Labrie ALLEY -GATOR RIGHT-HAND Maintenance Manual Download

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Maintenance

Recommended Maintenance Schedule

OTE

Some lube points may be greased by an automatic grease system. Consult manufacturer’s
manual for information.

Table 1

Lubrication

Description

Schedule (Performer)

Tailgate hinge pins (2)

Biweekly (optional)

Tailgate cylinder pins (4)

Biweekly (optional)

Latch pins (2)

Biweekly (optional)

Rear body hinge pins (2)

Biweekly (optional)

Inspect hydraulic oil level in

tank

Daily (optional)

Manual greasing system

manifold, pack blade (6)

Daily (optional)

Inspect grease in auto greasing

system reservoir

Weekly (optional)

Grease all arm grease zerks (8)

Daily (optional)

Inspect unit for leaks

Daily (optional)

Grease pump drive line (3)

Weekly (optional)

Table 2

Cleaning (cont’d)

Description

Schedule (Performer)

Safety decals

Pre-trip (operator)

Mirrors, lights, windows,

camera

Pre-trip (operator)

Clear

debris at tailgate seal

At landfill (operator)

Clear

contact surfaces of body

and chassis

At landfill (operator)

Summary of Contents for ALLEY -GATOR RIGHT-HAND

Page 1: ...ALLEY GATOR RIGHT HANDTM MAINTENANCE MANUAL...

Page 2: ......

Page 3: ...ALLEY GATOR RIGHT HANDTM MAINTENANCE MANUAL...

Page 4: ...f use of refuse body parts components or assemblies cost of rental equipment facilities or services resulting from downtime claims from third parties including customers of injury or damage of propert...

Page 5: ......

Page 6: ......

Page 7: ...Grease Manifold 9 Counterbalance Valves 10 Environmental Spill Kit optional 10 Access Ladder Proximity Switch optional 11 IQAN MDM Master Control Module 11 Fire Extinguisher 12 First Aid Kit optional...

Page 8: ...trical System 44 Electrical System Components 45 Auto Reset Circuit Breakers 45 Electrical Junction Box 45 Relay Box 46 Proximity Limit Switches 46 Valve Solenoids 47 External Lights and Vision Equipm...

Page 9: ...Circuit Hydraulic Pressure Adjustment 77 Working Sections of the Arm Body Directional Control Valve 80 Slide Work Circuit 81 Lift Work Circuit 81 Grabber Work Circuit 81 Tailgate Work Circuit 82 Body...

Page 10: ...viii Table of Contents...

Page 11: ...Operator s Manual Topics not Included in this Manual Maintenance of the chassis This is dealt with in the chassis manufacturer s service manual Cameras and backing accident prevention systems For thes...

Page 12: ...otected from trash and waste products The Pendulum packing system eliminates trash build up behind the packing panel allowing the hopper to self clean hence no need for the operator to clean behind th...

Page 13: ...right Danger and Caution Lamps on the Control Console Danger Lamp This lamp will illuminate whenever the following occurs The tailgate is ajar The body is raised The packer blade is stalling The acces...

Page 14: ...ating Instructions Upon receipt of your new ALLEY GATOR RIGHT HANDTM perform a complete lubrication as per the lubrication guide shown on page 37 and on the decal affixed to the side of the body Facto...

Page 15: ...75A Route Marie Victorin Levis QC G7A 2T3 Toll Free 1 877 831 8250 Telephone 1 418 831 8250 Service Fax 1 418 831 1673 Parts Fax 1 418 831 7561 Parts and warranty During business hours 8 00 AM to 5 00...

Page 16: ...6 Introduction...

Page 17: ...for the Owner Labrie Enviroquip Group strongly believes that safety is a team effort With this in mind we encourage the employer to implement the following guidelines Provide all employees both opera...

Page 18: ...that all mirrors windows and lights are clean and properly adjusted Ensure that all cameras and monitors are properly adjusted and operating correctly Do not operate any vehicle while under the influe...

Page 19: ...and Operator s Manual for a list of decals that are used on the truck Be sure to familiarize yourself with these decals Safety Features NOTE Your unit may not have all the safety features explained he...

Page 20: ...l out of a cylinder in the event of hose failure see Figure 2 2 Figure 2 2 Counterbalance valve Environmental Spill Kit optional This kit is used to contain hydraulic oil or diesel spill due to compon...

