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Summary of Contents for EXPERT

Page 1: ...EXPERT TM MAINTENANCE MANUAL...

Page 2: ......

Page 3: ...EXPERT MAINTENANCE MANUAL...

Page 4: ...on 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 care...

Page 5: ...ties 10 Employee Responsibilities 11 Do s 11 Don ts 11 General Precautions 12 Welding 14 Fire 14 Locking Out and Tagging Out the Vehicle 14 Prior to Start Up 15 Shutting Down the Vehicle 17 Body Safet...

Page 6: ...ding Shoe Replacement 128 Replacing Sliding Shoes 131 Finishing Up Replacing Sliding Shoes and Floor Guides 134 Floor Guides 135 Upper Wear Pads 135 Preparing for Upper Wear Pad Replacement 136 Replac...

Page 7: ...ple 238 Lubrication Charts 240 Specific Components To Be Lubricated 244 Crusher Panel optional 244 Body Hinges 245 Tailgate Locking Mechanism and Hinges 245 Tailgate Hooks Co Mingle Units 248 Hopper D...

Page 8: ...Schematic 1 305 Schematic 2 306 Schematic 3 307 Schematic 4 308 Electrical System 311 How the Electrical System Works 311 Electrical Schematics 311 Control Panel 311 Adjusting and Repairing Electrical...

Page 9: ...g Valve 386 Adjusting Arm In Out Holding Valve Pressure 387 Gripper Auto Closing System 388 Testing the Auto Closing System 389 Cylinder Cushion Adjustment 390 Auto Packing 392 Adjusting the Arm Vane...

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

Page 11: ...stems For these options refer to the appropriate manufacturer s service manual Operating the EXPERT For procedures related to the operation of the EXPERT please refer to the EXPERT Operator s Manual A...

Page 12: ...afer faster and easier to load The hopper can be accessed from both curbside and streetside making collection in alleys and one way streets quick and productive Figure 1 1 Drop frame chassis The EXPER...

Page 13: ...sses to operate It can also monitor various function status of the body and display warning and caution messages Through its monitor see Figure 1 2 Labrie s multiplexed system informs you of any malfu...

Page 14: ...you have a problem with a Labrie unit you should contact your Labrie authorized dealer first They should be able to provide you with the proper help that you need whether it is for parts or technical...

Page 15: ...ting Arm Next to the packer the lifting arm on an Automated Side Loader is the piece of equipment with the most amount of movement throughout the course of a route Due to this the arm has the shortest...

Page 16: ...roximity limit switches see Proximity and Limit Switches on page 200 General Wear and Damage 1 Leaks Verify that they are not any leaking hydraulic cylinders hoses tubes valves or pumps Leaks in the h...

Page 17: ...torin Levis QC G7A 2T3 Toll Free 1 877 831 8250 Telephone 1 418 831 8250 Service Fax 1 418 831 1673 Parts Fax 1 418 831 7561 Parts and warranty During business hours 8 00 AM to 5 00 PM Eastern Standar...

Page 18: ...8 Introduction...

Page 19: ...this manual and on the decals affixed to the vehicle Danger Indicates a hazardous situation which if not avoided will result in serious injury or death Warning Indicates a hazardous situation which i...

Page 20: ...rmation 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...

Page 21: ...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 t...

Page 22: ...y and or to 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 th...

Page 23: ...y away from the arm may result in personal injury or even death Never under any circumstances maintenance or otherwise stand underneath a loaded body Caution Maintenance and repairs carried out on thi...

Page 24: ...eral maintenance being done on the vehicle whether on the road or at the shop it is the employer s responsibility to establish and see to the application of a proper lockout and tagout procedure To lo...

Page 25: ...d off Figure 2 2 Master switch 7 Put an OFF SERVICE tag on the driver s wheel and on the front windshield 8 Use safety props to block any system that could move by gravity open tailgate raised body et...

Page 26: ...r pressure to build up to at least 70 PSI Figure 2 4 Air pressure indicator IMPORTANT Do not operate or move the vehicle until air pressure has reached 70 PSI 4 Engage the hydraulic system by turning...

Page 27: ...2 Make sure that all moving parts are in their home position tailgate arm body crusher panel packer etc 3 Turn OFF in sequence the hydraulic pump the electrical system the engine and if installed the...

Page 28: ...t the body safety prop 1 Make sure that there is enough clearance above the body to raise it safely 2 Start the engine and engage the hydraulic pump see Figure 2 5 3 With the Body Up switch on the in...

Page 29: ...ut the vehicle see Locking Out and Tagging Out the Vehicle on page 14 You can now work safely underneath the body Putting the Body Safety Prop Back in Place To put the body safety prop back in place 1...

Page 30: ...It is mandatory to set the safety prop every time the tailgate is open for such purposes NOTE Co mingle vehicles have 2 tailgate safety props IMPORTANT Make sure the body is empty before setting safet...

Page 31: ...in cab control panel see Figure 2 12 raise the tailgate about 3 feet enough to lift and rotate the safety prop Figure 2 12 Tailgate Up Down switches 6 Pull the safety prop upward and set it down see F...

Page 32: ...s not resting properly on the safety prop see Tailgate Safety Prop Adjustment on page 26 to correct the problem Putting theTailgate Safety Prop Back in Place Standard Units To put the tailgate safety...

Page 33: ...nel see Figure 2 12 close the tailgate completely The TAILGATE OPEN light indicator should turn OFF 7 Put both safety pins back in place Setting theTailgate Safety Props Co Mingle Units The tailgate s...

Page 34: ...its always open the tailgate to which the full ICC bumper is attached before opening the other tailgate For example if the ICC bumper is installed on the left hand side tailgate see top illustration o...

Page 35: ...TE If the tailgate is not resting properly on the safety prop see Tailgate Safety Prop Adjustment on page 26 to correct the problem Putting theTailgate Safety Prop Back in Place Co Mingle Units To put...

Page 36: ...ts Tailgate Safety Prop Adjustment Sometimes the tailgate safety prop may need to be adjusted for the tailgate pin to rest perfectly at the center of the prop head pin must be as centered as possible...

Page 37: ...ings are safe at all times Clean the contact surface between the body and the chassis Labrie Enviroquip Group recommends cleaning the chassis after every unloading Remove any stacked garbage in the ho...

Page 38: ...tion Chart on side of the truck X See page 250 Wiring System Check for damaged harnesses and or bad connections X See page 311 Battery Cables Ensure cables are not coming in contact with an area that...

Page 39: ...a year See page 280 Check pressure X See page 288 Hopper area Clean traps on each side X See page 30 Tilt down the floating panel and clean dirt under or behind the packer if no arm is installed X See...

Page 40: ...rusher panel glass compartment automated arm etc A Units with a HELPING HAND arm NOTE For units with no HELPING HAND arm go to page 35 To clean the hopper of an EXPERT vehicle equipped with a HELPING...

Page 41: ...pe unit place it on the left hand side of the hopper NOTE When a truck is equipped with a dualchute the operator has to place both sections of the chute on the left hand side of the hopper To know how...

Page 42: ...4 Keep this switch pressed until the panel is raised completely Figure 3 4 Crusher Panel Up switch on in cab control panel 7 Using the arm joystick or the auxiliary arm controls below the right hand s...

Page 43: ...vehicle see Locking Out and Tagging Out the Vehicle on page 14 10 Open the clean out trap door on both sides of the hopper 11 Clean all accumulated dirt under the cylinders and inside the side rails s...

Page 44: ...g the hydraulic system 18 Fully retract the packer 19 Park the automated arm inside the hopper 20 Close the hopper doors Caution Avoid spraying pressurized water directly on connectors and battery fus...

Page 45: ...see Figure 3 2 Both switches must be blue lighted 5 If the truck is equipped with a chute as in a co mingle type unit place it on the left hand side of the hopper NOTE When a truck is equipped with a...

Page 46: ...ors 10 Slowly open the clean out trap door on both sides of the hopper NOTE Keep the clean out trap doors open while cleaning the hopper Figure 3 11 Clean out trap door 11 Clean all accumulated dirt u...

Page 47: ...and hoses for leaks as well as bolts for proper tightness 15 Climb inside the hopper using a small step ladder 16 Fully open both floating panels see Figure 3 12 To open panel just pull down the slidi...

Page 48: ...area with pressurized water 23 Close both clean out trap doors Danger Always use the handle to hold the floating panel Holding the floating panel by its edge will cause severe injuries to hands and o...

Page 49: ...Lubrication on page 235 Any problem found on the packing system must be corrected immediately For technical support contact your distributor Preparing Packer for Inspection To prepare the packer for i...

Page 50: ...out dirt every time the packer goes back and forth Replace this scraper before it is worn down to the top of its holding screws see Lower Wear Pad on page 165 3 Visually inspect both packer side rails...

Page 51: ...king internally resulting in insufficient packing power For more information see Detecting Cylinder Internal Leaks on page 285 B Inspecting Packer Standard Units W O Loading Arm To inspect the packer...

Page 52: ...r shows vertical or horizontal movement wear pads need to be replaced Extensive wear on the hopper floor also suggests that sliding shoes require immediate replacement see Sliding Shoes on page 127 7...

Page 53: ...ay cause the cylinder to leak oil Should you find oil leaks the cylinder must be replaced immediately NOTE During the warranty period do not attempt to change cylinder seals and packing 6 Check the pa...

Page 54: ...top of its holding screws see Lower Wear Pad on page 165 3 Visually inspect both packer side rails and rollers see Figure 3 20 If signs of premature wear are apparent replace the faulty parts see Slid...

