Labrie automizer Maintenance Manual Download Page 184

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174

Troubleshooting

Troubleshooting Guide

This troubleshooting guide will help identify the most commonly seen problems on the
A

UTOMIZER

™. The table below will also provide the possible cause of the problem and give solutions

to resolve that problem.

For further information regarding customized options that might not be found in this
troubleshooting guide, contact Labrie

Plus

Problem

Possible causes

Solution

Insufficient packing ratio

Low oil pressure

See

Adjusting Pressure and Relief

Valves

on page 139.

Packer hydraulic cylinders
internally bypassing

See

Detecting Cylinder Internal Leaks

on page 157.

Defective pump

Replace the pump.

Overheating hydraulic oil
(temperature above 77

°C

[180

°F])

Low oil level in the hydraulic
tank

Add oil to the required level. See

Replacing Hydraulic Oil

on page 156.

Hydraulic pressure too low or
too high

See

Adjusting Pressure and Relief

Valves

on page 139.

Not the proper grade of oil
(that is too thin in hot
temperatures or too thick in
cold temperatures)

Change for oil indicated in

Recommended Lubricants

on page 99

(see

Emptying the Hydraulic Tank

on page 152).

Contaminated oil

Clean the strainer and change the
return filter element. Fill with clean
oil. See

Cleaning the Strainer

page 153,

Replacing Filter Elements

Restriction in the system

Check all hydraulic components for
debris that could cause restriction in
the system. Have the pump
inspected by a specialist.

Foaming oil

Low oil level

Add oil to the required level. See

Replacing Hydraulic Oil

on page 156.

Air entering the system

Tighten all hose and pipe
connections between the pump and
the hydraulic tank.

Summary of Contents for automizer

Page 1: ...AUTOMIZERTM MAINTENANCE MANUAL...

Page 2: ......

Page 3: ...AUTOMIZER MAINTENANCE MANUAL...

Page 4: ...tion contained in this document All risks and damages incidental or otherwise arising from the use or misuse of the information contained herein are entirely the responsibility of the user Although ca...

Page 5: ...8 Employee Responsibilities 9 Do s 9 Don ts 9 General Precautions 10 Welding 11 Fire 11 Locking Out and Tagging Out the Vehicle 12 Prior to Start Up 13 Shutting Down the Vehicle 15 Setting the Body S...

Page 6: ...for Upper Wear Pad Replacement 56 Replacing and Adjusting Upper Wear Pads 58 Finishing Up Upper Wear Pad Replacement 59 Lower Wear Pad 60 Removing Lower Wear Pad Standard Units 60 Removing Lower Wear...

Page 7: ...e 117 Introducing the Dual Vane Pump 118 Directional Control Valve 120 Proportional Valve 121 Inspecting the Pump 122 Replacing the Hydraulic Pump 123 Installing a Yoke Locking Bolt 135 Priming a New...

Page 8: ...tem 187 Main Page 188 Main Menu 195 Warning Buzzer 204 Plugging a Computer 204 Replacing the CAN Bus Based Multiplex Joystick 205 Allison Transmission Parameters 205 Programmed Parameters 206 Cummins...

Page 9: ...Table of Contents vii Valve with Crusher Panel Section Standard Arm 231 Valve with Crusher Panel Section Heavy Duty Arm 232...

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

Page 11: ...e manual Cameras and backing accident prevention systems For these options refer to the appropriate manufacturer s service manual Operating the AUTOMIZER For procedures related to the operation of the...

Page 12: ...n simple yet robust The AUTOMIZER features a strong light weight body with a reliable loading arm called the RIGHT HAND arm This arm can reach positions of up to 12 feet from the hopper and lift up to...

Page 13: ...nefits Light weight high compaction fast cycle times Reliable electronic monitoring system Strongly built automated lifting arm Increased fuel efficiency and decreased fuel consumption Low maintenance...

Page 14: ...de loader In addition they should also be fully knowledgeable of the operation of this unit Please read the Operator s Manual carefully prior to attempting any maintenance work on your AUTOMIZER unit...

Page 15: ...T3 Toll Free 1 877 831 8250 Telephone 1 418 831 8250 Service Fax 1 418 831 1673 Parts Fax 1 418 831 7561 Parts and warranty During business hours 8 00 AM to 5 00 PM Eastern Standard Time Technical Sup...

Page 16: ...6 Introduction...

Page 17: ...d in this manual and on the labels on the vehicle Danger Indicates a hazardous situation which if not avoided will result in serious injury or death Warning Indicates a hazardous situation which if no...

Page 18: ...please contact the manufacturer or any of its authorized representatives To keep records of all vehicle breakdowns and malfunctions as well as any inspection and maintenance To ensure that all failur...

Page 19: ...for example televisions paint cans fluorescent light tubes etc Drive carefully when carrying an unevenly distributed load Inspect for overhead hazards power lines prior to hoisting the body or using...

Page 20: ...the lifting arm itself operators must be able to stop arm movement at any time Before activating the lifting arm operators shall make sure that people and obstructions are far away from the vehicle AU...

Page 21: ...and tag out the vehicle as required by the employer For more information see Locking Out and Tagging Out the Vehicle on page 12 Never stand underneath a raised arm gripper Should a hydraulic componen...

Page 22: ...ckout and tagout procedure To lock out and tag out your AUTOMIZER unit 1 Park the vehicle on safe level ground and apply the parking brake see Figure 2 1 Figure 2 1 Parking brake button 2 Make sure th...

Page 23: ...air tanks 10 Verify and inspect any security device and or mechanism to make sure that there is no bypass and that they are all functional Prior to Start Up Before starting the vehicle 1 Make sure no...

Page 24: ...tor IMPORTANT Do not operate or move the vehicle until air pressure has reached 70 psi 4 Engage the hydraulic system by turning ON the Pump switch on the in cab control panel see Figure 2 5 Figure 2 5...

Page 25: ...n off in sequence the hydraulic pump the electrical system the engine and if installed the master switch 4 Drain all air tanks and the water trap Figure 2 6 Drain valve on air tank left and water trap...

