RosRoca Olympus Mini Service Manual Download

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GeNeRAL SPeCIFICATION dATA

8‑4

OM1R-SM-GB01R

8.5

Hydraulic oils and greases

Recommended hydraulic oil

Temperature range

ISO grade

ISO Oil type

‑30° to +80°

VG 46

HL mineral oil to UNE‑EN ISO 6743‑4: 2002

Recommended greases

Application

Manufacturer’s specification

General lubrication

Shell Retinax A
BP Energol LS2 or L2
Castrol LM

Total EP2
Energol HLP32.

Carriage plate/Packer plate pivot pins

Fuchs Renolit Aqua 2 or similar lubricant to DEF STAN 91‑34/1

Summary of Contents for Olympus Mini

Page 1: ...www rosroca com 855376B 855370B 1 Stop engine before entering 855373B 855375B 855373B 855375B Olympus Mini Service Manual ...

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Page 3: ... servicing and repair of the systems and components described in the manual but can also be used as a reference workbook for training purposes Ros Roca S A Olympus Mini Refuse Collection Vehicle Caution IMPORTANT It is assumed that technicians carrying out service procedures described in this Service Manual appreciate understand and carry out all workshop safety and repair procedures generally acc...

Page 4: ...red in a retrieval system or transmitted in any form without the prior permission of the Company Publication Record Edition Publication reference Publication date Comments This edition OM1R SM GB01R June 2015 First edition Original instructions Description The Olympus Mini refuse collection bodywork is a rear loaded fixed refuse collection bodywork manufactured to EN 1501 1 Intended use The Olympu...

Page 5: ...CONTENTS PAGE 1 Introduction 1 1 2 Health and safety 2 1 3 Daily checks 3 1 4 Hydraulic system oil level 4 1 5 Cleaning 5 1 6 Scheduled maintenance 6 1 7 Operational maintenance 7 1 8 General specification data 8 1 9 Supplementary information 9 1 I index I 1 ...

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Page 7: ...CONTENTS PAGE 1 Introduction 1 3 1 1 Safety precautions 1 3 1 2 Immobilising the vehicle prior to service procedures 1 3 Introduction Olympus Mini Service Manual 1 1 1 OM1R SM GB01R 1 ...

Page 8: ...Introduction 1 2 OM1R SM GB01R This page intentionally left blank 1 ...

Page 9: ...obilising the vehicle prior to service procedures Before commencing any service procedure the refuse collection vehicle must be immobilised as follows 1 Stand the vehicle on clean level and stable ground 2 Engage the parking brakes 3 Select Neutral N 4 Stop the engine 5 Chock the wheels 6 Check that the tailgate is in the normal lowered position locked to the body 7 Turn the Body main switch to of...

Page 10: ...Introduction 1 4 OM1R SM GB01R This page intentionally left blank 1 ...

Page 11: ...leanliness 2 8 2 8 6 Moving or rotating parts 2 9 2 8 7 Hot components 2 9 2 8 8 Live work 2 9 2 8 9 Fasteners 2 9 2 8 10 Protecting vehicle components during grinding drilling and welding 2 9 2 8 11 Welding on or near the vehicle 2 9 2 8 12 Manual handling and movement of loads 2 10 2 8 13 Access and lifting equipment 2 10 2 8 14 Cleaning of equipment 2 10 2 8 15 Environmental protection precauti...

Page 12: ...Health and safety 2 2 OM1R SM GB01R This page intentionally left blank 2 ...

Page 13: ...dern commercial vehicle chassis cabs 2 2 Safety symbol warnings cautions and notes The following Safety Symbol is used throughout this Manual to indicate information that is essential to Health and Safety The symbol applies to ALL information contained in this chapter All Safety Information MUST be strictly adhered to WARNINGS WARNING A WARNING IS PRINTED IN THIS STYLE IT REFERS TO ANY PROCEDURE W...

Page 14: ... work period Note Preparations containing lanolin replace the natural skin oils which can be removed when washing 11 Do not wash skin with fuels thinners or solvents 12 Obtain medical advice if skin disorders develop 2 5 2 Protective clothing 1 Use and take care of all personal protective clothing and equipment supplied by your employer for your safety 2 While operating or carrying out maintenance...

Page 15: ...sed from the side or rear of the vehicle and it becomes necessary to work on top of the body roof or tailgate always wear an approved safety harness connected to a Safety Harness Attachment Lug see Fig 2 1 2 in accordance with all prevailing safe systems of work Health and Safety Regulations Workshop Regulations and Workshop Codes of Practice Safety Harness Attachment Lugs SHAL are primarily desig...