Page 21: ...ctions when the ladder is deployed NOTE Only on units equipped with an access ladder Figure 2 4 Extension ladder proximity switch with ladder deployed left and in stored position right IQAN MDM Master...

Page 22: ...e is not fully closed The tailgate should only be open during unloading and maintenance ACCESS LADDER Your ALLEY GATOR RIGHT HANDTM may be equipped with an access ladder If so this warning message wil...

Page 23: ...isher First Aid Kit optional Your vehicle should be equipped with a first aid kit It should be placed inside the cab for quick access Figure 2 7 First aid kit Triangle Kit A triangle kit is provided w...

Page 24: ...ease consult your Labrie distributor dealer for more information Figure 2 9 Rear vision camera Hopper Camera Side Door Camera optional The hopper and side door cameras send information to the monitor...

Page 25: ...LACE THEM IN STORED POSITION WHEN UNLOADING REFUSE Refer to Utilizing Tailgate Pins on page 21 Figure 2 12 Tailgate safety pin in stored position Tailgate Safety Props The tailgate safety prop is a st...

Page 26: ...ipped NOTE The following test is for units that are equipped with an access ladder Performing this test ensures the ASL1 access ladder proximity switch is working If the access ladder is deployed all...

Page 27: ...MDM display screen Arm Limit Switches 2 Performing this test ensures the Arm not parked message will appear on the IQAN MDM screen see Figure 2 15 when the slide is extended from the home position Fa...

Page 28: ...The Arm not parked message on the MDM screen should disappear and the caution lamp should turn off 6 IF the Arm not parked message DOES NOT appear on the MDM screen or the caution lamp DOES NOT illumi...

Page 29: ...is test 1 LOWER the body using the in cab console body UP DOWN switch 2 EXIT the cab and visually CONFIRM that the body is firmly seated on the chassis 3 REMOVE both tailgate safety pins and open the...

Page 30: ...page 14 To lock out and tag out your ALLEY GATOR RIGHT HANDTM unit 1 SET chassis park brake 2 TURN OFF engine REMOVE keys from ignition and STORE keys in a safe controlled area Extension ladder deplo...

Page 31: ...place an Out of Service sign in the front window 5 TURN OFF and LOCK the battery switch 6 CHOCK the wheels Figure 2 19 Lockout tags Figure 2 20 Shut off engine remove keys from ignition and store the...

Page 32: ...der see Figure 2 23 It is located on the street side of the tailgate This prop is there for your protection When latched it ensures that the tailgate will not close while you are working beneath or ar...

Page 33: ...2 Pulling safety prop upward left and setting it down right 5 LOWER the tailgate onto the safety prop 6 COMPLETE the Lockout Tagout Procedure Refer to Lockout Tagout Procedure on page 20 Figure 2 23 T...

Page 34: ...safety prop is designed to stabilize the lifted body thus allowing you to safely work beneath the body IMPORTANT The hoist safety prop must be engaged if access under a lifted body is required Do not...

Page 35: ...tched prop does not swing into place with the body raised the prop has been damaged and must be repaired prior to use 6 LOWER the body until the safety prop feet fit into the prop retainer cut outs an...

Page 36: ...table chains one shackle two grab hooks and a lifting device such as an overhead crane Use grade 80 lift chains with a working load limit of 7 100 lbs 3 23 tonnes NOTE The shackle used must have a wor...

Page 37: ...Safety 27 Figure 2 28 Example of a lifting installation Lifting lugs Grab hooks Shackle Lifting device...

Page 38: ...28 Safety...

Page 39: ...ey Gator Right HandTM Side Loader For Welding Purposes For welding purposes please note that the ASL1 body is primarily composed of two types of steel ASTM A715 grade 80 and Hardox 450 hardened steel...

Page 40: ...rmation to determine the cleanliness of the hydraulic oil Labrie Enviroquip Group recommends that the hydraulic oil be replaced or filtered every 1000 hours and following any major hydraulic failures...

Page 41: ...ents Hydraulic Oil Tank The Alley Gator Right HandTM has an aluminum or steel hydraulic oil tank with a 55 gallon 208 litre capacity see Figure 3 2 A ball valve is located within the suction line of t...

Page 42: ...r performance and longevity Excessive particle contaminants over a period of time will result in poor hydraulic performance and or failure The hydraulic system on your Alley Gator Right HandTM is prot...

Page 43: ...is passed through this filter The filter is fitted with a filter restriction indicator that signals time of replacement Please see above for the recommended replacement filter Filters may be ordered d...