Page 55: ...sure that hydraulic cylinders are not leaking internally resulting in insufficient packing power For more information see Detecting Cylinder Internal Leaks on page 285 E Inspecting Packer Dual HELPING...

Page 56: ...page 285 Preparing Packer for Removal NOTE Preparing packer for removal is the first step of a five part process of replacing a packer The others are the following Accessing Packer Disconnecting Pack...

Page 57: ...oceeding with the removal of the packer panel 1 Start the engine and engage the hydraulic pump 2 Fully raise the crusher panel if installed 3 Fully extend the packer then push the red emergency STOP b...

Page 58: ...he automated arm to get better access to the hopper area 4 Fully retract the packer by pressing the yellow button on the packer control station 5 Rotate the chute so that its upper edge is in the midd...

Page 59: ...ockout feature prevents a crusher panel from hitting the chute 3 Fully retract the packer by pressing the yellow button on the packer control station 4 Rotate the chute so that its upper edge is in th...

Page 60: ...Arm NOTE For standard units w o loading arm go to page 52 for co mingle units w loading arm go to page 55 for co mingle units w o loading arm go to page 62 for dual Helping Hand units go to page 70 On...

Page 61: ...the 4 bolts that hold the panel Figure 3 26 Deflector panel 3 Remove the transversal beam by taking out the 4 bolts 2 on each side that retain it Figure 3 27 Transversal beam 4 Remove the upper part o...

Page 62: ...W Loading Arm on page 73 B Accessing Packer Standard Units W O Loading Arm Once you have prepared the packer for removal you need to gain access to the packer To do so 1 Remove the anti spill guards...

Page 63: ...floating panel a open the panel b slide it to the right and c lift it up see Figure 3 31 To remove the left hand side floating panel a open the panel b slide it to the left and c lift it up Figure 3 3...

Page 64: ...move the upper part of both side rails one on each side of the hopper 6 bolts are to be taken out to remove this section of the side rail see Figure 3 33 Figure 3 33 Bolts to be taken out to remove up...

Page 65: ...C Accessing Packer Co Mingle Units W Loading Arm Once you have prepared the packer for removal you need to gain access to the packer To do so 1 Remove the anti spill guards located on each side of the...

Page 66: ...hese bolts are to be taken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must also be taken out see Figure 3 38 Figure 3 36 Hopper divider Figure 3 37 Bolts holding...

Page 67: ...the in cab control panel Figure 3 40 Chute NOTE The EXPERT may be equipped with a dual split crusher panel or a single split crusher panel which would be located either on the right hand side or on th...

Page 68: ...or also needs to be removed see Figure 3 42 Once the protective covers are removed you will be able to access the area where the chute cylinder and the rear end section of the chute shaft are Figure 3...

Page 69: ...button c Turn OFF the hydraulic pump and stop the engine d Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 4 j Remove the plate under the pillow block see Figur...

Page 70: ...ted arm assembly to free the chute shaft front end Two bolts need to be taken out to remove the flange bearing see Figure 3 45 The chute is now free to be pulled out Figure 3 45 Flange bearing 5 Remov...

Page 71: ...the arm cover open Figure 3 46 Deflector panel 6 Remove the transversal beam by taking out the 4 bolts 2 on each side that retain it Figure 3 47 Transversal beam 7 Remove the upper part of both side r...

Page 72: ...its W Loading Arm on page 76 D Accessing Packer Co Mingle Units W O Loading Arm Once you have prepared the packer for removal you need to gain access to the packer To do so 1 Remove the anti spill gua...

Page 73: ...divider see Figure 3 51 There are 6 bolts that hold the divider to the packer panel These bolts are to be taken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must a...

Page 74: ...he chute see Figure 3 55 To perform this task apply the following steps 4 a Use a suitable lifting device e g sling or cable to hold the chute in place 4 b Start the truck and engage the hydraulic pum...

Page 75: ...Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 4 f Remove both protective panels that are fixed to the rear hopper wall see Figure 3 56 Figure 3 56 Protective...

Page 76: ...linder rod to the chute lever see Figure 3 58 NOTE Take care not to cause misalignment of nearby both limit switches when disconnecting the chute operating cylinder 4 i If needed retract the chute ope...

Page 77: ...nscrew the greasing hose from its attachment on the pillow block see Figure 3 58 4 l Remove the pillow block Two bolts located under the pillow block hold this part in place see Figure 3 59 Figure 3 5...

Page 78: ...side floating panel a open the panel b slide it to the left and c lift it up Figure 3 61 Removing RHS floating panel 4 n Remove the chute flange bearing see Figure 3 62 by taking out the 2 bolts that...

Page 79: ...ic pump and the engine 8 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 9 Remove the transversal beam see Figure 3 63 Figure 3 63 Floating panel assembly Dange...

Page 80: ...id stroke position 13 Turn OFF the hydraulic pump and the engine 14 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 NEXT DISCONNECTING PACKER See D Disconnectin...

Page 81: ...lding anti spill guard in place 2 Remove the deflector panel Use a inch wrench to remove the 4 bolts that hold the panel Figure 3 67 Deflector panel 3 Remove the transversal beam by taking out the 4 b...

Page 82: ...il 5 Start the engine and engage the hydraulic pump 6 Extend packer to mid stroke position 7 Turn OFF the hydraulic pump and the engine 8 Lock out and tag out the vehicle see Locking Out and Tagging O...

Page 83: ...the packer you must now disconnect it To do so 1 Remove the access cover on the packer panel to reach the cylinder pin Take out the 2 bolts that hold the access cover in see Figure 3 70 Figure 3 70 A...

Page 84: ...aulic pump and the engine 8 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 NEXT REMOVING PACKER PANEL See A Removing Packer Panel Standard Units W Loading Arm...

Page 85: ...ylinder pin 3 Remove the cylinder pin Take 2 5 8 18 NF 9 inch long fine threaded bolts and screw them in the pin head holes Figure 3 76 5 8 18 NF fine threaded bolts Tighten the bolts until the cylind...

Page 86: ...e 14 NEXT REMOVING PACKER PANEL See B Removing Packer Panel Standard Units W O Loading Arm on page 83 C Disconnecting Packer Co Mingle Units W Loading Arm Once you have gained access to the packer you...

Page 87: ...ure 3 80 5 8 18 NF fine threaded bolts Tighten the bolts until the cylinder pin is completely removed Figure 3 81 Cylinder pin removed 4 Exit the hopper 5 Start the engine and engage the hydraulic pum...

Page 88: ...ou must now disconnect it To do so 1 Remove the access cover on the packer panel to reach the cylinder pin Take out the 2 bolts that hold the access cover in see Figure 3 82 Figure 3 82 Access cover 2...

Page 89: ...draulic pump and the engine 8 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 NEXT REMOVING PACKER PANEL See D Removing Packer Panel Co Mingle Units W O Loading...

Page 90: ...ylinder pin 3 Remove the cylinder pin Take 2 5 8 18 NF 9 inch long fine threaded bolts and screw them in the pin head holes Figure 3 88 5 8 18 NF fine threaded bolts Tighten the bolts until the cylind...

Page 91: ...oving Packer Panel Dual HELPING HAND Units on page 87 Removing Packer Panel A Removing Packer Panel Standard Units W Loading Arm NOTE For standard units w o loading arm go to page 83 for co mingle uni...

Page 92: ...removing the side panel Figure 3 91 Side panel 3 Remove the lower part of both side rails one on each side of the hopper by using a 5 16 inch Allen wrench and a 3 4 inch wrench see Figure 3 194 There...

Page 93: ...he hopper NEXT INSTALLING NEW PACKER See A Installing New Packer Standard Units W Loading Arm on page 89 B Removing Packer Panel Standard Units W O Loading Arm Once the packer has been prepared access...

Page 94: ...er assemblies from the follower panels See Rollers on page 190 4 Fold the follower panels over the packer 5 Weld the follower panels to the packer 6 Attach the packer to a lifting device fork lift etc...

Page 95: ...irst toremove it before removing the side panel 3 Remove the lower part of both side rails one on each side of the hopper by using a 5 16 inch Allen wrench and a 3 4 inch wrench see Figure 3 194 There...

Page 96: ...e hopper NEXT INSTALLING NEW PACKER See C Installing New Packer Co Mingle Units W Loading Arm on page 91 D Removing Packer Panel Co Mingle Units W O Loading Arm Once the packer has been prepared acces...

Page 97: ...ies from the follower panels See Rollers on page 190 4 Fold the follower panels over the packer 5 Weld the follower panels to the packer 6 Attach the packer to a lifting device fork lift etc and lift...

Page 98: ...removing the side panel Figure 3 101 Side panel 3 Remove the lower part of both side rails one on each side of the hopper by using a 5 16 inch Allen wrench and a 3 4 inch wrench see Figure 3 194 Ther...

Page 99: ...ard units w o loading arm go to page 90 for co mingle units w loading arm go to page 91 for co mingle units w o loading arm go to page 92 for dual Helping Hand units go to page 93 To install a new pac...

Page 100: ...er operation of the packer NOTE If the packer moves vertically by more than 3 16 the upper wear pads must be replaced or adjusted see Upper Wear Pads on page 135 and Replacing and Adjusting Upper Wear...

Page 101: ...proper operation of the packer NOTE If the packer moves vertically by more than 3 16 the upper wear pads must be replaced or adjusted see Upper Wear Pads on page 135 and Replacing and Adjusting Upper...

Page 102: ...per operation of the packer NOTE If the packer moves vertically by more than 3 16 the upper wear pads must be replaced or adjusted see Upper Wear Pads on page 135 and Replacing and Adjusting Upper Wea...

Page 103: ...for proper operation of the packer NOTE If the packer moves vertically by more than 3 16 the upper wear pads must be replaced or adjusted see Upper Wear Pads on page 135 and Replacing and Adjusting Up...