Page 16: ...espiration if the patient has stopped breathing 3 Summon an ambulance and send the patient to hospital If an ambulance is not available make sure the patient is accompanied by a proficient First aid person 2 7 4 Burns In the event of a skin burn immediately administer the following emergency treatment 1 Run cold clean water over the affected area 2 Cover the burned area including any clothing with...

Page 17: ...place activities Not carry out work which could expose employees to hazardous substances without first considering the risks and the necessary precautions and what else is required to comply with COSHH Prevent or control employees exposure to hazardous substances Ensure that control measures are used and maintained properly and that safety procedures are followed Monitor the exposure of employees ...

Page 18: ...he keys while work is in progress 6 If required turn the vehicle s battery isolation switch if fitted to off or disconnect the vehicle s battery 2 8 4 General workshop precautions 1 Chock the vehicle wheels at all times when maintenance work is in progress Refer to chassis cab manufacturer s Workshop Manual for information and instructions 2 Personnel must not enter the body or tailgate hopper unl...

Page 19: ...plit pins etc always use new fasteners Do not re use old fasteners except where specifically mentioned in the text 2 8 10 Protecting vehicle components during grinding drilling and welding When grinding drilling and welding or similar take appropriate precautions to prevent damage to pipes hoses wiring glazing cab paintwork and rubber suspension parts 1 Shield vulnerable components from the sparks...

Page 20: ... zone 6 Keep the work area clean and free from obstruction 7 Keep any personnel not involved with the procedure at a safe distance 2 8 13 Access and lifting equipment Some maintenance tasks require the erection of access platforms and or lifting equipment to provide a safe stable platform 1 Access platforms or lifting equipment must be erected by qualified personnel Under no circumstances must unq...

Page 21: ...levant local authority for disposal Wear a filter mask when you work on contaminated filters 5 Avoid lengthy excessive or repeated skin contact with diesel fuel lubricating oils hydraulic oil and lubricants Protect exposed skin with suitable barrier agent or protective clothing 6 Use an approved cleaning agent to clean ALL areas of skin that have come into contact with diesel fuel lubricating oils...

Page 22: ...t nozzle to approach closer than 1 metre 2 Whenever possible do not direct the jet straight at components but aim across them 3 Do not direct the jet at electrical components 2 10 Vehicle electrical systems 2 10 1 General electrical precautions 1 Always ensure correct polarity when making cable connections 2 Before using any test equipment always read the manufacturer s instructions 3 Do not pierc...

Page 23: ... higher ampere rating than specified and under no circumstances bridge the fuse terminals with anything other than a fuse Non observance of the latter may cause components to be damaged and or wiring to overheat leading to a fire 2 11 Welding on or near the vehicle Exercise extreme care when carrying out welding operations Electric arc welding will seriously damage any electronic items fitted to t...

Page 24: ...oth while loosening the pipe nuts to prevent pressurised oil spraying from connection 3 When working on the hydraulic and pneumatic systems it is important to ensure maximum cleanliness 4 Always clean the area around a connection before dismantling a joint 5 Plug any open connections as soon as possible 6 Use only lint free cloths 7 Wherever possible avoid using compressed air for cleaning compone...

Page 25: ...checks waste container lifting device when fitted 3 22 3 3 Daily safety checks footboard when fitted 3 24 3 4 Daily safety check safety light curtain when fitted 3 26 3 5 Warning labels 3 28 3 6 Explanation of pictorial warning labels 3 30 Daily checks Olympus Mini Service Manual 3 3 1 OM1R SM GB01R 3 ...

Page 26: ...Daily checks 3 2 OM1R SM GB01R This page intentionally left blank 3 ...

Page 27: ...y 7 Lock all cab doors Remove and retain the keys 8 Walk around the Refuse Collection Vehicle and Make sure that there is no refuse paper or flammable materials near the engine or exhaust These could cause a fire when the engine is started If necessary tilt the cab see Chassis cab Manufacturer s Operator s Handbook to make a thorough inspection Visually check level of oil in hydraulic oil tank The...

Page 28: ...t over rides function on cab control panel 4642 OM1 R GB G1 2748 DS002 OL1 D DE G3 01 06 2013 Hyd Öl Temp Grad C 09 00 00 32 o C 0 Keine Fehler 0 Keine Fehler 0 Keine Fehler 01 06 2013 Hyd Öl Temp Grad T T C 09 00 00 32 o C 0 Keine Fehler 0 Keine Fehler 0 Keine Fehler 17 Make sure that the parking brake is applied and Neutral N is selected 18 Engage the PTO see chassis cab manufacturer s operating...

Page 29: ...l Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS028 OL1 D GB G2 24 Check that Tailgate clear pictogram is white then press and release the switch below it one or more times so that the pictogram changes colour to green and a white number from 1 to 4 appears in the pictogram 2748 DS046 OL1 D GB G1 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0...

