Labrie Optimizer Maintenance Manual Download

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MAINTENANCE

MANUAL

RELEASE: February 2007

Part Number: 90313

Summary of Contents for Optimizer

Page 1: ...MAINTENANCE MANUAL RELEASE February 2007 Part Number 90313...

Page 2: ......

Page 3: ...opartsdepartmentpersonnel AnytimethatyouhaveaproblemwithaLabrieunit youshould contactyourvendorfirst Heshouldbeabletoprovideyouwiththe properhelprequired partsortechnicaladvice FIRST THINGS FIRST DO N...

Page 4: ...OPTIMIZERTM 4...

Page 5: ...e of contents 1 0 MAINTENANCE MANUAL 9 2 0 LUBRICATION 33 3 0 TROUBLESHOOTING SECTION 39 4 0 OPTIMIZER BODY PARTS 49 5 0 HYDRAULIC SYSTEMS PARTS AND DIAGRAMS 65 6 0 BODY AIR SYSTEMS PARTS AND DIAGRAMS...

Page 6: ...E 16 1 2 1 PACKING SYSTEM GENERALMAINTENANCE 16 1 2 2 PROXIMITY SWITCHESADJUSTMENT 16 1 2 3 PACKER BLADE WEAR PLATES REPLACEMENT 18 1 2 4 BODY GUIDE WEAR PLATES REPLACEMENT 19 1 2 5 PACKER BLADE REMOV...

Page 7: ...RS INSPECTION PROCEDURES 29 1 4 7 HYDRAULIC RESERVOIR INSPECTION PROCEDURE 29 1 4 8 HYDRAULIC FLUID REPLACEMENT PROCEDURE 30 1 4 9 HYDRAULIC FILTER REPLACEMENTPROCEDURE 32 1 4 10 HYDRAULIC STRAINER CL...

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Page 9: ...ectionbefore reusingtheequipment Onceamonth inspectthechassisandthebody foranybreaks cracksor possiblemalfunctions Any defects found must be repaired without delay To assure good working order of the...

Page 10: ...CEDURE Surface preparation Grit blasting Primary coat A n t i c o r r o s i v e epoxy primer Finishing coat Two 2 coats industrial type Imeron paint or equivalent Typeofsurfacefinishingrecommended 1 1...

Page 11: ...he hydraulic reservoir should be open Figure 1 1 Oncetheengineisstarted waitfortheairpressure to raise Once the air is above 70 psi you can then operate the equipment Oil Filter Filler Cap HYDRAULIC T...

Page 12: ...LINESS Cleanliness is part of safety Make sure that the equipment is kept in proper working order by removing any stacked garbage in the packer area Keep clean all the truck lights warning lights and...

Page 13: ...h this system perform the following steps to lift the body BODY HOISTING PROCEDURE A Unscrew the nuts of the 4 bolts 2 on each side that retain the body in place B Make sure to remove all hoses from t...

Page 14: ...WHEN THE SAFETY PROPS ARE NOT INSTALLED FAILURE TO DO SO WILL RESULT IN SERIOUS INJURIES OR EVEN DEATH PUTTHEBODY SAFETY PROPS IN PLACE SAFETY PROPS LOCKINGPIN USETHE PUMPLEVER TO LIFT THE BODY D C E...

Page 15: ...HAT THE ROOF IS NOT MEANT TO BE WALKED UPON BE VERY CAUTIOUS IF YOU HAVE TO WORK ON THE ROOF AREA ALWAYS FOLLOW PROPER LOCKOUT TAGOUTPROCEDURE SECTION 1 1 4 CLEANING BEHIND THE PACKER BLADE HOPPER DOO...

Page 16: ...erformeddaily itispossible thattheproximityswitcheswillnolongerstop thepackerautomatically Anaccumulationof dirt behind the packer prevent it to retract far enough to activate the proximity switch Als...

Page 17: ...ON when the packer blade reaches this position Apply the same procedure for the retractedposition proximityswitch 2 Test the packer for a full cycle Ensure that there is no knocking noise at the end...

Page 18: ...LATES FIGURE 1 6 REPLACING PACKERBLADE WEARPLATES Remove packer blade refer to packer blade removal procedure Sec 1 2 5 Remove the packer blade wear plates from packer blade Figure 1 6 Verify correspo...

Page 19: ...nders and move them out of the way Remove body wear plates by grinding or cutting the stitch welds attaching plates to guide Clean surfaces and position new plates by tacking them in place Once in pro...

Page 20: ...end of the body to easily access the pins Figure 1 8 Remove rear cylinder pins Figure 1 8 Retract cylinders Pull packer out of the body with lifting device Figure 1 9 FIGURE 1 8 PACKER BLADE CYLINDERS...

Page 21: ...ges 1 2 6 PACKERCYLINDERSREPLACEMENT PACKERCYLINDER REPLACEMENTPROCEDURE Extendthepackerbladecompletely Remove cylinder rear pins Figure 1 8 Retract the cylinders Remove hoses from cylinders and front...