Page 104: ...he upper wear pads must be replaced or adjusted see Upper Wear Pads on page 135 and Replacing and Adjusting Upper Wear Pads on page 163 Chute Co MingleVehicles Only A mobile chute located in the middl...

Page 105: ...cessary 10 Lubricate the front grease fitting of the chute pivot on units w o an automated arm see Figure 3 109 NOTE To access this grease fitting point you will have to remove the right hand side flo...

Page 106: ...f the chute pivot on units with an automated arm see Figure 3 110 Figure 3 110 Front pivot grease fitting unit with an automated arm 16 Exit the hopper 17 Lubricate the back end of the chute pivot usi...

Page 107: ...the hydraulic pump 2 Fully retract the packer and position the chute on the hopper streetside see Figure 3 113 3 Lower the crusher panel completely if equipped using the CRUSHER PANEL DOWN switch on t...

Page 108: ...he Vehicle on page 14 6 Remove the right hand side protective panel that is fixed to the rear hopper wall see Figure 3 115 Figure 3 115 RHS protective panel NOTE On some trucks especially those with a...

Page 109: ...linder 8 By using a straight edge check the cylinder rod to make sure it is straight 9 Lubricate the 2 grease fittings on the cylinder one at the base end the other at the rod end see Figure 3 118 Fig...

Page 110: ...Start the truck and engage the hydraulic pump 2 Fully retract the packer and position the chute on the hopper streetside see Figure 3 119 3 Lower the crusher panel completely if equipped using the CRU...

Page 111: ...be able to access the area where the chute cylinder is 7 Remove the pin see Figure 3 123 Remove the cotter pin to remove the pin 8 Loosen the locknut see Figure 3 123 9 Gently lift the rod head from...

Page 112: ...ngle of your chute differs from this value you should apply the following procedure To adjust the angle of the chute proceed this way 1 Start the truck and engage the hydraulic pump 2 Fully retract th...

Page 113: ...el in lowered position 4 Turn OFF the hydraulic pump and the engine 5 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 6 Remove the right hand side protective pa...

Page 114: ...that holds the cylinder pin in 8 Remove the cylinder pin that secures the cylinder rod to the chute lever see Figure 3 132 NOTE Take care not to cause misalignment of the limit switch when disconnect...

Page 115: ...ehicle see Locking Out and Tagging Out the Vehicle on page 14 21 Repeat Steps 7 to 16 until the chute angle is 21 22 Once the target angle is reached place the chute on the streetside if not already t...

Page 116: ...mp and the engine Figure 3 129 Dual chute control levers 5 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 6 Remove the protective panel by removing its retaini...

Page 117: ...oth chutes in vertical position Figure 3 131 Chutes in vertical position 16 Turn OFF the hydraulic pump and stop the engine 17 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehi...

Page 118: ...n place see Figure 3 132 NOTE Take care not to cause misalignment of both limit switches when disconnecting the two chute operating cylinders Figure 3 133 Location of both chute operating cylinders 21...

Page 119: ...n place 23 Unscrew the greasing hose from its attachment on the pillow block see Figure 3 132 24 Remove the pillow block Two bolts located under the pillow block hold this part in place see Figure 3 1...

Page 120: ...side floating panel a open the panel b slide it to the left and c lift it up Figure 3 136 Removing RHS floating panel 26 Remove the chute flange bearing see Figure 3 137 by taking out the 2 bolts tha...

Page 121: ...since the body is of co mingle type with two compartments The work sequence towards removal of the packer panel on a SSO tipper equipped EXPERT is the following Remove the fixed chute see procedure i...

Page 122: ...139 SSO tipper and lever NOTE If the tipper lever is combined with a deadman s switch see Figure 3 139 the latter must be pressed to enable the lever 3 Turn OFF the hydraulic pump and stop the engine...

Page 123: ...ding Arm on page 84 Hopper DividerWear Pads and Sliding Shoe NOTE These specially designed wear pads and sliding shoe are used only on co comingle units During packing the hopper divider slides along...

Page 124: ...e rear end of the hopper divider see Figure 3 141 Figure 3 141 Nut at rear end of hopper divider 7 Disconnect the divider front end from the packer panel Unscrew the vertical bolt and push out the pin...

Page 125: ...nce 115 Figure 3 143 Exterior guide 10 Remove all 6 wear pads 3 each in both upper and lower sections of the rail and the sliding shoe see Figure 3 144 Figure 3 144 Wear pads and sliding shoe Wear pad...

Page 126: ...and 2 wear pads one from each rail section Figure 3 146 Sliding shoe 11 Proceed with the installation of the new wear pads and sliding shoe To do so 11 a Insert 1 bolt into hole in both lower and uppe...

Page 127: ...tall the sliding shoe see Figure 3 148 Figure 3 148 Installing sliding shoe 11 d Place the 2 remaining wear pads one in each section of the rail This will keep the sliding shoe in place Figure 3 149 W...

Page 128: ...er to the packer panel Insert the pin into the divider front end bushing reinstall both bolt and nut and tighten the nut see Figure 3 142 Packer Cylinders Packer cylinders that become defective throug...

Page 129: ...the left 3 Extend the packer until it has reached of the total hopper length 4 Disengage the pump and stop the engine 5 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on...

Page 130: ...h grease fittings Figure 3 154 Grease fittings 9 Take 2 5 8 18 NF 9 inch long fine threaded bolts and screw them in the pin head holes Figure 3 155 5 8 18 NF fine threaded bolts 10 Tighten the bolts u...

Page 131: ...Removing Faulty Packer Cylinder To remove a faulty packer cylinder 1 Carry out the preceding procedure see Accessing Packer Cylinders on page 118 2 Ensure the hydraulic pump is disengaged and the engi...

Page 132: ...c hoses from the faulty cylinder Figure 3 158 Removing hydraulic hose 6 Cap each hose and cylinder fitting as soon as they are disconnected see Figure 3 159 Caution Make sure to place a bucket under t...

Page 133: ...ng reconnection Use of color coded tie wraps see illustration below is appropriate for such purposes Figure 3 160 Color based identification 8 Push the hoses away to facilitate cylinder removal Figure...

Page 134: ...der pin comes out NOTE Make sure the cylinder stays in horizontal position to make the removal process easier 12 Remove the front end pin completely see Figure 3 163 Figure 3 163 Front end pin complet...

Page 135: ...ee Installing Replacement Packer Cylinder on page 125 NOTE Replacement cylinder may be new rebuilt or refurbished Figure 3 165 Proximity switch target Installing Replacement Packer Cylinder To install...

Page 136: ...connect both hoses to the cylinder fittings To do so 6 a Place a bucket under the hoses to collect oil that may spill out 6 b Remove the caps from the hoses and connect the hoses to the appropriate fi...

Page 137: ...cking Out and Tagging Out the Vehicle on page 14 12 Insert the rear end pin into the hole to secure both cylinders 13 Connect the greasing hoses to the cylinder pin and secure them with the two provid...

Page 138: ...der the side rails see page 135 Preparing for Sliding Shoe Replacement Follow this procedure before proceeding with the sliding shoe replacement 1 Make sure the parking brake is applied 2 Start the en...

Page 139: ...es before the end of the stroke Figure 3 170 Packer at about 18 inches from end of stroke NOTE To extend or retract the packer over a short distance push the green or yellow button and then push the r...

Page 140: ...shoe see Figure 3 171 Figure 3 171 Retaining bolts 12 Tack weld a piece of steel tubing to the floor rail and to the front of both sliding shoes Figure 3 172 Tack welding 13 Start the engine engage t...

Page 141: ...urn OFF the hydraulic pump and the engine 2 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 3 Remove the old sliding shoes and temporary steel tubing NOTE Remov...

Page 142: ...he marks made in Step 4 do not tack or weld yet Make sure the floor guides are parallel to the hopper walls 9 If packer has been removed Reinstall the packer on the floor guides with the new sliding s...

Page 143: ...le see Locking Out and Tagging Out the Vehicle on page 14 17 Put back and tighten all retaining bolts 18 Remove the tubes that were installed in Step 11 then grind down to a smooth surface NOTE If the...

Page 144: ...r Guides Apply the following procedure to finish up replacing the sliding shoes and floor guides 1 Run the packer a few times 1 a If the packer is binding apply some primer paint on the floor guide to...

Page 145: ...acker to continue operating properly Usually replacement of floor guides is done at the same time when sliding shoes are replaced When sliding shoes need to be replaced because of wear chances are flo...

Page 146: ...gage the hydraulic pump 2 Using the joystick extend the automated arm to get better access to the hopper area In dual HELPING HAND units extend both arms 3 Fully retract the packer 4 Turn OFF the hydr...

Page 147: ...llow for the removal of the guard Figure 3 180 Anti spill guards Figure 3 181 R pin holding anti spill guard in place 8 Remove the deflector panel Use a inch wrench to remove the 4 bolts that hold the...

Page 148: ...engine and engage the hydraulic pump 12 Extend the packer to mid stroke position 13 Turn OFF the hydraulic pump and the engine 14 Lock out and tag out the vehicle see Locking Out and Tagging Out the...

Page 149: ...removing the side panel Figure 3 186 Side panel 17 Remove the lower part of both side rails one on each side of the hopper by using a 5 16 inch Allen wrench and a 3 4 inch wrench see Figure 3 194 The...

Page 150: ...d emergency STOP button to maintain the packer in its fully extended position 3 Turn OFF the hydraulic pump and the engine 4 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicl...

Page 151: ...Figure 3 189 Floating panels To remove the right hand side floating panel a open the panel b slide it to the right and c lift it up see Figure 3 190 To remove the left hand side floating panel a open...