Page 30: ...EVICE IF FITTED RAISED DRIVER MUST BE IN CAB PARKING BRAKE MUST BE APPLIED ALL PERSONNEL MUST BE CLEAR OF FRONT AND REAR OF VEHICLE VEHICLE MAY LURCH FORWARDS 26 Firmly apply the footbrake Then select a gear Tailgate out of locks warning buzzer in the cab should sound immediately the gear is selected 27 Select Neutral N Tailgate out of locks warning buzzer in the cab should silence immediately Neu...

Page 31: ...B G1 Start pack cycle push button 4550 OM1 R GB G1 Rescue push button Compaction mechanism should not operate 32 Turn the Body main switch off and then on 33 Press and release the Internal discharge controls switch The screen should display the Body discharge internal controls mode and Tailgate out of locks pictogram 2748 DS048 OL1 D GB G3 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No erro...

Page 32: ...ler 0 Keine Fehler 32 o C 01 06 2013 09 00 00 Hyd Öl Druck bar 210 Bar 2 Tailgate should rotate smoothly upwards about the hinge pins Vehicle reversing alarm should sound 36 While tailgate is rising release the switch before it reaches its fully raised position Tailgate should stop rising immediately the switch is released Tailgate should not lower Tailgate out of locks pictogram should display on...

Page 33: ...s full height the compaction mechanism should complete the number of full cycles shown by the white number in the tip clear pictogram i e packer plate open carriage plate down packer plate close and then carriage plate up in one continuous sequence until fully packed when it should stop WARNINGS MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTAINER LIFTING DEVICE...

Page 34: ... 00 Hyd_Oil_Pressure 60 Bar 2 Ejection plate should eject smoothly without judder 41 Press the retract switch Release the switch when the ejection plate has reached the end of its travel 4670 OM1 R GB G1 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 210 Bar 2 Ejection plate should retract smoothly without judder Daily checks 3 ...

Page 35: ... errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 60 Bar 2 WARNING MAKE SURE THAT THE TAILGATE AREA IS CLEAR OF PERSONNEL 43 Press each of the two push buttons on the Tailgate lowering control panel separately 4671 OM1 R GB G1 Tailgate should not lower Daily checks 3 11 OM1R SM GB01R 3 ...

Page 36: ...ate out of locks pictogram should continue to display on the control panel screen Release both push buttons 47 Press the two push buttons on the Tailgate lowering control panel simultaneously until the tailgate engages locks and then release the push buttons 4582 OM1 R GB G1 Tailgate should rotate smoothly downwards about the hinge pins until it engages face of body then lower into locks Vehicle r...

Page 37: ...n Immediately the tailgate reaches full height the compaction mechanism should not operate 50 Press and hold the Lower tailgate to 1 metre switch until the tailgate stops lowering and then release the switch 4700 OM1 R GB G1 A 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 10 Bar Tailgate should rotate smoothly downwards about t...

Page 38: ...6 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 52 Press and release the return switch 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS030 OL1 D GB G2 The screen should display the Body system run mode and...

Page 39: ... fixed welded rave rail Energise each Start pack cycle push button in turn and then press and release the Start pack cycle push button 4552 OM1 R GB G1 Green LED below push button should be illuminated Compaction mechanism packer plate should open 1 carriage plate and packer plate should move downwards 2 packer plate should close 3 carriage plate and packer plate should move upwards 4 and automati...

Page 40: ...Carriage plate and packer plate should continue to move fully downwards from stopped position and then stop when carriage plate fully lowered 61 Press and hold the Start pack cycle push button again The packer plate should close Release the push button after the packer plate has started to close Packer plate should automatically close and then the carriage plate and packer plate should move upward...

Page 41: ...ving press the Emergency stop push button 4679 OM1 R GB G1 Compaction mechanism should stop immediately Emergency stop warning buzzer in the cab should sound Emergency stop operated pictogram should display in the control panel screen 64 On each compaction mechanism control panel press in turn the Start pack cycle push button 4552 OM1 R GB G1 Compaction mechanism should not operate Signal push but...

Page 42: ...GB01 002 66 Pull the Emergency stop push button outwards 4678 OM1 R GB G1 Emergency stop warning buzzer in the cab should silence 67 Press the Start pack cycle push button 4552 OM1 R GB G1 Compaction mechanism should not operate 68 Turn the Body main switch off and then on again 0 0 OL1SMGB01 002 69 Press the Start pack cycle push button 4552 OM1 R GB G1 Check that the compaction mechanism restart...

Page 43: ... 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS005 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 09 00 00 Hyd_Oil_Pressure 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS031 OL1 D GB G2 WARNING MAKE SURE THAT YOU KNOW ...