Page 26: ...raise the body until the safety prop is free to tilt under it 4 Release the safety prop using the safety prop handle and position it adequately Figure 2 8 Safety prop handle 5 Lower the body until it...

Page 27: ...he Tailgate Safety Prop The tailgate safety prop is used to support and keep the tailgate open during inspection or maintenance procedures It is mandatory to set the safety prop every time the tailgat...

Page 28: ...about 3 feet enough to raise the safety prop 6 Pull the safety prop upward and set it down see Figure 2 11 Figure 2 11 Pulling the safety prop upward left and setting it down right 7 Lower the tailgat...

Page 29: ...the Tailgate Up switch on the in cab control panel 4 Raise the tailgate safety prop Figure 2 12 Raising the tailgate safety prop 5 Release your grip on the safety prop to set it in its home position F...

Page 30: ...20 Safety 7 Put the safety pin back in place...

Page 31: ...loading Remove any stacked garbage in the hopper area Make sure that the side step and or hopper step if installed are clean and free of any slippery material Danger Always lock out and tag out the ve...

Page 32: ...e Lubrication Chart on side of the vehicle X See page 104 Wiring System Check for damaged harnesses and or bad connections X See page 159 Battery Cables Ensure cables are not coming in contact with an...

Page 33: ...Twicea year See page 154 Clean strainer and refill X See page 153 Check pressure X See page 117 Hopper area Clean traps on each side X See page 25 Clean dirt under or behind the packer X See page 29...

Page 34: ...the Hopper for Clean Up To prepare the hopper for clean up 1 Start the engine and engage the hydraulic pump see Step 4 on page 14 2 Using the joystick extend the automated arm 3 Close the hopper door...

Page 35: ...Open the clean out traps on each side of the hopper see Figure 3 3 Figure 3 3 Clean out trap 2 Climb inside the hopper using the stepladder Figure 3 4 Stepladder 3 Pull out the floating panel to gain...

Page 36: ...s see Figure 3 7 5 Remove debris through the clean out traps see Figure 3 6 Figure 3 6 Removing debris through the clean out trap 6 Finish cleaning the area with pressurized water 7 Once cleaning is c...

Page 37: ...climb and reach the front part of the body just behind the cab NOTE On co mingle units the floating panel cannot be opened 3 With a scraper or pressurised water remove all accumulated dirt behind the...

Page 38: ...ar plates Because the packing system is put to such intensive use 1 000 to 3 000 cycles a day Labrie Enviroquip Group recommends that operators perform a visual inspection of the packer and its compon...

Page 39: ...and verify that there is no wear on the panel surface Figure 3 9 Follower panels 2 Inspect the scraper nylon strip at the bottom of the floating panel see Figure 3 9 This nylon strip wipes out dirt ev...

Page 40: ...tch on page 79 Proper adjustment is necessary to prevent cylinders from bottoming out under pressure 8 Make sure that hydraulic cylinders are not leaking internally resulting in insufficient packing p...

Page 41: ...the red button is pushed you have to pull said button back up then turn ON the Pump switch on the in cab control panel see Figure 2 5 4 Turn off the hydraulic pump and the engine 5 Lock out and tag ou...

Page 42: ...tion of the packer panel you must then use Method A for the removal of the packer Once you have prepared the packer panel for removal you can now proceed with the following removing procedure 1 Attach...

Page 43: ...val of the packer panel 1 Start the engine and engage the hydraulic pump 2 Using the joystick extend the automated arm to get better access to the hopper area 3 Fully retract the packer by pressing th...

Page 44: ...eneral Maintenance Figure 3 13 Side rail shields 2 Remove both side rails see Figure 3 14 and Figure 3 15 Figure 3 14 Right side rail Figure 3 15 Left side rail Bolts to be removed 7 Bolts to be remov...

Page 45: ...Units Method B Once you have gained access to the packer you must now disconnect it 1 Remove the floating panel from the hopper see Removing Lower Wear Pad Standard Units on page 60 2 Remove the acce...

Page 46: ...nel from a standard AUTOMIZER vehicle Methods A and B If you used Method B for the preparation of the packer panel you must then use Method B for the removal of the packer Once the packer has been pre...

Page 47: ...page 35 Disconnecting the Packer Std Units Method B in reverse order Also follow the procedure on page 33 Accessing the Packer Std Units Method B in reverse order to reinstall both side rail shields 4...

Page 48: ...To do so 1 Remove the chute see Figure 3 20 To perform this task apply the following steps 1 a Use a suitable lifting device e g sling or cable to hold the chute in place 1 b Take the hopper deflecto...

Page 49: ...Figure 3 21 Hopper deflector chute stopper assembly Figure 3 22 Chute front support 1 g Remove all bolts holding the chute shaft cover in place see Figure 3 23 1 h Take off the chute shaft cover Defle...

Page 50: ...4 Figure 3 24 Chute cylinder 1 j Unscrew the 2 bolts on the front shaft bracket to release the front end of the chute shaft see Figure 3 24 1 k Unscrew the 2 bolts on the rear shaft bracket to release...

Page 51: ...pper 2 Remove all bolts that secure the hopper divider guard in place see Figure 3 27 3 Take off the hopper divider guard Figure 3 27 Hopper divider guard 4 Remove all bolts that secure the hopper div...

Page 52: ...le Units Once you have gained access to the packer you must now disconnect it 1 Remove the floating panel from the hopper see Removing Lower Wear Pad Co Mingle Units on page 62 2 Remove the access cov...

Page 53: ...ning the packer with the floor guides 2 Install a new wiper blade on each side of the packer see Figure 3 19 These wiper blades may require to be adjusted to fit between the new packer and the hopper...

Page 54: ...reinstallation of the chute To perform this task go to page 38 and use steps 1a to 1l in reverse order of disassembly 12 Once finished re assembling the removed components lubricate and check for pro...

Page 55: ...age 60 for standard units and on page 62 for co mingle units 7 Open the access cover 8 Disconnect both rear cylinder pins from the greasing hoses see Figure 3 32 9 Remove both rear cylinder pins see F...