Page 44: ...efer to Lockout Tagout Procedure on page 20 Keep tools working area and equipment clean A pan will be required to collect a small amount of oil lost as the element is removed 2 SLOWLY remove the hydra...

Page 45: ...use In Line Pressure Filter Replacement Procedure Follow this procedure to replace in line pressure filters see Figure 3 6 1 SWITCH OFF the hydraulic system Complete the Lockout Tagout Procedure as in...

Page 46: ...the OEM product information that has been supplied with your Alley Gator Right HandTM for further information and maintenance material The provided data includes preventive maintenance system testing...

Page 47: ...7 Figure 3 9 Lube points on body NOTE Figure 3 9 represents the Alley GatorTM with the standard arm For lube points on the optional Right Hand arm see Figure 3 10 Figure 3 10 Lube points on optional R...

Page 48: ...optional Inspect hydraulic oil level in tank Daily optional Manual greasing system manifold pack blade 6 Daily optional Inspect grease in auto greasing system reservoir Weekly optional Grease all arm...

Page 49: ...linder ears 2 retaining hardware Pre trip operator monthly maintenance Body raise cylinder mounting bolts on chassis quantity varies Pre trip operator monthly maintenance Hoist safety prop and prop re...

Page 50: ...d pivots 2 Pre trip operator monthly maintenance Tailgate seal seal retainer At landfill operator Tailgate hinge ears 2 pins 2 retaining hardware Pre trip operator monthly maintenance Tailgate safety...

Page 51: ...est hopper cover limit switch optional if equipped Daily operator Lift up lockout lift up function locked out if body is raised Daily operator Other As specified by FMCSR and or owner Table 5 Operatio...

Page 52: ...aily optional Perimeter proximity motion sensors if equipped Pre trip operator IMPORTANT Check miscellaneous control console devices are functioning Other As specified by FMCSR and or owner Table 6 Hy...

Page 53: ...operator monthly maintenance Ensure driveline is security mounted Monthly maintenance Inspect valve banks for leaks Pre trip operator monthly maintenance Ensure valve banks are security mounted Pre t...

Page 54: ...S 10 5 216 cSt for all temperature ranges Electrical System The electrical system is made up of numerous components connected by generic harnesses Proximity and limit switches provide safety lockouts...

Page 55: ...he circuit breakers are mounted on the side of the relay box see Figure 3 12 Figure 3 12 Auto reset circuit breakers Electrical Junction Box The Alley Gator Right HandTM junction box is mounted to the...

Page 56: ...with the operation it controls Fuses There are six fuses installed in the relay box only three are resetable All fuses are located at the center of the relay box The three resetable fuses protect all...

Page 57: ...olenoid is used as a switch or control for the valves Solenoid valves are electro mechanical devices that use a solenoid to control valve actuation Electrical current is supplied to the solenoid coil...

Page 58: ...are variable for speed and control The grab and release thumbswitches are on off only switches located on the top of the control lever Figure 3 19 Joystick Harnesses Harnesses connect all electrical...

Page 59: ...witches may vary depending on the vehicle s equipment Figure 3 20 Location of the proximity limit switches curbside Figure 3 21 Location of the proximity switches streetside Hopper cover open proximit...

Page 60: ...the adjustment loosen nut slightly 5 With a flathead screwdriver turn the adjusting screw located at the center of the nut until a click is heard 6 Tighten the nut 7 Test the operation 8 If necessary...

Page 61: ...ximity switch nuts 2 Adjust the proximity switch so that there is a gap of approximately of an inch between the target tab and the switch 3 Tighten up the nuts 4 Test the operation The proximity switc...

Page 62: ...ladder proximity switch 1 RETURN ladder to home position 2 COMPLETE lockout tagout procedure see Lockout Tagout Procedure on page 20 3 LOOSEN the proximity switch mounting nuts Slide the switch forwa...

Page 63: ...ght limit switches are located on front side of the arm These limit switches do not really need any adjustment other than the target itself If they ever need adjustment adjust the target so that the l...

Page 64: ...ng message is cleared from the MDM display screen when the gripper is fully open and the arm is fully retracted To do this 3 a Loosen limit switch nut 3 b Adjust the rod so that the gripper finger wil...

Page 65: ...switches are normally open These switches control the AUTOPACK cycle as follows The pack proximity switch is triggered by a tab mounted to the pendulum arm pivot When the pendulum travels to the rear...