Page 44: ...t the tailgate resumes rotating upwards about the hinge pins until fully raised when it should stop without noticeable judder Vehicle reversing alarm should sound while Tailgate raise push button is pressed and tailgate is rising 4680 OM1 R GB G1 75 When the tailgate is raised the Tailgate fully raised pictogram should display on the control panel screen 76 Press the Ejection plate eject push butt...

Page 45: ...hould retract smoothly without judder 4682 OM1 R GB G1 78 Press the Ejection plate eject push button Release the push button when the ejection plate has reached the end of its travel Ejection plate should eject smoothly without judder 4681 OM1 R GB G1 WARNING MAKE SURE THAT THE TAILGATE AREA IS CLEAR OF PERSONNEL Daily checks 3 21 OM1R SM GB01R 3 ...

Page 46: ...cks footboard when fitted on page 3 24 82 Check level of oil in hydraulic oil tank and top up if required see 4 1 To check hydraulic system oil level on page 4 3 3 2 Daily safety checks waste container lifting device when fitted Caution If one or more footboards is fitted lower footboard s before operating waste container lifting device The following daily safety checks must be carried out on the ...

Page 47: ...til the lifting device reaches full height 6 Operate the Lifting device down push button 4562 OM1 R GB G1 Check that the lifting device lowers 7 While the lifting device is lowering release the push button Check that the lifting device mechanism stops immediately and remains in the stopped position 8 Operate the Lifting device down push button until the lifting device reaches fully down position C...

Page 48: ... Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors 4585 OM1 R GB G1 1 the compaction mechanism does not operate Open system vehicles the waste container lifting device mechanism does not operate WARNING TAKE EXTREME CARE CARRY OUT FOLLOWING TEST ON TRAFFIC FREE ROAD With the operative still standing on the footboard drive the vehicle forwards and steadily accelerate the vehicle C...

Page 49: ...5 minutes the refuse collection vehicle compaction and discharge mechanisms do not operate while the Footboard interlock override switch delay timer pictogram is displayed and operates when it has extinguished the waste container lifting device mechanism does not operate while the Footboard interlock override switch delay timer pictogram is displayed and operates when it has extinguished 4707 OM1 ...

Page 50: ...reen see Fig 3 1 1 and receiver screen see Fig 3 1 2 When the body main switch is turned off LED s A B C D should be off 7 segment display E should be off 4727 OM1 R GB G1 2 1 Power Transmitter Receiver A B C D E Fig 3 1 Safety light curtain status displays 3 Turn the body main switch on LED A should turn green LED B should be off LED C should turn green LED D should turn yellow 7 segment display ...

Page 51: ...rod from the light curtain 6 Press and release the Start pack cycle push button 4552 OM1 R GB G1 7 While the packer plate is closing and the carriage plate is moving upwards place a suitable soft test rod into the light curtain The mechanism should continue to operate and complete the packing cycle 8 Remove the soft test rod from the light curtain 9 Press and release the Start pack cycle push butt...

Page 52: ...tering 855371B Refer to workshop manual before any maintenance or repair operations 855377B6 It is an offence for any person to ride on the rear of a moving vehicle Note Label not fitted when footboards are fitted Fig 3 3 Warning labels left hand side rear of refuse collection bodywork Daily checks 3 28 OM1R SM GB01R 3 ...

Page 53: ...CLEAN UP ALL SPILLAGES ONLY USE CLEAN OIL OF THE CORRECT SPECIFICATION Max PT No 10019961 Stop engine before entering 104dB It is an offence for any person to ride on the rear of a moving vehicle Note Label not fitted when footboards are fitted Fig 3 4 Warning labels right hand side of refuse collection bodywork 4531 OM1 R GB G1 855373B 855375B 855373B 855375B Fig 3 5 Warning labels rear of refuse...

Page 54: ...3 6 Explanation of pictorial warning labels Lubrication point Do not put fingers into hole 104dB Maximum A weighted sound pressure level at operator s work stations Daily checks 3 30 OM1R SM GB01R 3 ...

Page 55: ...CONTENTS PAGE 4 Hydraulic system oil level 4 3 4 1 To check hydraulic system oil level 4 3 4 1 1 Topping up hydraulic oil 4 8 Hydraulic system oil level Olympus Mini Service Manual 4 4 1 OM1R SM GB01R 4 ...

Page 56: ...Hydraulic system oil level 4 2 OM1R SM GB01R This page intentionally left blank 4 ...

Page 57: ...hydraulic system oil level WARNING THE BODY MUST BE EMPTY WHEN CHECKING THE HYDRAULIC SYSTEM OIL LEVEL The level is checked with Tailgate fully lowered cylinders closed The ejection plate fully ejected to the rear of the body cylinder open The compaction mechanism packer plate is open and carriage plate is fully lowered cylinders closed This is shown on the label adjacent to the hydraulic oil leve...