Page 56: ...inder pins 14 Remove the roller assemblies on the follower panels see Follower Panel Roller Assemblies on page 65 15 Fold the follower panels over the packer see Figure 3 33 Figure 3 33 Folded followe...

Page 57: ...catch oil spills Figure 3 34 Location of cylinder hydraulic hoses 5 Enter the hopper to attach and secure the cylinder to an appropriate lifting device 6 Remove the piston side pin that holds the fau...

Page 58: ...nd reinstall the roller assemblies 6 Grease the cylinder pins and check for proper packer operation see Packer Lubrication Points 1 on page 113 7 Readjust the proximity switch if need be for proximity...

Page 59: ...age 56 Preparing for Sliding Shoe Replacement Follow this procedure before proceeding with sliding shoe replacement 1 Start the engine and engage the hydraulic pump 2 With the joystick extend the auto...

Page 60: ...en or yellow button and then push the red emergency button immediately Repeat the process until the packer has reached the desired position NOTE To reactivate the hydraulic system after the red button...

Page 61: ...rail and to the front of both sliding shoes Figure 3 40 Tack welding 12 Start the engine engage the hydraulic pump and press the yellow button to slowly retract the packer The sliding shoes will come...

Page 62: ...ceed with such removal refer to Removing the Packer Panel Std Units Method B on page 36 if you have a standard unit or Removing the Packer Panel Co Mingle Units on page 42 if you have a co mingle unit...

Page 63: ...iding shoes are back in place turn OFF the hydraulic pump and the engine 16 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 12 17 Put back and tighten all retainin...

Page 64: ...7 Turn OFF the hydraulic pump and the engine 28 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 12 29 Align the packer with the hopper walls 30 Tack weld both floo...

Page 65: ...welding behind it 4 Remove the temporary steel tubes installed in Step 7 on page 52 5 Spray grease on the floor guides for preventing premature corrosion and wear Figure 3 46 Welds on both sides of fl...

Page 66: ...2 Using the joystick extend the automated arm to get better access to the hopper area 3 Turn OFF the hydraulic pump and the engine 4 Lock out and tag out the vehicle see Locking Out and Tagging Out t...

Page 67: ...ral Maintenance 57 Figure 3 48 Side rail shields 6 Remove both side rails see Figure 3 49 and Figure 3 50 Figure 3 49 Right side rail Figure 3 50 Left side rail Bolts to be removed 7 Bolts to be remov...

Page 68: ...red button is pushed you have to pull this button back up then turn ON the pump switch on the in cab control panel see Figure 2 5 9 Turn OFF the hydraulic pump and the engine 10 Lock out and tag out...

Page 69: ...ing effect is achieved Figure 3 53 Installing and adjusting wear pad 3 Start the engine and engage the hydraulic pump 4 Retract the packer Finishing Up Upper Wear Pad Replacement Use the following pro...

Page 70: ...nd stop the engine 5 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 12 6 Take the floating panel out of the hopper with an appropriate lifting device To do so 6 a...

Page 71: ...ts at the base of the floating panel see Figure 3 55 Figure 3 55 Pivots 6 e Lift the floating panel out of the hopper using an appropriate lifting device 7 Remove the retaining screws holding the lowe...

Page 72: ...he engine and engage the hydraulic pump 2 Using the joystick extend the automated arm to get better access to the hopper area 3 Rotate the chute so that its upper edge is in the middle of the hopper o...

Page 73: ...ke the floating panel out of the hopper with an appropriate lifting device To do so 9 a Remove the 4 bolts that secure the floating panel to the front hopper posts 2 on each side Figure 3 57 Floating...

Page 74: ...58 11 Replace the old wear pad with a new one and put back all the retaining screws 12 Reinstall the floating panel For this task use steps 7a to 7e in reverse order of disassembly 13 Reinstall the ho...

Page 75: ...ined below will show you how to remove both bottom and top rollers and how to replace them Replacing Bottom Roller Assemblies NOTE This task must be performed by 2 people To replace the bottom roller...

Page 76: ...r until the top rollers are at the same height as the bottom rollers were in the previous procedure 3 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 12 4 Replace...

Page 77: ...ocedure 1 Once the roller has been removed from the follower panel see Follower Panel Roller Assemblies on page 65 remove the external snap ring Figure 3 61 Removing external snap ring 2 Remove the wa...

Page 78: ...When the body is raised you will see a steel gland at the top of each cylinder section They must be inspected as well Figure 3 64 Cylinder gland To inspect the body hoist cylinder 1 Park the vehicle o...

Page 79: ...g Body Hoist Cylinder on page 70 Figure 3 65 Gap on cylinder section 6 Make sure that the gland safety pins are in place Figure 3 66 Safety pin 7 When the inspection is completed put back the safety p...

Page 80: ...the hydraulic hose and fitting Figure 3 67 Hydraulic fitting 3 Take off the 2 cylinder base pillow blocks by unscrewing the bolts that hold them in place Figure 3 68 Base pillow blocks 4 Remove all 4...

Page 81: ...cylinder carefully Save both pillow blocks for the replacement cylinder see Figure 3 69 9 Place the pillow blocks that were set aside on the pins of the new cylinder 10 Using a lifting device install...

Page 82: ...der see Figure 3 67 15 Lubricate all cylinder grease fittings Figure 3 71 Grease fittings 16 Start the truck and engage the pump 17 Slowly operate the body raise function Raise the body just enough to...

Page 83: ...General Maintenance 73 Figure 3 72 Rubber seal...

Page 84: ...e left side of the hopper If not already done lower the grabber before attempting to move the chute Figure 3 73 Chute inside the hopper 3 Turn OFF both the hydraulic pump and the engine 4 Lock out and...

Page 85: ...sed position Adjusting Chute Cylinder When performing inspection inside the hopper check if the chute rests on all rubber bumpers The cylinder that controls the chute can be adjusted so that the chute...

Page 86: ...n the adjustment required Turning it clockwise reduces the length of the cylinder rod and turning it counterclockwise extends the rod Make only half a turn at a time 9 Tighten back the cylinder locknu...