Page 152: ...en out including 2 carriage bolts to remove the beam and unloose the central cover see Figure 3 32 9 Remove the upper part of both side rails one on each side of the hopper 6 bolts are to be taken out...

Page 153: ...n 12 Turn OFF the hydraulic pump and the engine 13 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 14 Remove both side panels one on each side of the hopper Fig...

Page 154: ...rail NOTE In order to get access to the last of the 6 bolts that hold the lower part of the side rail in place remove the midway flashing lights located on each side of the truck Figure 3 195 Flashin...

Page 155: ...le on page 14 6 Open the left right hand side hopper door 7 Remove the anti spill guards located on each side of the hopper see Figure 3 196 An R pin located just behind the anti spill guard see Figur...

Page 156: ...ivider see Figure 3 198 There are 6 bolts that hold the divider to the packer panel These bolts are to be taken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must a...

Page 157: ...he chute see Figure 3 202 To perform this task apply the following steps 10 a Use a suitable lifting device e g sling or cable to hold the chute in place 10 b Start the truck and engage the hydraulic...

Page 158: ...Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 10 f Remove both protective panels that are fixed to the rear hopper wall see Figure 3 203 Figure 3 203 Protect...

Page 159: ...the cylinder rod to the chute lever see Figure 3 205 NOTE Take care not to cause misalignment of the limit switch when disconnecting the chute operating cylinder 10 i If needed retract the chute oper...

Page 160: ...k see Figure 3 205 10 l Remove the pillow block Two bolts located under the pillow block hold this part in place see Figure 3 206 Figure 3 206 Bolts holding pillow block in The rear section of the chu...

Page 161: ...Also remove the 3 carriage bolts located at the center of the automated arm assembly see Figure 3 208 In order to access these bolts and remove them lift the arm cover open Figure 3 208 Deflector pan...

Page 162: ...engine and engage the hydraulic pump 15 Extend the packer to mid stroke position 16 Turn OFF the hydraulic pump and the engine 17 Lock out and tag out the vehicle see Locking Out and Tagging Out the...

Page 163: ...first toremove it before removing the side panel 20 Remove the lower part of both side rails one on each side of the hopper by using a 5 16 inch Allen wrench and a 3 4 inch wrench see Figure 3 194 The...

Page 164: ...tract the packer 3 Turn OFF the hydraulic pump and the engine 4 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 5 Open the left right hand side hopper door 6 Re...

Page 165: ...ivider see Figure 3 216 There are 6 bolts that hold the divider to the packer panel These bolts are to be taken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must a...

Page 166: ...the chute see Figure 3 220 To perform this task apply the following steps 9 a Use a suitable lifting device e g sling or cable to hold the chute in place 9 b Start the truck and engage the hydraulic p...

Page 167: ...Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 9 f Remove both protective panels that are fixed to the rear hopper wall see Figure 3 221 Figure 3 221 Protectiv...

Page 168: ...the cylinder rod to the chute lever see Figure 3 223 NOTE Take care not to cause misalignment of the limit switch when disconnecting the chute operating cylinder 9 i If needed retract the chute operat...

Page 169: ...screw the greasing hose from its attachment on the pillow block see Figure 3 223 9 l Remove the pillow block Two bolts located under the pillow block hold this part in place see Figure 3 224 Figure 3...

Page 170: ...side floating panel a open the panel b slide it to the left and c lift it up Figure 3 226 Removing RHS floating panel 9 n Remove the chute flange bearing see Figure 3 227 by taking out the 2 bolts th...

Page 171: ...fully extended position 12 Turn OFF the hydraulic pump and the engine 13 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 14 Remove the transversal beam see Figu...

Page 172: ...the side rail see Figure 3 229 Figure 3 229 Bolts to be taken out to remove upper part of side rail 16 Start the engine and engage the hydraulic pump 17 Retract the packer to mid stroke position 18 T...

Page 173: ...il in place remove the midway flashing lights located on each side of the truck Figure 3 231 Flashing light removed NEXT REPLACING AND ADJUSTING UPPER WEAR PADS see Replacing and Adjusting Upper Wear...

Page 174: ...the desired tightening or loosening effect is achieved Figure 3 233 Installing and adjusting wear pad NOTE The easiest way to reach the upper wear pad adjustment screws is through the sump box or cle...

Page 175: ...pad or scraper is a replaceable wearing part that is located between the packer and the arm box assembly units with a HELPING HAND arm see Figure 3 234 or between the packer and the floating panels un...

Page 176: ...In dual HELPING HAND units extend the right hand side automated arm only 3 Fully retract the packer using the yellow button on the packer control station 4 Turn OFF the hydraulic pump and the engine...

Page 177: ...ession rubber inside the beam under the scraper Replace if needed 12 Install a new wear pad 13 Put the transversal beam back in place 14 Reinstall the transversal beam retaining bolts 2 on each side 1...

Page 178: ...e anti spill guards located on each side of the hopper see Figure 3 238 An R pin located just behind the anti spill guard see Figure 3 181 must be pulled completely to allow for the removal of the gua...

Page 179: ...he right and c lift it up see Figure 3 240 To remove the left hand side floating panel a open the panel b slide it to the left and c lift it up Figure 3 240 Removing RHS floating panel 8 Remove the tr...

Page 180: ...he transversal beam its retaining bolts and the 2 carriage bolts see Figure 3 241 13 Check for even contact between the new lower wear pad and the packer follower panels 14 Reinstall both floating pan...

Page 181: ...le on page 14 6 Remove the anti spill guards located on each side of the hopper see Figure 3 242 An R pin located just behind the anti spill guard see Figure 3 243 must be pulled completely to allow f...

Page 182: ...ken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must also be taken out see Figure 3 246 Figure 3 244 Hopper divider Figure 3 245 Bolts holding divider 6 Figure 3...

Page 183: ...out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 14 Remove the deflector panel on the automated arm assembly see Figure 3 248 Use a inch wrench to remove the 4 lower bolts that h...

Page 184: ...am retaining bolts 2 on each side 22 Check for even contact between the new wear pad and the packer follower panels 23 Put the 3 carriage bolts back in see Figure 3 248 24 Put back the deflector panel...

Page 185: ...gine 4 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 5 Remove the anti spill guards located on each side of the hopper see Figure 3 250 An R pin located just...

Page 186: ...ken out to remove the hopper divider A 5 8 nut located at the rear end of the divider must also be taken out see Figure 3 254 Figure 3 252 Hopper divider Figure 3 253 Bolts holding divider 6 Figure 3...

Page 187: ...11 Turn OFF the hydraulic pump and the engine 12 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 13 Remove the transversal beam see Figure 3 256 Figure 3 256 Fl...

Page 188: ...th floating panels and the chute use Step 4 on page 64 in reverse order 24 Reinstall the divider guard 25 Reinstall the hopper divider 26 Reinstall both anti spill guards PackerWiper Blades These UHMW...

Page 189: ...nits with loading arm go to page 184 To replace the panel roller assemblies 1 Start the engine and engage the hydraulic pump 2 Fully extend the packer then push the red emergency STOP button to mainta...

Page 190: ...igure 3 259 R pin holding anti spill guard in place 7 Remove the deflector panel Use a inch wrench to remove the 4 bolts that hold the panel Figure 3 260 Deflector panel 8 Remove the transversal beam...

Page 191: ...3 262 4 bolts are to be taken out to remove this section of the side rail Figure 3 262 Side rail 10 Remove all panel rollers from the follower panels and replace them with new ones To do so 10 a Flip...

Page 192: ...respective holes before tightening them up 10 d Flip the bottom follower panel backward panel next to packer see Figure 3 263 The two follower panels are now folded over the packer 10 e Remove both ro...

Page 193: ...he packer 3 Co mingle units only Set the chute upright 4 Turn OFF the hydraulic pump and the engine 5 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 6 Open the...

Page 194: ...p 20 Run a full cycle to check for proper operation 21 Reinstall both anti spill guards C Co Mingle Units W Loading Arm To replace the panel roller assemblies 1 Start the engine and engage the hydraul...

Page 195: ...rd in place 6 Remove the hopper divider see Figure 3 267 There are 6 bolts that hold the divider to the packer panel These bolts are to be taken out to remove the hopper divider A 5 8 nut located at t...

Page 196: ...7 Remove the divider guard 4 bolts are to be taken out to remove the divider guard 2 on each end Figure 3 270 Divider guard 8 Remove the chute see Step 10 on page 147 for the chute removing procedure...

Page 197: ...arm assembly see Figure 3 271 Use a inch wrench to remove the 4 lower bolts that hold the panel Also remove the 3 carriage bolts located at the center of the automated arm assembly see Figure 3 271 In...

Page 198: ...nes To do so 16 a Flip the top follower panel backward panel nearest the arm see Figure 3 274 Figure 3 274 Packer and follower panels 16 b Remove both rollers one on each side of the top follower pane...

Page 199: ...re tightening them up 16 g Unfold both follower panels All panel rollers must now rest on the lower section of both side rails 17 Reinstall the upper part of both side rails one on each side of the ho...

Page 200: ...the roller itself has to be replaced because of wear apply the following procedure 1 Once the roller has been removed from the follower panel see Follower Panels on page 179 remove the external snap r...

Page 201: ...packer proceed this way 1 Start the engine and engage the hydraulic pump 2 Fully retract the packer so the follower panels are upright Figure 3 278 Follower panels 3 Turn OFF the hydraulic pump and t...

Page 202: ...panels to the packer see Figure 3 282 NOTE It is possible to remove the first bolts through the clean out traps To remove those that are closer to the center go between the cab and the hopper Figure 3...