Page 58: ...on The screen will display the Body system run mode 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors Check that the System on pictogram displays in the message area of the screen WARNING IF A WARNING PICTOGRAM DISPLAYS IN THE MESSAGE AREA OF THE SCREEN INVESTIGATE AND RECTIFY THE CAUSE OF THE WARNING BEFORE OPERATING THE SYSTEM 10 Press the Start p...

Page 59: ... 00 00 0 No errors 0 No errors 0 No errors 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS028 OL1 D GB G2 WARNING MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTAINER LIFTING DEVICE IF FITTED RAISED 15 Press and hold the tailgate raise switch until the tailg...

Page 60: ...errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 60 Bar 17 Press the two push buttons on the Tailgate lowering control panel simultaneously to lower the tailgate fully into its locks 4582 OM1 R GB G1 The engine speed will increase When the tailgate is lowered fully and engaged in its locks the System on pictogram will display on the control panel screen 18 Turn the Body main switch to off positi...

Page 61: ...red and the ejection plate to the rear of the body the level should align with the point of the arrow corresponding to the body size see Fig 4 1 C on the label adjacent to the upper glass Caution If the oil level is only visible in the lower sight glass the hydraulic system must not be used until the system has been filled to the correct level Hydraulic Oil ONLY USE CLEAN OIL OF THE CORRECT SPECIF...

Page 62: ...ct level using new hydraulic oil to the correct specification Temperature Range ISO Grade ISO Oil Type 30 to 80 VG 46 HL mineral oil to UNE EN ISO 6743 4 2002 Caution Do not mix different oil types 3 Replace the filler cap 4 If the hydraulic level is very low inspect all the hydraulic systems including waste container lifting device if fitted for hydraulic oil leaks Rectify any leaks before operat...

Page 63: ...ins 5 4 5 1 1 Body drain 5 4 5 1 2 Tailgate drains 5 4 5 2 Daily cleaning 5 5 5 3 Pressure washing 5 6 5 4 Cleaning the leachate tank 5 6 5 5 Cleaning the light curtain units 5 6 Cleaning Olympus Mini Service Manual 5 5 1 OM1R SM GB01R 5 ...

Page 64: ...Cleaning 5 2 OM1R SM GB01R This page intentionally left blank 5 ...

Page 65: ...D WITH A BODY TAILGATE SEAL WHICH MINIMISES FLUID LOSS WHEN COLLECTING VERY WET REFUSE IT IS IMPORTANT THE SEAL AND ITS MATING FACE ARE KEPT CLEAN CLEANING SHOULD TAKE PLACE AFTER THE DISCHARGE OPERATION REPORT ANY SEAL DAMAGE TO SUPERVISION IMMEDIATELY WHEN CLEANING THE TAILGATE AND BODY BE AWARE OF DANGEROUS REFUSE SUCH AS GLASS AND HYPODERMIC NEEDLES NEVER CLEAN THE SEAL AREA UNLESS THE TAILGAT...

Page 66: ...h side of the tailgate and leachate tank if fitted 4683 OM1 R GB G1 Fig 5 2 Tailgate drains 1 Plug Type 4689 OM1 R GB G1 B A A To open Unscrew drain plug off drain B To close Screw drain plug onto drain 2 Valve Type 4692 OM1 R GB G1 D C C To open Turn lever outwards D To close Turn lever inwards WARNING MAKE SURE THAT ALL BODY AND TAILGATE DRAINS ARE CLOSED AND THAT THEIR OPERATING LEVERS ARE NOT ...

Page 67: ...Pull the electrical distribution cupboard outwards 2 this enables access to the body in front of the ejection plate 14 Clean out any refuse which has entered the body in front of the ejection plate 15 Clean debris from the body sump and wash out thoroughly Drain through the external hose to ensure thorough cleaning is achieved 16 Push the electrical distribution cupboard back into position and sec...

Page 68: ...ignition off Remove and retain the key 8 Secure a sign DO NOT START or OPERATE VEHICLE to the steering wheel 9 Lock all cab doors Remove and retain the keys 10 Using a proprietary pressure washer clean the compaction mechanism and ejection plate and their slide blocks and tracks 11 Inspect the seal and its mating face 12 Unprop the tailgate see Operator s Handbook 13 Close the tailgate drains see ...

Page 69: ... mounting bolts 6 11 6 9 2 Clean the tailgate proximity switches 6 12 6 9 3 Hydraulic system components checks 6 13 6 9 4 Electrical system checks 6 13 6 9 5 Slide block checks 6 14 6 9 6 Waste container lifting device checks 6 15 6 10 12 Week 600 operating hours service operations 6 16 6 10 1 Body checks 6 16 6 10 2 Tailgate checks 6 16 6 10 3 Waste container lifting device checks 6 17 6 10 4 Pow...