Page 87: ...nd Figure 3 78 show where the proximity limit switches are located on the truck Figure 3 77 Switches on the street side of the body Figure 3 78 Switches on the curb side of the body Warning Proximity...

Page 88: ...With a flathead screwdriver turn the adjusting screw located at the center of the nut until a click is heard 6 Tighten up the nut 7 Test the operation 8 If necessary repeat steps 1 through 7 Proximity...

Page 89: ...n of the packer An adjustment might be necessary to prevent cylinders from completely extending and retracting to the end of their strokes Two proximity switches control the packer range of motion The...

Page 90: ...cker reaches the correct position push the red emergency STOP button 4 Locate the packer extend proximity switch on the front right hand side body corner see Figure 3 79 5 Loosen both bolts see Figure...

Page 91: ...switches may no longer stop the packer creating a knocking noise when the packer reaches the end of a stroke bottoming out The packer may also not retract far enough to trigger the proximity switch pr...

Page 92: ...ome position or if the packer cylinders remain pressured up or abruptly bottom out while the packer is at the home position adjust the switch as follows To adjust the packer retract proximity switch 1...

Page 93: ...bolts 7 Engage the hydraulic pump and check for proper operation Make sure that the proximity switch detects the plate properly Ideally there should be a gap of approximately 3 16 inch between the pr...

Page 94: ...the cab as soon as the body is raised to a certain height from the chassis It can also be combined with different interlocks such as air suspension and tag axle interlocks Adjust this limit switch ac...

Page 95: ...he proximity switch occurs the cylinder having moved downward away from the switch1 This activates the backup alarm and a warning buzzer inside the cab This also turns on the TAILGATE UNLOCKED warning...

Page 96: ...he nuts on each side of the proximity switch bracket see Figure 3 88 Figure 3 88 Proximity switch 2 Adjust the proximity switch so that the switch can be triggered by the cylinder casing as the cylind...

Page 97: ...nterlock for dual tailgates Figure 3 89 Tailgate fully open proximity switch This switch is on the body street side near the tailgate hinge To adjust the tailgate fully open proximity switch 1 Fully o...

Page 98: ...nuts 4 Test the operation The proximity switch light should turn on when the target is detected if not repeat the adjustment procedure NOTE The automated arm must be extended in order to open the hopp...

Page 99: ...ge 12 4 Enter the hopper 5 Adjust the crusher panel up limit switch so that it is triggered when the crusher panel is in the up position 6 Exit the hopper and enter the cab 7 Start the truck and engag...

Page 100: ...er than about 3 mph 5 km h These limit switches are located behind each of the gripper fingers one for each finger To adjust the arm stowed limit switches 1 Park the vehicle on safe level ground 2 Ful...

Page 101: ...than the mid height sensor and activates the gripper automatic close function gripper auto close when arm is higher than the sensor The higher switch is used as a trigger for the camera auto switching...

Page 102: ...s Co Mingle Vehicles Co mingle vehicles have 2 tailgates that can move independently of one another Under each tailgate a hook is provided to lock the tailgate and seal the body Each hook needs to be...

Page 103: ...oth the pin and the cotter pin Fork must be positioned correctly to allow insertion of the pin 8 Raise the tailgate by about 3 feet 9 Tilt the safety prop toward the back of the body see Figure 2 12 1...

Page 104: ...proximity switch bracket Figure 3 94 Chute proximity switch 3 Push or pull the proximity switch until there is a gap between 3 16 and 1 4 between the plate and the switch 4 Tighten up both nuts 5 Move...

Page 105: ...ity switch bracket Figure 3 95 Right hand side proximity switch 3 Move the proximity switch laterally and perform tests until the chute stops at a position that will prevent garbage from falling betwe...

Page 106: ...orming these tests see Adjusting Chute Proximity Switch Gaps Co Mingle Vehicles on page 94 Fuel Filter Replacement Fuel filter needs to be replaced periodically according to manufacturer s specificati...

Page 107: ...ter installing the fuel filter move back the pipe to its original place 5 Clip the pipe on the collars IMPORTANT To prevent air from getting into the system make sure the fuel filter that you install...

Page 108: ...N Grit blasting 50 or sandblasting 80 for a 1 4 to 2 4 mil deep profile PRIMARY COAT Dupont Black Urethane Primer 373p27678 to get a minimum thickness of 2 mils dry FINISHING COAT Dupont Emron Elite P...

Page 109: ...ated on the side of the vehicle for a complete list of lube locations and the frequency with which they should be greased Recommended Lubricants You will find below the recommended types of lubricants...

Page 110: ...s This will also optimize the oil change frequency Apply the following procedure to take oil samples on Labrie vehicles NOTE The procedure may differ from other laboratories sample kits Hydraulic Oil...

Page 111: ...il out of the coupler Use a small container to recuperate the oil that will come out Let the oil leak for a few seconds about half a cup In this operation the pump must be engaged Figure 4 2 Spring ba...

Page 112: ...probe on the coupler to fill the sample bottle Use an EMA coupler with M16 2 0 threads Figure 4 5 Installing probe on coupler 4 Fill the bottle to the level mark the pump must be engaged to do this Re...

Page 113: ...bottle 6 Put the seal cover over the bottle cap Figure 4 8 Sealing bottle 7 Fill in the identification form sticker and apply it on the sample bottle see Figure 4 9 Figure 4 9 Identification form sti...

Page 114: ...104 Lubrication Figure 4 10 Lube charts on vehicle right hand side...

Page 115: ...Lubrication 105 Figure 4 11 AUTOMIZER lubrication charts...

Page 116: ...106 Lubrication...

Page 117: ...the grease fittings on the lower tube rings see Figure 4 13 Figure 4 12 Grease areas Caution Never grease the side rails and the outside of rollers Sand and other abrasives stick to grease which may c...

Page 118: ...The body chassis hinges should be lubricated monthly Also check for cracks or corrosion Any crack must be reported and repaired by qualified personnel If necessary contact LabriePlus for technical sup...

Page 119: ...99 as per the lubrication schedule NOTE In co mingle units tailgate hooks must also be lubricated regularly Also inspect the welds around the hinges The proper working condition of the following comp...