Page 66: ...ive cover see Figure 3 26 2 LOOSEN the mounting nuts for the pack proximity switch see Figure 3 25 and move it fully FORWARD in the mounting slot 3 Operate a MANUAL pack cycle and move the pendulum fu...

Page 67: ...ry In the RETURN MODE the pendulum should travel fully forward in the bowl and stop before the cylinders bottom out fully retracted Repeat steps 6 through 9 as necessary NOTE The autopack cycle should...

Page 68: ...sume However some troubles may occur if the tailgate unlocked proximity switch is out of adjustment For example the tailgate is locked but the in cab buzzer is still sounding or the tailgate unlocked...

Page 69: ...gate 7 EXAMINE that the tailgate unlocked warning message appears on the MDM display screen and that the buzzer and backup alarm sound immediately after the switch lost contact with the target 8 CLOSE...

Page 70: ...Refer to Stabilizing A Hoisted Body in the Operator s Manual 2 COMPLETE the Lockout Tagout Procedure refer to Lockout Tagout Procedure on page 20 3 LOOSEN the proximity switch mounting nuts Slide the...

Page 71: ...ust the hopper cover proximity switch 1 Fully OPEN the hopper cover 2 COMPLETE the Lockout Tagout Procedure refer to Lockout Tagout Procedure on page 20 3 LOOSEN the proximity switch mounting nuts 4 S...

Page 72: ...ting nuts 5 SLIDE the switch forward or backward in the mount to achieve a gap of approximately with the tab of the crusher panel 6 TIGHTEN the proximity switch nuts 7 EXIT the hopper 8 TEST the opera...

Page 73: ...ugh the control module The packer valve section see Figure 3 37 is fitted with solenoids that are electrically activated by two proximity switches mounted to the body via the control module These sole...

Page 74: ...on the MDM display screen Figure 3 38 Temperature sending unit Oil Cooler Fan Thermostat When the pack circuit hydraulic oil temperature exceeds 150o F 66o C the thermostat is triggered and a relay i...

Page 75: ...3 40 Arm hopper lights Hydraulic System Maintenance Safety The hydraulic system of your Alley Gator Right HandTM may require periodic system check and adjustments It may be that a major hydraulic comp...

Page 76: ...composed of two circuits The hydraulic pack circuit component is supported by its own individual pump and directional valve The hydraulic body and arm components are supported by a second pump and co...

Page 77: ...e See procedure on page 93 700 n a n a Function Pressure Setting Engine RPM Cycle Time sec MIN Cycle Time sec MAX VPL main relief valve 2800 50 PSI 700 n a n a Body hoist up 2500 100 PSI 700 65 0 75 0...

Page 78: ...ripper 1200 50 PSI 700 1 5 2 5 Gripperclose highpressure on 300 gallon gripper 1800 50 PSI 700 1 5 2 5 Gripper open 1200 50 PSI 700 1 5 2 5 External gripper close holding valve w flow divider to keep...

Page 79: ...ce Schedule starting on page 38 a daily pre trip inspection is to be performed by the operator We advise maintenance personnel to perform a monthly hydraulic hose inspection for leaks and wear NOTE Ea...

Page 80: ...ve any doubts CONSULT THE MANUFACTURER PTO Driven or Front Mounted Pump The pump used on the Alley Gator Right HandTM is either driven by the power take off PTO or front mounted through the engine cra...

Page 81: ...rol Valve Your Alley Gator Right HandTM is equipped with a packer directional control valve and an arm and body directional control valve These solenoid operated directional valves are for directing a...

Page 82: ...each individually devoted to a single hydraulic function Identification of each section is made as such from left to right arm in out arm up down grabber open close hopper cover open close optional o...

Page 83: ...essure is 250 psi To adjust the standby pressure proceed as follows 1 ENSURE the pump is disengaged and the engine is OFF 2 INSERT a 0 3000 psi gauge into the P2 port see Figure 3 43 3 START the truck...

Page 84: ...si Figure 3 44 Test port on arm and body directional control valve NOTE An adaptor may be needed to connect the gauge to the test port Figure 3 45 Connecting the gauge to the test port using an adapto...

Page 85: ...the cap from the relief valve LOOSEN the locknut and TURN the adjustment screw OUT to decrease pressure 7 b Once completed TIGHTEN BACK the locknut 8 START the truck and ENGAGE the pump 9 While a hel...