Page 70: ...Scheduled maintenance 6 2 OM1R SM GB01R This page intentionally left blank 6 ...

Page 71: ... to the procedures and at the intervals specified in this chapter Only approved lubricants fluids and replacement parts must be used when servicing the vehicle as specified in Chapter 8 General specification data of this Manual If the vehicle is being operated in Great Britain the lifting device mechanism its components and any associated accessories such as hooks shackles slings etc should be ins...

Page 72: ...n integrity and security of hydraulic system components Page 6 13 X X X X Check condition integrity and security of electrical system components Page 6 13 X X X X Check condition of ejection plate slide blocks Page 6 14 X X X X Check condition of carriage plate slide blocks Page 6 14 X X X X Check condition integrity and security of body components Page 6 16 X X X Check condition integrity and sec...

Page 73: ... 5 X X X X X X Daily safety check Page 3 22 X X X X X X Check warning labels Page 3 28 X X X X X X Lubricate hinges and linkages Page 6 9 X X X X X Check condition of all buffers and rubbers Page 6 10 X X X X X Check condition of all safety guards Page 6 10 X X X X X Check condition integrity and security of hydraulic system components Page 6 13 X X X X Check condition integrity and security of el...

Page 74: ...N ACCESS HOLE 6 When the grease nipple see Fig 6 1 1 is visible in the access hole press an Emergency stop push button 7 Reset the Emergency stop push button 8 If the vehicle is fitted with a waste container lifting device operate the Lifting device up push button until the lifting device reaches full height 9 Immobilise the vehicle see 1 2 Immobilising the vehicle prior to service procedures on p...

Page 75: ...rease Shell Retinax A BP Energol LS2 or L2 Castrol LM Total EP2 Energol HLP32 12 If the vehicle is fitted with footboards clean the grease nipples see Fig 6 2 2 and lubricate with the recommended grease Shell Retinax A BP Energol LS2 or L2 Castrol LM Total EP2 Energol HLP32 4696 OM1 R GB G1 1 1 1 1 1 1 1 1 1 2 2 1 1 A A A Fig 6 2 Waste container lifting device lubrication points 6 ...

Page 76: ... ROTATES WHEN THE ENGINE IS RUNNING Where a propeller shaft is used to connect the hydraulic pump to the power take off grease nipples may be fitted to enable greasing of the universal joints and splined connection see Fig 6 3 1 These should be greased every 300 hours 4699 OM1 R GB G1 1 Fig 6 3 Power Take Off lubrication points 6 ...

Page 77: ... Make sure you remove foreign matter from The hopper 2a The slide ways in the tailgate 2b The gap between the carriage plate and retaining plate 2c The bottom end of the carriage plate carriage plate cylinder bearing block 2d The area where hydraulic cylinders close into the body or small spaces 2e 3 Clean the body in front of the ejection plate Make sure that all debris and foreign matter is remo...

Page 78: ...VER OPERATE THE LIFTING DEVICE IF ANY OF THE GUARDS ARE MISSING OR DAMAGED 6 Check the lifting device for any signs of undue wear and or damage 7 Report any findings to supervision 4729 OM1 R GB G1 2 2 2 3 3 4 6 9 6 Week 300 operating hours service operations The following service operations should be carried out once every 6 weeks 300 operating hours or more frequently when the Refuse Collection ...

Page 79: ...Components Size Spring length gap mm Nm 1 Front body mounting bolts M12 x 35 142 2 Front body mounting bolts M12 x 90 42 3 Body bracket mounting rail bolts M10 x 25 48 4 Body bracket mounting setscrews M10 x 25 48 5 Intermediate body mounting bolts M12 x 35 142 6 Intermediate body mounting bolts M14 X 40 225 4703 OM1 R GB G1 A B C A A A A B B C C C C B B 2 2 6 3 3 4 4 1 5 Fig 6 5 Body mounting bol...

Page 80: ...the tailgate proximity switches 1 Remove the tailgate side covers and clean the tailgate proximity switches Carefully wipe any dirt away from the face of each proximity switch and its operating plate 4592 OM1 R GB G1 Fig 6 6 Tailgate proximity switches 6 ...

Page 81: ...exposure to excessive heat Check for leaks particularly when the system is in operation Check for signs of weakness or bulging particularly when under maximum pressure Check for signs of perishing on the outer cover 6 9 4 Electrical system checks 1 Examine all the electrical wiring looms their connectors wires and mountings for condition security fractures displacement wear distortion cracks damag...

Page 82: ...Check condition of ejection plate slide blocks 1 The maximum wear allowed for any of each slide block s dimensions is 6 mm 2 Check condition of carriage plate slide blocks 2 The maximum wear allowed for any of each slide block s dimensions is 6 mm 4730 OM1 R GB G1 1 2 6 ...

