI
K10
10
44 Grams
100 PSI
Based on cumulative data from tests run at Schroeder's laboratory in McKees Rocks, PA. all tests
conducted using the method of ANSI B93.31-1973 (ISO 4572) using in-line counting.
** Ref. ANSI B93.25
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UHE REAR END LOADER MANUAL
Section 7.0
Options
Section 7.1 PINCH POINT PROTECTION SYSTEM
One of the many options that can be included with the Universal Handling Equipment’s Rear End Loader
is the pinch point protection system. This system permits a safer operation of the Rear End Loader during
the packing cycle. The system consists of a junction box located in the cab with a selector switch and 3
palm worker buttons. When the packing blade control lever is pushed in to start the pack cycle a proximity
sensor wired into the cab junction box stops the hydraulic function from operating through the solenoid
valve. The operator of the Rear End Loader then has to push in the green mushroom button on the side
of the tailgate to energise the solenoid valve again, allowing the packing blade to continue. To do this the
operator has to be at the side of the tailgate, away from the pinch point of the packing blade and out of
danger.
A selector switch located on the front of the junction box in the cab controls the number of buttons that
have to be pushed in order for the packing blade to pack. There are 3 settings, which are outlined below.
This switch is operated with a key, which should be set by a supervisor before the route and the key
removed to prevent tampering with the settings.
Key selector in position #1
This position is to be used only if there is one operator on the vehicle or by maintenance personnel
working on the vehicle. When the control lever is pushed to start the pack cycle, the system will shut down
and nothing will move until the green override button is pressed and held. The packing blade will then
move through the pack phase of the cycle. The override button needs to be held only during this first
phase of the pack cycle. When the first phase is completed and the control lever kicks back to neutral the
cycle will continue without the override button being held. The motion of the packing blade can be
observed through the window provided.
Key selector in position #2
This position is most common and is used when there are a driver and a rear operator on the vehicle.
When the control lever is pushed to start the pack cycle the system will shut down. A green push button
light located in the cab near the driver will come on to show the driver the system has shut down. The
driver must press and hold the green push button and the rear operator must also press and hold the rear
override button to start the pack cycle. The light will go out in the cab when the pack phase is complete
and the pack cycle will continue.
There is a right side mid body override button provided for the driver to use if the driver is outside the cab.
This button or the in cab button can be used to start the cycle along with the rear override button.
NOTE:
A timer is installed in the system to prevent the system from being tampered with such as
permanently holding in an override button. The system will automatically shut down until the
button is released and pressed again.
Key selector in position #3
This position is used if there are two rear operators and a driver on the vehicle. In this position all three
buttons (light button in cab, rear and mid body) must be held to start the pack cycle.
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UHE REAR END LOADER MANUAL
Summary:
One operator or mechanic: Rear override button must be held.
Two operators: The rear override button and either the in cab or the right side mid body button must be
held.
Three operators: All three override buttons must be held
Key selector must be set by a supervisor and the key removed.
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UHE REAR END LOADER MANUAL
Section 7.2 Tipper Bar
This option that can be added to a Universal Rear End Loader is designed to help dump large containers.
The tipper bar consists of two hydraulic cylinders attached to the rear of the tailgate connected by a steel
bar. A valve section and a control handle is added to the tailgate valve and the tailgate control section on
the tailgate. The tipper bar comes with a set of container latches that will be described later on. This
container latches serve as a pivot point allowing the tipper bar to swing through its motion and dump the
container. Controlling the tipper bar is done through depressing or pulling out the supplied control handle
on the tailgate. Pushing the controls towards the tailgate causes the tipper bar to lower and pulling the
handle out causes the tipper bar to raise up and dump. The tipper bar also comes with polyethylene rings
to cushion the blow from the container against the bar, as well as, protecting the container itself.
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Section 7.3 Reeving Cylinder
A Reeving cylinder is an option similar in function as the tipper bar described earlier. Again this option
comes with the container latches and ears. This works similar to a winch in function, and is designed to
dump large containers into the Rear End Loader. Again as with the tipper bar a valve section and a
control lever is added to the tailgate. The Reeving cylinder assembly is composed of a cylinder in a track
designed to slide up and down the roof. A cable with a 5 tonne hook runs through a series of pulleys to
allow the cylinder to lift up containers. Controlling the Reeving cylinder is done through depressing or
pulling out the supplied control handle on the tailgate. Pushing the controls towards the tailgate causes
the Reeving cylinder to lower the cable and pulling the handle out causes the Reeving cylinder to pull the
cable up.
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Section 7.4 Container Ears
Container ears are an item that is common to many options. This assembly allows you to lock in a
container using the latches attached to the elephant ears. These latches open up and allow a container to
be inserted into hopper area. The latches can then be lifted up manually and locked around the container
lifting bar. To lock the latches simply lift the curved lock latch up and lower it onto the notch of the lifting
bar. The container can now be lifted up with the ears serving as a pivot point for the container. The lifting
can be accomplished with one of the optional components such as a Reeving cylinder, tipper bar, etc.
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