Page 120: ...ng mechanism Figure 4 17 Cylinder retaining ring Figure 4 18 Tailgate hinges on standard and co mingle units Locking mechanism Tailgate locking pin Safety pin Grease fitting Cylinder retaining ring Gr...

Page 121: ...Lubrication 111 Figure 4 19 Tailgate hooks on co mingle units only Figure 4 20 Tailgate hinges on co mingle units only Grease fittings Grease fittings...

Page 122: ...112 Lubrication Hopper Door Lubrication Points Hopperdoor latch Hopper door hinges Hopperdoor latch...

Page 123: ...Lubrication 113 Packer Lubrication Points 1 Remote grease fittings for rear cylinder pins Rollergrease fitting...

Page 124: ...114 Lubrication Packer Lubrication Points 2 Grease fitting LH side front cylinder pin...

Page 125: ...Lubrication 115 Chute Lubrication Points Co Mingle Vehicles Pump Drive Shaft U Joint Grease fittings...

Page 126: ...116 Lubrication Sump Box Hinges Grease fittings...

Page 127: ...ses fittings pipes or any other ingress points from dirt that would eventually get into the oil Plug hoses that are not connected Inspect the hydraulic system at least once a month and adjust pressure...

Page 128: ...er and clean the strainer after the first 50 hours of use and then once a year The hydraulic fluid must be changed once a year Hydraulic fluid contamination will severely damage hydraulic components I...

Page 129: ...hoist and packer through the directional control valve see below It is capable of delivering a flow of 20 gallons per minute gpm at 700 rpm A dump valve located on the chassis see Figure 5 1 limits t...

Page 130: ...igure 5 2 Directional control valve Tailgate 4 ways 3 positions Packer 4 ways 3 positions Body hoist 3 ways 3 positions NOTE All sections are air actuated Electro hydraulic actuators are also availabl...

Page 131: ...movement of the arm Each section of this valve is actuated by an electric coil located under the valve Figure 5 3 Proportional valve Input output cover provided with main relief valve Crusher panel se...

Page 132: ...ut the Vehicle on page 12 If electrical problems occurred with the pump see Troubleshooting on page 171 Caution Very corrosive chemicals used to wash trucks may cause serious damage to the point where...

Page 133: ...he pump A To replace a front mounted hydraulic pump perform the following procedure 1 Disengage the pump and turn off the engine 2 Make sure the parking brake is applied and the vehicle is tagged out...

Page 134: ...he vehicle is built on 11 Attach the pump to a lifting device and remove both 5 8 bolts that hold the pump to the pump support 12 Remove the pump If need be disconnect the drive shaft from the pump an...

Page 135: ...125 13 b Remove all 4 retaining bolts that hold the mounting cap in place NOTE You may leave two retaining bolts partially unscrewed to facilitate rotation with a metallic bar 13 c Rotate the mounting...

Page 136: ...e picture NOTE Make sure pump does not come apart NOTE The cartridge will rotate with the housing IMPORTANT Do not pull on the mounting cap 13 d Put all 4 bolts back in place 13 e Check if the shaft r...

Page 137: ...ay leave two retaining bolts partially unscrewed to facilitate rotation with a metallic bar 13 h Rotate the front cap accordingly Rotation can be done by turning the front cap clockwise or counter clo...

Page 138: ...ing number sequence to avoid damaging the seals 14 Reinstall the drive shaft if it has been removed from the engine Before proceeding with the installation of the drive shaft apply the following proce...

Page 139: ...inclusively to reinstall the various components of the pump assembly 18 Tighten back the breather cap 19 Prime the new pump see Priming a New Pump on page 136 20 Put the front pump guard back on see F...

Page 140: ...s they were before uninstallation Make sure you do not invert them 8 Remove the suction block see Figure 5 6 and save it for the new pump Figure 5 8 Suction block 9 Disconnect the drive shaft by remov...

Page 141: ...mark the location where a hole must be drilled Use the yoke as a jig to determine where exactly the hole must be drilled then remove it NOTE The yoke must be fully engaged on the shaft before determi...

Page 142: ...valve see Figure 2 3 4 Loosen the breather cap on the hydraulic tank to depressurize the tank If tank is of the pressurized type 5 Disconnect the electric coil on the dump valve if equipped 6 Place a...

Page 143: ...the replacement pump must be positioned the same way as on the uninstalled pump If not proceed with changing the porting configuration of the new pump The replacement pump must be oriented in such a...

Page 144: ...ely to reinstall the various components of the pump assembly 15 Tighten back the breather cap 16 Prime the new pump see Priming a New Pump on page 136 NOTE Labrie Enviroquip Group strongly recommends...

Page 145: ...the drive shaft see illustration below 2 Place the yoke on the shaft as illustrated above The yoke must be fully engaged on the shaft with both holes aligned one hole over the other 3 Apply Loctite 2...

Page 146: ...agged out for maintenance purposes refer to Locking Out and Tagging Out the Vehicle on page 12 2 With the ball valve closed fill the suction line before installing it on the pump 3 Fill the pump housi...

Page 147: ...cle on page 12 2 Clean the strainer and replace the filter element inside the tank after the first 50 hours of service see Cleaning the Strainer on page 153 and Replacing Filter Elements on page 154 F...

Page 148: ...The illustration above shows the model of hydraulic oil tank most often installed on our trucks However other models exist and your truck may be equipped with one of these Filter Suction Breather cap...

Page 149: ...on the chassis Adjustment of vane pump relief valves must be done before adjusting the relief valve of the directional control valve The following pressure chart gives the proper adjustment pressure...

Page 150: ...gauge on the quick connect fitting located at the valve inlet cover 3 Start the engine and engage the hydraulic pump 4 Release the body vane pump relief To adjust the vane pump relief valve tighten t...

Page 151: ...Directional Control Valve To adjust the pressure 1 Start the engine and engage the hydraulic system 2 Install a 0 4000 psi pressure gauge on the quick connect coupler located on the hydraulic valve Fi...