Page 203: ...General Maintenance 193 Figure 3 282 Location of all 6 retaining bolts 7 To reattach the follower panels to the packer repeat this procedure in reverse order Bolt...

Page 204: ...ed you will see a steel gland at the top of each cylinder section They must be inspected as well Figure 3 284 Cylinder gland To inspect the body hoist cylinder 1 Park the vehicle on safe level ground...

Page 205: ...196 Figure 3 285 Gap on cylinder section 6 Make sure that the gland safety pins are in place Figure 3 286 Safety pin 7 When the inspection is completed put back the safety prop and lower the body Dan...

Page 206: ...the hydraulic hose and fitting Figure 3 287 Hydraulic fitting 3 Take off the 2 cylinder base pillow blocks by unscrewing the bolts that hold them in place Figure 3 288 Base pillow blocks 4 Remove all...

Page 207: ...cylinder carefully Save both pillow blocks for the replacement cylinder see Figure 3 289 9 Place the pillow blocks that were set aside on the pins of the new cylinder 10 Using a lifting device instal...

Page 208: ...roperly secure the cylinder to the support on the body front 14 Reconnect the hydraulic hose atop the cylinder see Figure 3 287 15 Lubricate all cylinder grease fittings Figure 3 291 Grease fittings 1...

Page 209: ...ust not show any sign of wear or metal fatigue The retaining bolts must be kept tight The tailgate rubber seal must not show any signs of damage Replace if necessary Figure 3 292 Tailgate hinge and pi...

Page 210: ...properly Serious damage to the equipment injuries or death may occur if you operate the machinery with improperly adjusted switches Top door fully open limit switch optional Arm stowed limit switch op...

Page 211: ...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 212: ...gnment of the components may occur due to the frequent back and forth motion of the packer An adjustment might be necessary to prevent cylinders from completely extending and retracting to the end of...

Page 213: ...OTE To extend or retract the packer over a short distance push the green or yellow button and then push the red emergency STOP button immediately Repeat the process until the packer has reached the de...

Page 214: ...16 inch between the proximity switch and the plate If this is not the case apply the following procedure To adjust the gap between the proximity switch and the plate 1 On the proximity switch loosen...

Page 215: ...3 299 Packer retract proximity switch To verify that the switch needs adjusting empty all refuse from the body start a pack cycle and observe the home position of the packer when it completes its cycl...

Page 216: ...by the switch 6 Retighten the 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 approxim...

Page 217: ...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 accordingly if needed see...

Page 218: ...its always open the tailgate to which the full ICC bumper is attached before raising the body This is to avoid the bumper coming into contact with the ground For example if the ICC bumper is installed...

Page 219: ...ubles 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 warning light is off...

Page 220: ...full ICC bumper equipped co mingle units always open the tailgate to which the full ICC bumper is attached before raising the body This is to avoid the bumper coming into contact with the ground For...

Page 221: ...the proximity switch is properly adjusted NOTE On full ICC bumper equipped co mingle units always open the tailgate to which the full ICC bumper is attached before raising the body This is to avoid t...

Page 222: ...er adjustment screws see Figure 3 308 2 Raise or lower the detection lever a little bit and tighten up the screws The detection lever must touch the side of the top door for the switch to be triggered...

Page 223: ...age 14 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 enga...

Page 224: ...mph 5 km h This limit switch is located behind the gripper s right side fingers see illustration above On dual HELPING HAND units the arm stowed limit switch on the street side is behind the gripper...

Page 225: ...Fully extend the arm 3 Turn OFF the engine 4 Proceed with the tagout lockout procedure Refer to Locking Out and Tagging Out the Vehicle on page 14 5 Open the black plastic spring equipped retracting...

Page 226: ...c pump 10 Test the operation 11 Repeat the procedure until the limit switch is properly adjusted The ARM EXTENDED warning light see Figure 3 313 should turn off when the arm is in the parked travel po...

Page 227: ...eral Maintenance 217 Figure 3 311 Helping HandTM arm base Figure 3 312 Arm parked limit switch adjustment Figure 3 313 Arm extended warning light Top cover plate Curved cover plate Detection lever Scr...

Page 228: ...5 Locate the mid height limit switch at the base of the Helping HandTM arm 6 Loosen the two screws indicated in Figure 3 314 7 Slide the limit switch forward or backward to achieve proper contact wit...

Page 229: ...f these limit switches must be triggered NOTE In the case of a two crusher panel setup only one panel will move and this panel is dependent on which side the chute is resting In the case of a one crus...

Page 230: ...e 2 m Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 2 n Remove the left hand side protective cover see Figure 3 317 Figure 3 316 Hopper rear side NOTE Once th...

Page 231: ...pivot see Figure 3 315 13 If there is a gap between the rod and its target proceed with the adjustment of the former To do so 13 a Loosen the adjustment screw on the limit switch see Figure 3 315 13...

Page 232: ...ion on the body right Tailgate Hooks Co Mingle Units 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...

Page 233: ...nce completed put back both 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 th...

Page 234: ...f seals LabriePlus part number HYJ04107 Inlet Section Seal Kit one kit required per valve assembly Valve Removal 1 Thoroughly clean the valve connecting hoses and the area directly surrounding the val...

Page 235: ...ate it to the end plate 8 Using an o ring pick remove and discard the old o rings 9 Clean the seats in the o ring seal face and inspect for cracks abnormal wear rust or uneven sealing surfaces 10 Usin...

Page 236: ...ck up ring onto the spool eye end of the valve spool 27 Using the seal retaining plate press the spool seal and backup ring into the valve body recess 28 Ensure the actuator is properly attached to th...

Page 237: ...evice minimum 500 lb capacity overhead winch shop crane etc Nylon sling minimum 500 lb rating Lint free rags Petroleum jelly Parts Required LabriePlus part number HYV04429 Section Seal Kit one kit req...

Page 238: ...normal wear rust or uneven sealing surfaces 4 Slide the tie rods through the backing plate and stand it upward on end 5 Lubricate the o rings with petroleum jelly and install them into their correspon...

Page 239: ...1 Carefully install the actuator to the valve section ensuring that the valve spool is properly attached to the manual actuator lever and torque the four socket head bolts with a 5 mm Hex key driver t...

Page 240: ...ve 36 Coat the outside surface of the o ring with petroleum jelly and reinstall the adjustment screw turning it the appropriate revolutions in accordance with the counted revolutions recorded during r...

Page 241: ...General Maintenance 231 Figure 3 321 Electric actuator seal configuration Figure 3 322 Manual actuator seal configuration Figure 3 323 Valve section seal configuration...

Page 242: ...ow 2 Move the pipe close to the oil pan for more working space 3 Proceed with the replacement of the fuel filter NOTE Always follow your chassis manufacturer s recommendations regarding fuel filter re...

Page 243: ...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 Paint 2 mil deep single coat dry At the end of the pa...

Page 244: ...234 General Maintenance...

Page 245: ...ube locations and the frequency with which they should be greased Recommended Lubricants You will find below the recommended types of lubricants Grease Any lithium based commercial multipurpose grease...

Page 246: ...ERT units IMPORTANT It is the customer s responsibility to use oil that is appropriate to the climate Engine Oil Refer to the engine manufacturer s maintenance manual for recommended type of engine oi...

Page 247: ...he body onto it 5 Disengage the pump and turn OFF the engine 6 Locate the oil sample coupler along the right hand side chassis frame rail It is located behind the filter cover see Figure 4 1 Figure 4...

Page 248: ...e To do so 1 Remove the sample kit from its bag and using a screwdriver remove the vent cap from the bottle cap see Figure 4 3 Figure 4 3 Vent cap 2 Remove the protective cap from the probe Figure 4 4...

Page 249: ...o do this Remove excess oil through the vent DO NOT OPEN THE BOTTLE Figure 4 6 Recommended oil level 5 Once the sample is taken remove the probe from the coupler and pull out the probe to remove it fr...

Page 250: ...ple bottle see Figure 4 9 Figure 4 9 Identification form sticker Lubrication Charts Lubrication charts in this manual may differ from the ones displayed on the vehicles For lubrication specifications...

Page 251: ...Lubrication 241 Figure 4 11 Glass compartment lubrication chart optional...

Page 252: ...242 Lubrication Figure 4 12 EXPERT lubrication chart...

Page 253: ...chart Caution Never grease the side rails and the outside of rollers Sand and other abrasives stick to grease which may cause premature component wear Caution Because of their intensive use the packer...

Page 254: ...ase the crusher panel bushings 3 Grease the grease fittings on the lower tube rings see Figure 4 15 Figure 4 14 Grease areas Figure 4 15 Grease fittings on lower tube rings NOTE If the truck is equipp...

Page 255: ...e 4 17 Body hinge view from behind the rear mudguard Tailgate Locking Mechanism and Hinges It is important to lubricate the tailgate locking mechanism and tailgate hinges and cylinders with multipurpo...

Page 256: ...circlips Tailgate hinges and pins Wear on the locking mechanism Wear on the tailgate locking pins Tailgate rubber seal Figure 4 18 Tailgate locking mechanism Figure 4 19 Cylinder retaining ring Cauti...

Page 257: ...Lubrication 247 Figure 4 20 Tailgate hinges standard and co mingle units Figure 4 21 Tailgate hinges co mingle units only Tailgate hinge Grease fitting Grease fittings...

Page 258: ...248 Lubrication Tailgate Hooks Co Mingle Units Figure 4 22 Tailgate hook lubrication points Hopper Door Figure 4 23 Standard hopper door lubrication points Grease fittings Hopper door hinges...