Page 86: ...on front relief valve pressure see Figure 3 47 To do so 11 a While pulling the tailgate lever outward TURN the tailgate adjustment screw COUNTER CLOCKWISE until the pressure reaches 2500 psi using an...

Page 87: ...CKWISE or COUNTER CLOCKWISE until the pressure reaches the proper value using an Allen key See page 80 for the proper value corresponding to the working section of which the pressure is being adjusted...

Page 88: ...ustment screw clockwise until it stops 6 REDUCE packer pump pressure to minimum using the main relief valve see Figure 3 53 To do so 6 a REMOVE the cap from the relief valve LOOSEN the locknut and TUR...

Page 89: ...set ADJUST the relief valve pressure on the packer valve see Figure 3 52 To do so 9 a Using an Allen key TURN the adjustment screw COUNTER CLOCKWISE until the pressure reaches 2700 psi The packer mus...

Page 90: ...ody directional valve part 1 Figure 3 55 Arm and body directional valve part 2 The individual working section secondary relief valves should not require adjustment However should adjustment become nec...

Page 91: ...circuit see Figure 3 54 consists of two hydraulic motors and brake one valve bank section with proportional solenoid a counter balance valve and two secondary port relief valves Grabber Work Circuit...

Page 92: ...al weight of the body thus enabling the relief port to be set at the very minimum Hopper Cover Crusher Panel Work Circuit optional Your Alley Gator Right HandTM may be equipped with a hopper cover or...

Page 93: ...gripper in order to grip containers In Out hydraulic circuit This subcircuit includes two cylinders bore 1 in stroke 54 in and a holding valve It controls the extend retract motion of the arm in orde...

Page 94: ...leaking out TIGHTEN the fitting Keep the hydraulic function engaged until the fitting is tightened 5 LOOSEN do not disconnect fitting number 4 6 Fully RETRACT the rail cylinders of the arm 7 REPEAT s...

Page 95: ...r holding valves see Figure 3 58 standard arm or Figure 3 59 HD arm 4 CONNECT a pressure gauge to the test port on the arm and body directional control valve Figure 3 57 Pressure test port 5 START the...

Page 96: ...cylinders in fully extended position and activate the lever on the arm and body directional control valve to initiate the closing movement of the other cylinder Proceed vice versa for the other side...

Page 97: ...RT the engine and ENGAGE the hydraulic pump 6 Using a lever on the arm and body directional control valve manually EXTEND the Right Hand arm gradually 7 If the gauge does not indicate a pressure of ab...

Page 98: ...er The up down cylinder on a HD lifting arm is fitted with a holding valve as well as a cushioning adjustment screw which is used to adjust the stroke end cushioning during extension retraction of the...

Page 99: ...Turn the screw counter clockwise to increase pressure or clockwise to reduce pressure NOTE This pressure value of 700 psi is a reference value it could be more or less It all depends on how much press...

Page 100: ...Put the transmission in Neutral start the engine and engage the hydraulic pump 4 Clearly identify the stopper screw on the valve that relates to the proper function boom extension retraction gripper...

Page 101: ...T pressure to 250 psi by turning the adjustment capscrew clockwise or counter clockwise depending on the gauge reading see Figure 3 65 3 REMOVE the gauge after correctly setting the pressure Figure 3...

Page 102: ...ion SET pressure to 3000 psi by turning the adjustment capscrew clockwise or counter clockwise depending on the gauge reading see Figure 3 67 3 REMOVE the gauge after correctly setting the pressure Fi...

Page 103: ...acker choke valve 1 LOCATE the choke valve on the front side of the packer valve see Figure 3 69 2 REMOVE cap from the valve 3 With the auto pack running SCREW the adjustment screw in until there is a...

Page 104: ...94 Maintenance Figure 3 69 Packer choke valve w cap w o cap Adjustment screw Valve with cap...

Page 105: ...Maintenance 95 Hydraulic System Schematic Alley Gator Crusher Panel Front Body Hoist HD Right Hand Arm...

Page 106: ...s Check the obvious things first Keep it simple Work through troubleshooting charts methodically Many problems can be traced not to one part alone but to the relationship of one part with another For...

Page 107: ......

Page 108: ...ts Fax 1 418 831 7561 Mailing Address Mailing Address P O Box 530 175A Route Marie Victorin LaFayette GA 30728 Levis QC G7A 2T3 Parts and Warranty Parts and Warranty During business hours During busin...

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