Page 152: ...n of the electric valve see page 142 5 Set the pressure at idle to 2000 psi for a single axle or to 3000 psi for tandem chassis Adjusting the Utility Section Optional Electric Valve only To adjust the...

Page 153: ...nal Valve AUTOMIZER vehicles use an extra valve stack to control the arm the chute and the crusher panel if equipped This valve is of the proportional type meaning that the amount of flow coming out o...

Page 154: ...y residual hydraulic pressure in the system 4 Connect a 0 4000 psi gauge on the quick coupler located on the proportional valve Figure 5 22 Control lever and quick coupler 5 Start the engine and engag...

Page 155: ...ea using safety tape or barricades 2 Start the engine and engage the hydraulic system pump switch ON 3 Activate the chute manually with the control lever see Figure 5 24 until the cylinder reaches the...

Page 156: ...valve and it is equipped with a built in relief valve that allows gripper pressure adjustment To adjust the 96 gallon gripper built in relief valve 1 Lock out and tag out the vehicle see Locking Out a...

Page 157: ...the gripper close side of the valve section to 1200 psi1 screw or unscrew depending on the gauge readout 7 c Open the gripper and maintain the lever in place 7 d Adjust the pressure of the gripper ope...

Page 158: ...ion in Neutral start the engine and engage the hydraulic pump 7 Adjust the gripper pressure 7 a Close the gripper using the corresponding lever on the valve 7 b While maintaining the lever in place ad...

Page 159: ...nd move the manual levers back and forth to release any residual pressure 4 Make sure that all hoses are tight and not leaking 5 Connect a pressure gauge 0 4000 psi to the quick connect coupler on the...

Page 160: ...150 Hydraulic System Figure 5 29 External relief valve adjustment screw External relief valve adjustment screw...

Page 161: ...A gauge and a pressure regulator are installed to adjust air pressure inside the tank This gauge is located inside the frame rail on the curbside of the chassis it can be accessed only when the body...

Page 162: ...pare the vehicle accordingly 1 a Apply the parking brake 1 b Start the engine 1 c Engage the hydraulic pump 1 d Retract all cylinders packer crusher panel tailgate etc 1 e Raise the body and install t...

Page 163: ...n plug Cleaning the Strainer To clean the strainer 1 Empty the hydraulic tank see Emptying the Hydraulic Tank on page 152 2 Remove the hose clamp from the suction hose 3 Slide the hose over the pipe u...

Page 164: ...irst 50 hours of operation of the vehicle Change the element twice a year afterwards see AUTOMIZER Preventive Maintenance Chart on page 22 The filter restriction indicator will indicate when the engin...

Page 165: ...bucket to collect the oil that will come out of the filter housing two gallons of oil 3 Remove the filter head cover bolts four This in tank return filter system contains a check valve that closes whe...

Page 166: ...e interior with a dry clean cloth 4 Change the return filter element see Replacing Filter Elements on page 154 5 Using a filtering screen refill the tank with high quality oil until it reaches the mar...

Page 167: ...ate and inspect all cylinders mounting points pins retaining bolts etc Detecting Cylinder Internal Leaks An internal leak is caused by a damaged seal inside the hydraulic cylinder see 1 on Figure 5 37...

Page 168: ...roximity switch This prevents the packer from returning to its initial position 6 Disconnect and plug hose A 7 Engage the hydraulic pump 8 Push the green button and see if oil is leaking from port A t...

Page 169: ...Control panel Electronic controllers Harnesses Valve controls Limit proximity switches Sensors ex temperature pressure sensors Electrical Schematics Electrical schematics are provided as part of the...

Page 170: ...of this electronic controller enables mechanics to perform troubleshooting which facilitates the debugging process Labrie Enviroquip Group offers training on this technology To know more about electro...

Page 171: ...m stowed limit switches 2 Arm mid height limit switches 2 Crusher panel limit switch Body raised limit switch For information on limit and proximity switch adjustment go to page 78 and the following F...

Page 172: ...ip Group The following table provides a description of the circuit breakers located in the control box inside the truck cab Important Never hold down the reset button when the reset operation fails Th...

Page 173: ...n NOTE Before searching for parts identify the type of cab of your unit cab over or conventional The mounting of some components for the body depends on the type of cab configuration The main hydrauli...

Page 174: ...hicle especially under cold weather conditions you must maintain the air system regularly drain the air tanks the water trap and the air filter at the end of every working day The air filter element m...

Page 175: ...he Vehicle on page 12 2 Using a rag unscrew the drain cocks This will bleed all the water from the water trap and the air filter bowl located on the chassis This water trap helps keep residual moistur...

Page 176: ...NT Pay particular attention to the dryer cartridge On this type of equipment the compressor works all the time frequent use of the brake system As a result lots of moisture is injected into the air sy...

Page 177: ...iplex module then operates the air solenoid valve inside the air control box with a 12 volt signal one signal for packer extend one signal for packer retract When receiving the 12 volt signal extend o...

Page 178: ...hol evaporator These devices are used to reduce water in the air system preventing corrosion or freezing of the air components in cold weather Maintenance on the air dryer and or alcohol evaporator is...

Page 179: ...ematic HYDRAULIC MAIN VALVE PRIMARY TANK 65 psi SUPPLY CHUTE LOCK OPTION TAILGATE OPEN TAILGATE CLOSE RETURN PACK BODY LOWER BODY RAISE SPARE OUT SPARE SPARE SPARE IN TAILGATE PACKER BODY LIFTING PRES...

Page 180: ...170 Pneumatic System...

Page 181: ...that all safety procedures are applied The lockout tagout procedure outlined on page 12 is mandatory See Troubleshooting Guide on page 174 to resolve commonly seen problems or contact LabriePlus to ta...

Page 182: ...eter or VOM Volt Ohm Milliammeter NOTE The ammeter must support at least 10 amps Figure 8 2 Jumper wire with alligator clips Figure 8 3 Two oil pressure gauges 0 4000 psi 0 4000 psi pressure gauge Par...

Page 183: ...Troubleshooting 173 Figure 8 4 Ball end hex wrench metric and SAE...