Page 259: ...Lubrication 249 Figure 4 24 Split hopper door lubrication points Sump Box Figure 4 25 Sump box lubrication points Hopper door hinges...

Page 260: ...250 Lubrication Packer Figure 4 26 Packer lubrication points 1 Remote grease fittings for rear cylinder pins Roller grease fitting...

Page 261: ...Lubrication 251 Figure 4 27 Packer lubrication points 2 Grease fitting LH side front cylinder pin...

Page 262: ...252 Lubrication Chute Co MingleVehicles Figure 4 28 Single chute lubrication points Figure 4 29 Dual chute lubrication points...

Page 263: ...Lubrication 253 Pump Drive Shaft U Joint Figure 4 30 Pump drive shaft lubrication points Grease fittings...

Page 264: ...254 Lubrication...

Page 265: ...nusual noises When maintenance is carried out protect all hoses fittings pipes or any other ingress points from dirt that would eventually get into the oil Plug hoses that are not connected Inspect th...

Page 266: ...everely damage hydraulic components It is recommended to have the hydraulic fluid tested and analyzed by a lab to prevent hydraulic system or pump breakdown This will also optimize the frequency of hy...

Page 267: ...is activated by an electric solenoid valve The electrical signal that activates the solenoid is sent by the pump switch on the control panel Figure 5 1 Single vane pump The single vane pump powers all...

Page 268: ...s tailgate body hoist and packer through the directional control valve see Directional Control Valve on page 258 It is capable of delivering a flow of 20 GPM at 700 RPM A dump valve located on the cha...

Page 269: ...onal control valve may have up to 5 sections depending on whether or not the unit is equipped with a crusher panel and or a glass compartment For example if the unit is equipped with a crusher panel b...

Page 270: ...nal control allows infinite control of the arm speed and movement Each section of this valve is actuated by an electric coil located under the valve Figure 5 5 Proportional valve Input output cover pr...

Page 271: ...mp and at connection points 6 If electrical problems occurred with the pump see Troubleshooting on page 331 Caution Very corrosive chemicals used to wash trucks may cause serious damage to the point w...

Page 272: ...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 fo...

Page 273: ...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 274: ...tem 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 275: ...mp does not come apart NOTE The cartridge will rotate with the housing IMPORTANT Do not pull on the mounting cap because inside components may move and damage the pump 13 d Put all 4 bolts back in pla...

Page 276: ...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 277: ...ect the following 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 f...

Page 278: ...5 inclusively to reinstall the various components of the pump assembly 18 Retighten the breather cap 19 Prime the new pump see Priming New Pump on page 275 20 Put the front pump guard back on see Fig...

Page 279: ...as they were before uninstallation Make sure you do not invert them 8 Remove the suction block see Figure 5 10 and save it for the new pump Figure 5 10 Suction block 9 Disconnect the drive shaft by re...

Page 280: ...t 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 determ...

Page 281: ...ve 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 pan...

Page 282: ...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 283: ...ively to reinstall the various components of the pump assembly 15 Retighten the breather cap 16 Prime the new pump see Priming New Pump on page 275 NOTE Labrie Enviroquip Group strongly recommends you...

Page 284: ...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 285: ...nstalled pump 1 Make sure the parking brake is applied and the vehicle is tagged out for maintenance purposes refer to Locking Out and Tagging Out the Vehicle on page 14 2 With the shut off valve clos...

Page 286: ...n EXPERT unit varies according to whether the truck cab is of the cab over type or the conventional type The former requires a saddle type non pressurized model see Figure 5 18 while the latter requir...

Page 287: ...see Figure 5 17 is not obstructed and works properly 4 Make sure that the hydraulic oil is clean not colored and at least full on the oil level gauge with all cylinders retracted The complete system r...

Page 288: ...tion is needed for behind the cab mounted tanks saddle model gravity is enough to cause the oil to flow Cavitation inside the pump generates excessive wear and noise Shut off valve Suction line Strain...

Page 289: ...when the body is raised To adjust the pressure turn the knob until the pressure reaches 3 to 3 5 PSI The hydraulic tank is also equipped with a 5 PSI relief valve and a 5 PSI pressurized screw on the...

Page 290: ...Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 3 Clean around the filler breather cap and remove it 4 Place a clean container minimum capacity 60 gallons under...

Page 291: ...as to be turned counter clockwise to be removed 8 Clean the strainer using solvent and check for damage replace if necessary 9 Apply thread seal compound on the strainer threads and reinstall the stra...

Page 292: ...ilter needs to be changed Replace the filter before the indicator reaches the red zone This will keep the oil clean extend component life and reduce failures Figure 5 26 Filter restriction indicator T...

Page 293: ...he hydraulic tank see Emptying Hydraulic Tank on page 280 2 Remove the strainer see Cleaning Strainer on page 280 Clean the strainer if necessary 3 Remove the return filter element see Replacing Filte...

Page 294: ...hes the pump see Pump Cavitation on page 338 11 Reinstall the filler cap and fully open the shut off valve 12 Prime the pump see Priming New Pump on page 275 13 Start the engine without pushing on the...

Page 295: ...mly set and that there are no leaks 4 Using a straight edge make sure that cylinder rods are straight 5 Lubricate and inspect all cylinders mounting points pins retaining bolts etc Detecting Cylinder...

Page 296: ...leaks in packer cylinders 1 Apply all safety measures and set the parking brake 2 Pull on the red emergency STOP button 3 Start the engine and engage the hydraulic pump 4 Fully extend the packer cyli...

Page 297: ...is leaking from port A then push the emergency STOP button If oil leaks out of port A when pressure is applied there might be an internal leak replace or repair the cylinder NOTE It may be necessary t...

Page 298: ...e other 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 pr...

Page 299: ...on chassis To adjust the body vane pump relief valve 1 Lock out and tag out the vehicle see Locking Out and Tagging Out the Vehicle on page 14 2 Install the 0 4000 PSI pressure gauge on the quick conn...

Page 300: ...relief valves are adjusted to the proper pressure adjust the relief valve on the directional control valve according to the pressure chart see page 288 Adjusting Directional ControlValve Pressure To a...

Page 301: ...inlet cover see E on Figure 5 35 3 Disconnect the packer extend proximity switch 4 Activate the packer extend until it reaches the end of stroke 5 If no reading is shown adjust the utility section of...

Page 302: ...e packer extend proximity switch 11 Activate the packer extend until it reaches the end of stroke 12 Adjust the pressure reducing valve to 550 PSI 20 PSI using the adjustment screw located at the fron...

Page 303: ...have been properly identified on the valve Figure 5 36 Hydraulic pressure table Figure 5 37 Proportional valve by section NOTE A helper may be needed when adjusting arm pressure Use all necessary safe...

Page 304: ...connect coupler 5 Start the engine and engage the hydraulic system 6 Fully retract the arm and keep it retracted using the lever 7 Adjust the main relief valve to 2000 PSI using the adjustment screw...

Page 305: ...ON 3 Activate the chute manually with the control lever see Figure 5 40 until the cylinder reaches the end of its stroke chute leaning to either left or right 4 Take a reading of the maximum pressure...

Page 306: ...ing Out and Tagging Out the Vehicle on page 14 2 Secure the area around the path of the arm with barrier tape or barricades 3 Move the manual levers back and forth to release any residual pressure 4 M...

Page 307: ...adjust the working pressure of the tipper valve 1 Connect a 0 4000 PSI gauge to the flow divider quick connect coupler just above the main valve see Figure 5 42 2 Start the engine and engage the hydra...

Page 308: ...valves are equipped with a relief valve that sometimes needs to be adjusted Newer versions of regeneration valves 2014 and later are not equipped with a relief valve so no adjustment is needed Regene...

Page 309: ...wed only in case of a first installation Please ignore these steps when proceeding with subsequent pressure adjustments 7 Loosen the nut that secures the solenoid to the regeneration valve 8 If the re...

Page 310: ...ollowing procedure is used to ensure good working condition of the tailgate hydraulic system To check the tailgate hydraulic system 1 Fully open and close the tailgate three times to ensure there is n...

Page 311: ...oler then the hydraulic cooler may be treated with a liquid cleaner flushed with water and dried with compressed air for drying and removal of debris Care should be taken when using compressed air a h...

Page 312: ...5P if adjustable 4x2 with tag and 6x4 body hoist up body hoist down packer extend packer retract relief setting on regeneration valve chassis 4x2 before 2014 programed in IFM module after 2000 50 psi...

Page 313: ...1 SSO bucket down 2000 50 psi hydraulic chute to curb side 2000 50 psi hydraulic chute to street side 2000 50 psi SSO bucket up 2000 50 psi cart tipper complete cycle 2000 50 psi PL14 IT40 twin cart t...

Page 314: ...HVVXUH 3 7 JULSSHU F OLQGHU KROGLQJ YDOYH WR NHHS RSHQ LI HTXLSSHG SVL DUP XS V VWHP SUHVVXUH 3 7 JULSSHU FORVH SVL 3 7 JULSSHU RSHQ SVL 3 7 fonction pressure setting Labrie procedure DQIRVV 39 PDLQ U...

Page 315: ...RICTLY 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 LABRIE INC EST STRICTEM...

Page 316: ...IROQUIP 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 DESCRIPTION APPR DATE HY...

Page 317: ...OU COMMUNICATION DE CE DOCUMENT SANS LE CONSENTEMENT CRIT DE GROUPE ENVIROQUIP LABRIE INC EST STRICTEMENT INTERDITE REV PAR BY DESCRIPTION APPR DATE HYD SCH EX CO MINGLE DUAL CRUSHER ELEC HYD VALVE R...