Page 83: ...nsure all clips and supporting devices are present and securely attached and fastened 4 Check all flexible hydraulic hoses for security fractures displacement wear distortion cracks damage leaks corrosion deterioration stretching or twisting fouling by moving parts or chafing Make sure hoses have sufficient room to move as necessary without fouling any part of the vehicle Make sure there are no sh...

Page 84: ...aring members near the mounting points Tailgate lock pins Cylinder mountings and pivots Body access door and its hinges locks and switch Ejection plate Ejection plate guides Ejection plate slide blocks 3 Check that structural stressed panels are not damaged or worn to less than 75 of their original thickness 6 10 2 Tailgate checks 1 Check that the tailgate is sitting square on the body 2 Check tha...

Page 85: ...er Take Off propeller shaft if fitted 1 Examine the power take off propeller shaft universal joints for security worn bearings damage to grease seals and cracks 2 Examine the power take off propeller shaft flange nuts for security and condition 3 Examine the power take off propeller shaft slider joint and grease seal for wear and damage 6 10 5 Hand wash unit optional item 1 Check the hand wash uni...

Page 86: ...m control panel again and time one complete cycle it should be 15 16 secs Body hopper empty 4552 OM1 R GB G1 4675 OM1 R GB G1 3 1 2 4 6 10 8 Tailgate lower time check Check the tailgate lower time as follows 1 Start engine WARNINGS MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE BODY TAILGATE AND REAR OF THE VEHICLE MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTA...

Page 87: ...tom of the bowl and the O ring locations 9 Fit new O rings and a new filter element 10 Install the filter bowl assembly and tighten to 20 4 Nm 15 lbf ft Return line oil filter 11 Remove the 3 screws securing the filter head cover plate 12 Remove the square section sealing ring from the cover plate and fit a new one 13 Remove the filter element and insert a new filter element 14 Fit the filter head...

Page 88: ... The following service operations should be carried out in addition to the Daily service checks Weekly service operations 6 Week 300 operating hours service operations 12 Week 600 operating hours service operations and 12 Month 2400 operating hours service operations 1 Replace ejection plate slide blocks 1 Refer to Olympus Mini Workshop manual for procedure 2 Replace carriage plate slide blocks 2 ...

Page 89: ...nance Olympus Mini Service Manual 7 7 1 OM1R SM GB01R CONTENTS PAGE 7 Operational maintenance 7 2 7 1 Fuses and relays 7 2 7 2 Maintenance screen 7 4 7 2 1 Entering a password 7 5 7 2 2 Adjusting the clock calendar 7 6 7 ...

Page 90: ... 2 Release the anti loose clip see Fig 7 1 1 3 Pull the electrical distribution cupboard outwards see Fig 7 1 2 4 Unlatch the cover and lower it see Fig 7 1 3 5 Unscrew the bolts securing the access door and open it see Fig 7 1 4 Fuses Fuse Function Fuse rating F11 Sensors and control push buttons 5A F10 Spare 10A F9 Spare 10A F8 Rear view camera 5A F7 Controller outputs 15A F6 Waste container lif...

Page 91: ...7 3 OM1R SM GB01R 4687 OM1 R GB G1 BC9 CR10 CR8 CR1 SW1 SPR1 BC8 BC10 SPR2 CS BR RW HL SW2 SIDE 1 SIDE 2 CR4 F10 F9 F8 F7 F6 F5 F4 F3 F2 CR5 CR6 CR2 CR3 BC7 10 F11 6 10 5 15 7 5 2 10 5 15 F1 15 4 3 2 1 Fig 7 1 Main body box 7 ...

Page 92: ...C 0 No errors 0 No errors 0 No errors Hyd Oil Temp 09 00 00 0 No errors 0 No errors 0 No errors Hyd Oil Temp 01 06 2013 09 00 00 F2 F3 F4 F5 F6 F7 F8 0 No errors 0 No errors 0 No errors Password Level 32 o C 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors To leave the maintenance screen menu Press this switch to return from the maintenance screen ...

Page 93: ...p 32 o C 01 06 2013 09 00 00 F2 F3 F4 F5 F6 F7 F8 0 No errors 0 No errors 0 No errors Password Level 4 Using the keys F2 to F8 as a numerical keypad enter the password All passwords comprise 6 digits from 2 to 8 Example For password 226534 press keys F2 F2 F6 F5 F3 F4 As each number is entered the square changes colour from blue to white The screen will display the Maintenance screen appropriate t...

Page 94: ...ttings 1 10 100 and 1000 If the Scale setting is not suitable for the value you are setting e g 100 or 1000 for setting Hours or Minutes incorrect values will be shown when you try to set a value 3 If the value is not suitable for example it shows 100 when you want to change the time in steps of 1 hour press the Scale switch until the correct value 1 is shown Each press of the switch changes the S...