Page 184: ...Add oil to the required level See Replacing Hydraulic Oil on page 156 Hydraulic pressure too low or too high See Adjusting Pressure and Relief Valves on page 139 Not the proper grade of oil that is to...

Page 185: ...rn filter Fill with clean oil See Cleaning the Strainer on page 153 Replacing Filter Elements on page 154 and Replacing Hydraulic Oil on page 156 Take an oil sample for further analysis see Testing Hy...

Page 186: ...sliding shoes as indicated in Sliding Shoes on page 48 Tailgate is unlocking or lowering by itself Dirty or defective velocity fuse Clean or replace the velocity fuse See Tailgate Locking Mechanism on...

Page 187: ...ge 84 Proximity switch Check the proximity switch with a multimeter or VOM for proper operation ON OFF or click Faulty harness Check for continuity on the electrical harness that is connected to the p...

Page 188: ...ng in Neutral will affect pump operation once the pump is engaged Pump Cavitation Cavitation is defined as the formation of air pockets in a moving fluid Air in the hydraulic oil causes excessive wear...

Page 189: ...uge Packer Air System If the packer does not complete a full cycle the problem may be related to the air system To fix the problem 1 Apply all safety measures to ensure safety around the vehicle at al...

Page 190: ...xiting from the quick exhausts valves close to the packer valve section actuator If not check that air lines are not blocked or bent and if necessary replace the quick exhaust valves Figure 8 7 Inject...

Page 191: ...lding up in the hydraulic system that is when the packer is working The pressure burst goes to the holding valve into port D1 and then out to the cylinder by port U1 see Figure 8 9 This will keep the...

Page 192: ...182 Troubleshooting Figure 8 9 Tailgate locking mechanism...

Page 193: ...cycle button to start the packer and pressurize the system Gauge 1 should always indicate 0 psi and gauge 2 should indicate a sudden burst of pressure from 0 psi to 3000 psi each time the packer reac...

Page 194: ...your truck based on the body serial number is found in the truck s cab HYDRAULIC MAIN VALVE PRIMARY TANK 65 psi SUPPLY CHUTE LOCK OPTION TAILGATE OPEN TAILGATE CLOSE RETURN PACK BODY LOWER BODY RAISE...

Page 195: ...ON OU COMMUNICATION DE CE DOCUMENT SANS LE CONSENTEMENT CRIT DE GROUPE ENVIROQUIP LABRIE INC EST STRICTEMENT INTERDITE REV PAR BY APPR DATE Hydraulic schematic AU pneumatic valve crusher panel RH HD w...

Page 196: ...ST STRICTEMENT INTERDITE REV PAR BY APPR DATE Hydraulic schematic AU pneumatic valve packer regen crusher panel RH HD 300 gal dual pressure R Allard 11 10 2014 2 843236 AUTOMIZER 11 10 2014 R Allard 1...

Page 197: ...of electronic controllers This whole system has been designed to help you operate your unit in an efficient and easy way Labrie s multiplexed system is reliable and safe and it requires less wiring ha...

Page 198: ...monitor and the master control module Refer this problem to the maintenance personnel NOTE The monitor display works even if the engine is not started All it needs is electrical power However if you s...

Page 199: ...e Time and Date indicator go to the Main Menu and choose Time Adjust Hydraulic Oil Temperature Indicator optional This optional indicator when provided shows you the current hydraulic oil temperature...

Page 200: ...ed Engage Pump Buzzer Arm Not Stow Retract Arm to Stowed Position Buzzer Body Raised Lower Body Buzzer TailGate Unlocked Lock Tailgate Chute Arm Too High Lower Arm Chute Crusher Not Up Raise Crusher C...

Page 201: ...per Door Open Close Hopper Door Pump Not Started Main Air Pressure Let the Air Build Up to Required Pressure Pump Not Started RPM Too High Lower Engine Speed Below 900 RPM Pump Stop Main Air Pressure...

Page 202: ...Pump J1 CloseGripper Switch ON Release J1 CloseGripper Switch prior to Engaging Pump Pump J1 Deadman Switch ON Release J1 Deadman Switch prior to Engaging Pump Pump J1 OpenGripper Switch ON Release J1...

Page 203: ...p Trans Not OK Refer to Maintenance Personnel or LabriePlus Raise Body Air Susp Not Down Lower Air Suspension Raise Body Arm Not Stow Retract Arm to Stowed Position Raise Body Tag Not Down Lower Tag R...

Page 204: ...Level 2 Refer to LabriePlus CAN Error Level 3 Refer to LabriePlus Comm Lost with Master Refer to Maintenance Personnel or LabriePlus Module 11 is disconnected Refer to Maintenance Personnel or LabrieP...

Page 205: ...problem stems from the highlighted or active cause One possible cause is highlighted at a time What is shown in light and small print in the lower part of the screen are causes that have already been...

Page 206: ...isplay of Labrie s multiplex system is user friendly Say you want to change the multicycle settings of the packer All you have to do is select MENU from the Main Page by pressing the corresponding but...

Page 207: ...to the electronic controller The controller then counts the amount of cycles that the packer does and will stop the packer after the preset amount of cycles has been reached I O Status In this section...

Page 208: ...tangles represents input elements which in turn correspond to a particular function of the truck For example if you select rectangle I00 a short description appears in the lower part of the screen whi...

Page 209: ...fic function of the truck However for a given number the related function may vary from truck to truck Press Esc to return to the preceding page Press the Force button to display the Force page NOTE T...

Page 210: ...or 15 seconds Then an OK prompt appears on the lower right end corner of the screen IMPORTANT It is very important to read this message entirely before accessing the next page Figure 9 12 Warning mess...

Page 211: ...ectangle means there is an open circuit A white bordered rectangle means that this rectangle is selected Use the directional arrows to select a specific rectangle or function When a rectangle is selec...

Page 212: ...ess a joystick button the corresponding button on the monitor will turn green If nothing happens there may be a communication problem between the joystick and the master control module Refer to the ma...

Page 213: ...ftware version page With the information on this page it is possible for the operator or maintenance personnel to determine the electric schematic number pertaining to a vehicle Looking at Figure 9 17...