Page 318: ...ENVIROQUIP LABRIE INC EST STRICTEMENT INTERDITE REV PAR BY DESCRIPTION APPR DATE HYD SCH EX CO MINGLE CRUSHERS ELEC HYD VALVE HYD CHUTE HH LONG REACH LH 220 330 TIPPER PTO R ALLARD 2017 02 22 0 84352...

Page 319: ...Hydraulic System 309 NOTE The preceding schematics are for reference only The hydraulic schematic specific to your truck based on the body serial number is found in the truck s cab...

Page 320: ...310 Hydraulic System...

Page 321: ...s 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 322: ...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 323: ...The 40A circuit is subdivided into 2 secondary circuits 10A and 30A which are protected by in line fuses Figure 6 1 Circuit schematic Ignition relay box Figure 6 2 Ignition relay box with without cov...

Page 324: ...installed These breakers are located within the in cab control box Mounted on each circuit breaker is a button which once pushed resets the breaker see Figure 6 5 Figure 6 5 Circuit breaker Caution Ne...

Page 325: ...ully extended proximity switch Hopper door fully open limit switch optional Tailgate unlocked proximity switch Tailgate fully open proximity switch optional Arm stowed limit switch es optional Arm ext...

Page 326: ...below OK The current program and revision is listed next to Module 10 The program number should match the new program to be installed the revision number will be different example if the program numb...

Page 327: ...on the PC Select the Identity tab to ensure that the PC is communicating with the Labrie IFM system Select the Upload tab A prompt will appear to name the program typically the original program and re...

Page 328: ...rmed to match the previous setting Failure to do so may result in chassis fault codes To ensure the baud rate setting is correct and the chassis is communicating with the Labrie multiplex system it ma...

Page 329: ...into the Settings option and verify the baud rate value Ensure that the Labrie system and the chassis system are communicating correctly by checking the engine RPM as explained earlier Checking Contro...

Page 330: ...eal time supply voltages of the control modules Nodes will be displayed If voltage s are below 12 volts check the supply power to the module if all voltages are below 12 volts check the chassis batter...

Page 331: ...ching 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 On most EXPERT trucks the main hydr...

Page 332: ...o the air actuators mounted on the hydraulic valve sections The air actuators are dedicated to a particular hydraulic function and influence the direction in which the valve spool is moved The air act...

Page 333: ...O Lube or a silicon based equivalent LabriePlus offers a seal kit to replace the internal seals in the actuator Contact LabriePlus for more details Control System Pneumatic Pressure Switch All EXPERT...

Page 334: ...ontaminates introduced to the system that may affect operation of the pressure switch see Air Filter Assembly on page 326 Figure 7 4 Air intake port of pressure switch Next locate the hole on the back...

Page 335: ...of this pressure switch is bypassed AirTanks To drain the air tanks apply the following procedure 1 Locate the drain valves on the air tanks see Figure 7 6 NOTE Some trucks are equipped with more than...

Page 336: ...water from the water filter bowl and all the air from the coalescing filter bowl The water filter bowl helps keep residual moisture out of the body air system while the coalescing filter bowl helps c...

Page 337: ...ched the end of its stroke The multiplex module then operates the air solenoid valve inside the air valve box with a 12 volt signal one signal for packer extend one signal for packer retract When rece...

Page 338: ...neumatic System Schematic 1 2 3 4 6 7 9 8 11 5 10 TAILGATE PACKER HOIST CRUSHER PANEL GLASS COMPARTMENT BUCKET GLASS COMPARTMENT DOOR LOCK Air schematic Standard EX Crusher Panel 5 yd 3 Glass Compartm...

Page 339: ...kout tagout procedure outlined on page 14 is mandatory See Troubleshooting Guide on page 333 to resolve commonly seen problems or contact LabriePlus to talk to one of our product specialists IMPORTANT...

Page 340: ...st support at least 10 amps Figure 8 2 Jumper wire with alligator clips Figure 8 3 Two oil pressure gauges 0 4000 PSI Figure 8 4 Ball end hex wrench metric and SAE 0 4000 PSI pressure gauge Part HYF00...

Page 341: ...288 Packer hydraulic cylinders internally bypassing See Detecting Cylinder Internal Leaks on page 285 Defective pump Replace the pump Overheating hydraulic oil temperature above 77 C 180 F Low oil lev...

Page 342: ...ge the return filter Fill with clean oil See Cleaning Strainer on page 280 Replacing Filter Elements on page 282 and Replacing Hydraulic Oil on page 283 Take an oil sample for further analysis see Tes...

Page 343: ...replace sliding shoes as indicated in Sliding Shoes on page 127 Tailgate is unlocking or lowering by itself Dirty or defective velocity fuse Clean or replace the velocity fuse See Tailgate Locking Mec...

Page 344: ...linder see Adjusting Tailgate Unlocked Proximity Switch on page 208 Body raised limit switch adjustment Adjust the limit switch rod with the body floor see Adjusting Body Raised Limit Switch on page 2...

Page 345: ...at the pump switch is ON Cut off or defective power cables Follow wires on the electrical schematic for 12 volt supply move joystick to get signal Faulty joystick Contact LabriePlus Packer moves forwa...

Page 346: ...to the hydraulic tank If the pump is still generating unusual noise after performing the priming procedure you will have to bleed the hydraulic system To do so 1 Apply all safety measures to ensure s...

Page 347: ...r section actuator by pushing on the green sleeve with a screwdriver and pulling the tube Figure 8 6 Air tube 3 Inject compressed air into the actuator to ensure that the spool moves freely inside the...

Page 348: ...the tailgate section of the valve is designed in such a way as to allow pressure to pass through it every time pressure is building up in the hydraulic system that is when the packer is working The p...

Page 349: ...elocity fuse Figure 8 9 Holding valve Tailgate Unlocking Spontaneously If the tailgate seems to unlock by itself when using the packer the power bleed inside the valve might not be working on the righ...

Page 350: ...Gauge 1 should remain at 0 PSI and Gauge 2 should indicate a sudden burst of pressure from 0 PSI to 3000 PSI each time the packer reaches the end of a stroke If Gauge 1 indicates pressure this may be...

Page 351: ...s at Node 10 When the pump switch is depressed voltage is sent through wire 104o Wire 104o is used to sense all safety features are met and terminates as an input into the Transmission Control Module...

Page 352: ...oubleshooting Utilizing the Labrie multiplex display perform the following steps 1 Depress Menu then select I O Status 2 Next select Module 10_Cabine 3 Once in the Module 10 screen depress the Output...

Page 353: ...a countdown will begin At the end of the countdown press the OK button to enter force mode Note the addition of Force Active in the center of the screen This is to alert the technician that force mode...

Page 354: ...the wiring caused by an Emergency stop switch panic bar or an outside fault such as an abraded cut wire corrosion water in a connector etc is present Repair the 104 wire before proceeding to step 4 St...

Page 355: ...schematic locate wire 130 and trace it to the diode pack typically on page 1 Step 6 Reconnect the diode onto wires 130 and 149 Check for voltage on wire 149 If voltage is not present then the diode co...

Page 356: ...ings of both voltage and resistance without poking or damaging wires Simply connect the compatible harness between two 2 existing connectors and use the additional connector as test points see picture...

Page 357: ...Troubleshooting 349...

Page 358: ...350 Troubleshooting...

Page 359: ...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 harne...

Page 360: ...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 361: ...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 362: ...p Arm Right Door Not Open Open Right Door Arm Tailgate Unlocked Lock Tailgate Arm Wrong Driver Position Change Driver Position Switch to Correct Position AutoDump Cab EStop Pull Out Cab EStop Button A...

Page 363: ...Door Not Close Close Left Door Crusher Packer Not Retracted Retract Packer Crusher Pump Not Started Engage Pump Crusher Right Door Not Close Close Right Door ESTOP Right Emergency Stop Pull Out Right...

Page 364: ...t Started Main Air Pressure Let the Air Build Up to Required Pressure Pump Not Started Right Cab Estop Pull Out Right Cab EStop Button Pump Not Started Right Panic Release Right Panic Bar Pump Not Sta...

Page 365: ...N Release TailgateDown Switch prior to Engaging Pump Pump Cab TailgateUp Switch ON Release TailgateUp Switch prior to Engaging Pump Pump Glass Comp Down Switch ON Release Glass Comp Down Switch prior...

Page 366: ...Engaging Pump Pump Left ChuteToRight Switch ON Release Left ChuteToRight Switch prior to Engaging Pump Pump Left Crusher Down Switch ON Release Left Crusher Down Switch prior to Engaging Pump Pump Le...

Page 367: ...Extend Switch ON Release Right Packer Extend Switch prior to Engaging Pump Pump Right Packer Retract Switch ON Release Right Packer Retract Switch prior to Engaging Pump Pump Right Panic Release Right...

Page 368: ...15 is disconnected Refer to Maintenance Personnel or LabriePlus CAN Error Level 1 Refer to LabriePlus CAN Error Level 2 Refer to LabriePlus CAN Error Level 3 Refer to LabriePlus Comm Lost with Master...

Page 369: ...perator should check if the 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 ca...

Page 370: ...c NOTE The higher the network load value is the heavier the traffic is on the network To exit this page and return to the Main Page press Esc To choose a section from the Main Menu highlight the desir...

Page 371: ...er it may be required to select the higher number of cycles This will allow the hopper to be clear for the next house pickup Each time the packer completes a full cycle the proximity switch located on...

Page 372: ...module and pressing OK the Input Status page of the selected module is displayed see Figure 9 9 Figure 9 9 Input Status page The Input Status page contains a set of rectangles Each of these rectangles...

Page 373: ...Status page see Figure 9 10 is accessible from the Input Status page Figure 9 10 Output Status page The rectangles on this page are used to check the status of different outputs NOTE Each rectangle is...