Page 95: ...Day 01 Minute 00 Month 06 Second 00 Hour 09 Minut Hour 11 Minut 7 Press Set to confirm the setting 2748 DS076 OL1 D GB G3 0 No errors Hyd Oil Temp Date 01 06 2013 Time 11 00 00 0 No errors 0 No errors 32 o C Hyd Oil Pressure 2 Bar 01 06 2013 Config Date Time 09 00 00 SET Date Set Scale 1 Year 2013 Hour 11 Day 01 Minute 00 Month 06 Second 00 8 Press either of the arrow switches to select the next p...

Page 96: ...15 Month 06 Second 00 Date 01 06 2013 Time 11 15 00 Hour 11 Minute 15 Secon Hour 11 Minute 15 10 Press the return switch to return to the maintenance screen 2748 DS079 OL1 D GB G3 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 Maintenance 11 15 00 Config Date Time Data Logger Inform Monitoring Inform Config Inform Monitoring In Out Config RCV RIDE ON REAR ENTER BODY WITH ENGINE...

Page 97: ... PAGE 8 General specification data 8 3 8 1 Body identification label 8 3 8 2 Typical operation times 8 3 8 2 1 Cycle time 8 3 8 2 2 Ejection plate 8 3 8 2 3 Tailgate raise lower 8 3 8 3 Noise level 8 3 8 4 Hydraulic pressures 8 3 8 5 Hydraulic oils and greases 8 4 8 6 Dimensions 8 5 8 ...

Page 98: ...General specification data 8 2 OM1R SM GB01R This page intentionally left blank 8 ...

Page 99: ...e Cycle time with an empty tailgate 15 16 seconds 8 2 2 Ejection plate Eject stroke 25 35 seconds Note Ejection plate times are approximate because of friction on the tracks Times may vary depending on body size and type of refuse 8 2 3 Tailgate raise lower Tailgate raise 17 21 seconds Tailgate lower 22 28 seconds 8 3 Noise level The maximum A weighted sound pressure level at operator s work stati...

Page 100: ...ade ISO Oil type 30 to 80 VG 46 HL mineral oil to UNE EN ISO 6743 4 2002 Recommended greases Application Manufacturer s specification General lubrication Shell Retinax A BP Energol LS2 or L2 Castrol LM Total EP2 Energol HLP32 Carriage plate Packer plate pivot pins Fuchs Renolit Aqua 2 or similar lubricant to DEF STAN 91 34 1 8 ...

Page 101: ...3 H6 405 Height from chassis base to the platform mm 3 H7 200 Maximum external width mm W1 2000 Tailgate internal width without bin lifter mm W2 1600 Hopper volume m3 1 Packing surface pressure kg cm2 2 3 Compaction mechanism cycle time s 15 Absortion speed m3 min 2 5 Lifter Bar Lifter Lifting capacity Kg 500 Lifter weight including DIN arms Kg 250 Lifter overhang mm L4 360 Lifter comb height mm F...

Page 102: ...General specification data 8 6 OM1R SM GB01R This page intentionally left blank 8 ...

Page 103: ...Supplementary information Olympus Mini Service Manual 9 9 1 OM1R SM GB01R CONTENTS PAGE 9 Supplementary information 9 2 9 ...

Page 104: ...on 9 2 OM1R SM GB01R 9 Supplementary information Supplementary information owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes 9 ...

Page 105: ...tary information 9 3 OM1R SM GB01R Supplementary information owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes 9 ...

Page 106: ...tary information 9 4 OM1R SM GB01R Supplementary information owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes 9 ...

Page 107: ...tary information 9 5 OM1R SM GB01R Supplementary information owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes 9 ...

Page 108: ...tary information 9 6 OM1R SM GB01R Supplementary information owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes 9 ...

Page 109: ...Protective clothing 2 4 Safety symbol warnings cautions and notes 2 3 Trained personnel 2 3 Use of these instructions 2 3 Vehicle electrical systems 2 12 Disconnection and reconnection of electrical components 2 13 General electrical precautions 2 12 Welding on or near the vehicle 2 13 Working at high level 2 5 Workshop precautions procedures and practices 2 7 Access and lifting equipment 2 10 Cle...

Page 110: ...ydraulic system oil 6 19 Renew hydraulic oil filter Selements and breather filter 6 19 12 Week 600 operating hours service operations 6 16 Body checks 6 16 Compaction mechanism cycle time check 6 18 Hand wash unit optional item 6 17 Operational check 6 17 Power Take Off propeller shaft if fitted 6 17 Tailgate checks 6 16 Tailgate lower time check 6 18 Waste container lifting device checks 6 17 24 ...

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