Page 214: ...he truck is in reverse or when the body is being hoisted Figure 9 18 Buzzer with red light in its center Plugging a Computer The control panel has a computer plug on it that can be used to connect a c...

Page 215: ...c system is engaged Labrie s multiplex system monitors all safety and operating functions to insure they work at their best This system transfers data to and from Allison transmission ECU and Cummins...

Page 216: ...r chassis may have different programming packages Refer to your local Allison dealer for original programming packages For further information regarding ECU programming contact LabriePlus The followin...

Page 217: ...ON ground signal 143 PTO enable Active when the PTO switch is ON 12 V signal 142 Auto neutral pack input Active when the brakes are used and when the PTO and auto neutral switches are ON ground signal...

Page 218: ...s For more information call LabriePlus Table 9 Cummins engine parameters Menu Features Parameters Parameter Name Value Adjustable low idle speed Low idle speed adjustment switch Low idle speed Disable...

Page 219: ...ion of the arm looking for leaks cracks or premature wear of the moving parts For detailed information on greasing points see Lubrication on page 99 To perform the daily inspection 1 Start the engine...

Page 220: ...210 Lifting Arms Figure 10 1 Mounting bolts Figure 10 2 Rollers and bearings Figure 10 3 Bolt locks Bearings Rollers...

Page 221: ...Lifting Arms 211 Figure 10 4 Right Hand gripper Figure 10 5 Hoses and connections 5 Check for loose nuts and bolts...

Page 222: ...preset height preventing collision between the gripper and the hopper wall Also if the vehicle is parked for a long period of time with the gripper inside the hopper the gripper cylinder may leak pre...

Page 223: ...stem To inspect the system 1 Make sure that the vehicle is parked on safe level ground 2 Secure the area around the path of the arm with barrier tape or barricades 3 Start the engine and engage the hy...

Page 224: ...To adjust the auto closing system 1 Make sure that the vehicle is parked on safe level ground 2 Secure the area around the path of the arm with barrier tape or barricades 3 Start the engine and engag...

Page 225: ...return to its home position no matter where it was in the hopper This is to prevent refuse from falling directly on the packer However there is one exception to this if after 3 consecutive packing cyc...

Page 226: ...Figure 10 11 This measurement should be as close as possible to the targeted value shown in the table below next page but more importantly it should be the same on each side Figure 10 11 Target measu...

Page 227: ...adjustment nut to the target torque value 3 f Lower the gripper to verify that the link arms are in contact with the bumpers and that the target values are still right Operate the Right HandTM arm or...

Page 228: ...ing a hydraulic cylinder a holding valve or when opening the Right Hand hydraulic circuit air may enter the hoses located between the proportional valve and the arm cylinder Because air cannot be comp...

Page 229: ...safety around the vehicle at all times and make sure to have enough room to fully operate the arm and gripper 2 Make sure that the parking brake is applied 3 Park the arm against the hopper wall move...

Page 230: ...out tighten the fitting Keep the hydraulic function engaged until the fitting is tightened 5 Loosen do not disconnect fitting number 6 6 Fully retract the lifting cylinder of the arm 7 Repeat step num...

Page 231: ...upler for pressure gauge 5 Start the engine and engage the hydraulic pump 6 Using the pressure gauge on the automated arm valve adjust the opening pressure of each of the gripper closing movement cart...

Page 232: ...ure NOTE There is a holding valve mounted on the in out cylinder standard and HD To adjust the in out holding valve pressure 1 Apply all safety measures to ensure safety around the vehicle at all time...

Page 233: ...ockwise to increase pressure or clockwise to reduce pressure NOTE This pressure value of 650 psi is a reference value it could be more or less It all depends on how much pressure the in out holding va...

Page 234: ...all safety measures to ensure safety around the vehicle at all times 2 Make sure that the parking brake is applied 3 Locate the holding valve on the up down cylinder see Figure 10 20 4 Connect a pres...

Page 235: ...on No adjustments are required for these functions Only gripper close requires proper adjustment to prevent crushing roller carts See Adjusting Arm Speed on page 226 to adjust the gripper load sense r...

Page 236: ...d tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 12 Gripper down 2000 96 gallons std HD 2700 300 gallons HD 2 5 all models Gripper close 1200 96 gallons std HD 1200 1800 300 g...

Page 237: ...e proper function boom extension retraction gripper open close 5 Move the lever to evaluate arm speed then release it 6 Loosen the locknut 7 Turn the restrictor adjustment screw only one eighth 1 8th...

Page 238: ...les of lubrication charts and hydraulic schematics for the RIGHT HAND lifting arm Please note that these documents are for reference purposes only The lubrication charts are based on a 40 hour a week...

Page 239: ...Lifting Arms 229 Figure 10 23 Arm w 96 gallon gripper...

Page 240: ...OQUIP GROUP INC IS STRICTLY PROHIBITED TOUS DROITS R SERV S GROUPE ENVIROQUIP LABRIE INC TOUTE REPRODUCTION ADAPTATION OU COMMUNICATION DE CE DOCUMENT SANS LE CONSENTEMENT CRIT DE GROUPE ENVIROQUIP LA...

Page 241: ...OITS R SERV S GROUPE ENVIROQUIP LABRIE INC TOUTE REPRODUCTION ADAPTATION OU COMMUNICATION DE CE DOCUMENT SANS LE CONSENTEMENT CRIT DE GROUPE ENVIROQUIP LABRIE INC EST STRICTEMENT INTERDITE REV PAR BY...

Page 242: ...T SANS LE CONSENTEMENT CRIT DE GROUPE ENVIROQUIP LABRIE INC EST STRICTEMENT INTERDITE REV PAR BY APPR DATE Hydraulic schematic AU pneumatic valve packer regen crusher panel RH HD 300 gal dual pressure...

Page 243: ...418 831 7561 Mailing Address Mailing Address P O Box 2785 175A Route Marie Victorin Oshkosh WI 54903 2785 Levis QC G7A 2T3 Parts and Warranty Parts and Warranty During business hours During business h...

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