Page 374: ...esponding button to access the Force page But before the Force page is displayed a warning message appears on the monitor screen see Figure 9 11 Figure 9 11 Warning message This message stays on for 1...

Page 375: ...s on the screen Figure 9 13 Force page input As no input function can be forced to be active or inactive the operator must press the Output button to go to the following page see Figure 9 14 Figure 9...

Page 376: ...n the lower part of the screen After selecting a rectangle press ON to activate the corresponding function rectangle turns from blue to green press OFF to deactivate the corresponding function rectang...

Page 377: ...nder the illustration changing If no change occurs when moving the joystick a communication problem between the joystick and the master control module may be the cause Call LabriePlus for support Pres...

Page 378: ...ected by passwords The Password Menu is available through the Settings Menu An associated menu Locked Features is also available allowing you to choose among the features that can be locked After crea...

Page 379: ...ssword 6 Enter a new password using the arrow keys Press Esc to quit or OK to create a new password NOTE Entering a new password with only zeros as the number such as 000000 will result in deactivatin...

Page 380: ...h the information on this page it is possible for the operator or maintenance personnel to determine the electrical schematic number pertaining to a specific vehicle Looking at Figure 9 17 above you w...

Page 381: ...be hazardous When this happens the operator can look at the monitor screen for more information on the situation A caution or warning message will be displayed The buzzer also sounds when the truck i...

Page 382: ...N bus based joystick replacement contact LabriePlus Figure 9 20 CAN bus based multiplex joystick NOTE The PTO can only be turned on when the engine speed is lower than 900 RPM and the air pressure hig...

Page 383: ...t are closely related to your vehicle contact LabriePlus and ask for the electrical schematic pertaining to your truck model with all the options installed Programming the TCM affects the engine speed...

Page 384: ...Engagement 5000 PTO Drive Interface 1 Maximum Output Speed for Operation 5000 Table 6 Allison wires to be enabled Wires Wire WTEC IV Pack enable 117 Input PTO enable 143 Output PTO enable 130 Output n...

Page 385: ...Programmed Parameters on page 375 145 Neutral signal output Active when the transmission is in neutral This signal ground signal is used to allow fast idle engagement For more details refer to the ele...

Page 386: ...378 Multiplexing...

Page 387: ...greasing points see Lubrication on page 235 To perform the daily inspection 1 Start the engine and engage the hydraulic pump pump switch ON 2 Fully extend the arm NOTE If the vehicle is equipped with...

Page 388: ...380 Lifting Arms Figure 10 1 Mounting bolts Figure 10 2 Wear pads Figure 10 3 Helping Hand gripper...

Page 389: ...ng Out and Tagging Out the Vehicle on page 14 Arm Hydraulic System The EXPERT side loader equipped with the Helping HandTM automated arm uses an independent hydraulic valve to control all arm function...

Page 390: ...ng Out the Vehicle on page 14 Before adjusting the valve pressure make sure to identify each section of the valve see Figure 10 5 and its adjustment screws NOTE Extra personnel may be needed to adjust...

Page 391: ...tment Procedure The operating pressure of the arm retract extend and the gripper up down depends on the pressure that is generated by the hydraulic system No adjustment is required for these functions...

Page 392: ...or the gripper close side of the valve section to 1200 PSI screw or unscrew depending on the gauge reading 9 Open the gripper and adjust the relief valve for the gripper open side of the valve section...

Page 393: ...traction gripper opening closing etc see Figure 10 9 Move the lever to evaluate the speed of the arm gripper then let go of it 5 Loosen the locknut 6 Turn the restrictor adjustment screw only one eigh...

Page 394: ...pper cylinder holding valve see Figure 10 10 is used to prevent the gripper from closing unexpectedly An adjustable cartridge is directly mounted on the cylinder To adjust the gripper holding valve pr...

Page 395: ...dure applies only to EXPERT units equipped with 2 HELPING HAND arms On a 2 HELPING HAND arm equipped EXPERT unit there are 2 holding valves one for each automated arm These valves see Figure 10 12 are...

Page 396: ...System The HELPING HAND automated arm is equipped with a safety system that closes the gripper automatically when the arm is returning to the hopper The auto closing system prevents the gripper from...

Page 397: ...ng System To test 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 an...

Page 398: ...determine if the amount of cushioning has to be adjusted 6 If an adjustment is necessary stop the hydraulic pump and turn OFF the engine NOTE To be able to make the necessary adjustment the temperatur...

Page 399: ...r movement at the end of the stroke or loosen it if the movement is too slow no shock shall occur Figure 10 16 Cushioning adjustment screw inner rail retraction cylinder 7 To adjust the inner rail ext...

Page 400: ...he gripper reached the mid height position on its way up If the packer is performing a cycle while the lifting arm carries a rolling cart towards the hopper the packer will immediately stop and return...

Page 401: ...e 2 components that cause this the dump or recirculation valve or the pump The first step in troubleshooting is to verify that the electrical system is operating correctly If the dump valve is receivi...

Page 402: ...move the recirculation hose from the arm dump valve to the body pump and cap off the port at the body pump Figure 10 20 Recirculation hose 6 Remove the arm dump valve and orifice block and reinstall t...

Page 403: ...up down and in out movements of the HELPING HAND arm depend on a type of signals that varies according to the position of the joystick Those signals are called proportional signals meaning that the m...

Page 404: ...9V traveling along the signal wire and entering the proportional coil will cause the sectionspool to move very swiftly in either direction 3V signal in one direction 9V signal in the other direction w...

Page 405: ...itch on the arm joystick Do not move the joystick The mid range signal voltage should be around 6V and the lift arm should not move 8 Using a voltmeter or multimeter check the voltage status of the si...

Page 406: ...and when it returns to its neutral position the arm stops completely see Figure 10 22 The proportional signal is faulty when one of the following occurs voltage is lower than 3V higher than 9V no volt...

Page 407: ...of the gripper to which it is linked while the adjustment rod moves the other side of the gripper In case the gripper does not close correctly one side of the gripper is more extended than the other...

Page 408: ...one finger section of the gripper see Figure 10 26 The pin is held in place by a bolt 11 Pull the adjustment rod towards you 12 With a wrench loosen the locknut see Figure 10 26 Figure 10 27 Location...

Page 409: ...tall the adjustment rod end connected to the one finger section of the gripper refer to steps 2 11 of the previous procedure 3 Locate the other adjustment rod end where the bushing spacer system is mo...

Page 410: ...Repeat the adjustment procedure if necessary Gripper Arm Pivot Bushing Installation When installing replacement bushings into HELPING HAND gripper arm pivots the replacement bushing will slightly comp...

Page 411: ...at its lower position or inside the gripper head see Figure 10 32 when the gripper is at its upper position 6 Secure the plate to the arm lever using all 3 vertical bolts 7 Reinstall all 3 horizontal...

Page 412: ...ure the arm 3 Remove the packer scraper or lower wear pad to access the T track retaining bolts 8 See Lower Wear Pad on page 165 4 Remove the T track bolts and take the T track out through the opening...

Page 413: ...ed 9 Clearly identify the disconnected hoses and fittings to avoid any mix up during reinstallation 10 Remove the outer rail cylinder bolt and pull out the pin see Figure 10 37 Figure 10 37 Outer rail...

Page 414: ...ING HAND automated arm 2 Open the doghouse located on the streetside and remove the 2 wear pad retaining bolts that are exposed on each side of the sliding rail see Figure 10 39 These bolts are only a...

Page 415: ...d C IMPORTANT As dust particles and sand stick to grease never lubricate the HELPING HAND automated arm wear pads If you do this may jam the moving parts and or cause premature wear 6 Remove wear pad...

Page 416: ...pads and the arm structure These shims are used to fill space between these parts and usually they should be kept However their number may vary after the installation of new wear pads 10 Fully retract...

Page 417: ...n of the keyless locking devices on the HELPING HAND arm Figure 10 46 Keyless locking devices on HELPING HAND arm The disassembly and assembly procedures differ some depending on the part number you a...

Page 418: ...HAND lift cylinder pin Procedure for disassembly 1 Loosen locking screws gradually in a cross sequence shown in Figure 10 47 Figure 10 47 Loosening screws in a cross sequence 2 Remove all locking scre...

Page 419: ...409 Replace any worn or damaged parts 3 If keyless locking device is to be re used thoroughly clean all the surfaces and lubricate both screws and treads with a thin film of light weight oil Procedure...

Page 420: ...all push off threads in the front collar see Figure 10 51 Figure 10 51 Transferring screws into push off threads 3 4 Release front collar by progressively tightening all push off screws Typically the...

Page 421: ...in a cross pattern see Figure 10 47 5 During the first round of tightening all locking screws apply up to 50 of the tightening torque listed in the table above 6 Repeat steps 4 and 5 however this time...

Page 422: ...OL01062 Bottle 18 Oz 540 ml with hand pump LabriePlus part number FOL01065 Bulk 5 Gal 20 l If arm in out functions become slow or erratic and the hydraulic system is in good working order and operatin...

Page 423: ...Schematic The following are examples of lubrication chart and hydraulic schematic for the HELPING HAND lifting arm Please note that these documents are for reference purposes only The lubrication cha...

Page 424: ...CRUSHER PANEL 0 078 0 078 U1 D1 U2 D2 ARM UP DOWN ARM IN OUT ARM IN OUT 550 psi GRABBER 2000 psi 2000 psi B A 1200 psi 1200 psi B A B A B A P T G 2000 psi A B A B 2000 psi single axle 3000 psi dual a...

Page 425: ...6 Parts 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...

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