Page 22: ...cylinders Cylinderpinsandcirclips Tailgatehingesandpins Wearonthebearingsurfaceofthelocking machanisms Wearonthetailgatelockpins FREQUENTLY VERIFY THAT THE RETAININGRINGS FIGURE 1 12 ARE IN PLACE TO A...

Page 23: ...l cracksmustbereported recordedandrepaired byqualifiedpersonnel 1 3 4 PROXIMITY SWITCHES ON TAILGATE Theunithasaproximity switchthatactivates the back up alarm and a warning buzzer inside the cab to t...

Page 24: ...impossible to start the packer That way youwillavoiddamagestothebody Also the roof MUST be open to raise the arms If the roof is closed it won t be possible to raise thearmsinordertoavoiddebrisfallin...

Page 25: ...HEY ARE WORKING PROPERLY 1 3 9 PROXIMITY SWITCH ADJUSTMENT Here is a general procedure to adjust the proximity switches GENERAL PROXIMITY SWITCH ADJUSTMENTPROCEDURE Park the truck on a safe and level...

Page 26: ...and adjust the oilpressureinthehydraulicsystem asfollows 2500PSI 25PSI 1500 RPM 2300PSI 700 RPM idle speed Frequently inspect the hydraulic lines and connections for leaks correct if necessary The su...

Page 27: ...ays 3 positions operated with an air actuator Forks 4ways 3positions operatedwithan air actuator MAIN HYDRAULIC VALVE Sliding roof Arm 4ways 3positions operatedwithanair actuator Packer 4 ways 3 posit...

Page 28: ...2450 and 2550 PSI Adjust the main relief if necessary Figure 1 17 Loosen the lock nut and turn the adjustment knob clockwise to increase the pressure and counter clockwise to reduce the pressure USE T...

Page 29: ...nting points pins retaining bolts etc 1 4 7 HYDRAULICRESERVOIRINSPECTION PROCEDURE Verifythattheoilinthereservoiriscleanand alwaysattheproperlevel HYDRAULICRESERVOIR MAINTENANCEPROCEDURE For increased...

Page 30: ...ied and the vehicle is tagged outformaintenancepurposes refer tothesection1 1 4 Lockout Tagout procedure 2 Start the engine engage the hydraulic pump and disable the speed up system 5 Use a clean cont...

Page 31: ...an cloth 11 Change the return filter element twice a year 12 Refill the tank until oil reaches the3 4oftheoilgauge Figure 1 20 Use a high quality oil that has good performance in cold weather if appli...

Page 32: ...STRAINER REPLACEMENT PROCEDURE Shut the engine off and let the hydraulic oil to cool down Clean around the filler cap and remove it Use a clean container of at least 60 gallons to drop the old oil int...

Page 33: ...12 BODY HOISTING SYSTEM MAINTENANCE TheOPTIMIZERTM isequippedwithahoisting systemusedtoraisedthebody Thissystem is fed by its own hydraulic pump see Figure 1 21 Since this pump is energized by electr...

Page 34: ...sed each time the body is raised These safety props MUST be lubricated properly to ensure their efficiency To used the safety props do the following steps HOW TO USE BODY SAFETY PROPS Raise the body b...

Page 35: ...see Figure 1 25 There are a greasing point on each side FIGURE 1 25 The hoisting system also needs to be lubricated properly The greasing points are located on each hoisting system cylinder One is lo...

Page 36: ...arm stops 3 Positionthecam sothereis4inches between its boss and the body see Figure 1 29 4 Tighten the retaining bolts of the cam 5 Lower and raise the arms while running the engine at idle speed and...

Page 37: ...37 MAINTENANCE FIGURE 1 29 CAM BOSS BODY 4 BETWEEN CAM BOSS AND BODY DECELERATIONVALVE PLUNGER DECELERATIONVALVE FIGURE 1 30 FIGURE 1 31 CAM BOSS...

Page 38: ...1 32 3 Tighten the retaining bolts of the cam see Figure 1 33 4 Raise and lower the arms while running the engine at idle speed and again while running the engine at 1500 RPM NOTE The arms should slow...

Page 39: ...l To avoid loss of air control on packer blade especially under cold wet weather conditions westronglyrecommendtocheck the following items AIRSYSTEMMAINTENANCE PROCEDURE Ensure that the parking brake...

Page 40: ...is open on tank Check oil level in tank and refill if necessary Check on ground for overnight leaks Check cylinders pump control valve and system for leaks Repair replace if required Replace hydraulic...

Page 41: ...41 MAINTENANCE...

Page 42: ...required Check for proper operation Check for proper operation Drain Check for leaks Check for proper operation tailgate alarm safety prop warning light ect Air tanks Pneumatic system Light and wirin...

Page 43: ...43 LUBRICATION...

Page 44: ...OPTIMIZERTM 44 2 0 LUBRICATION 46 2 1 RECOMMENDED LUBRICANT 46 2 1 1 HYDRAULIC FLUIDS 46 2 1 2 MOTOR OIL FOR VEHICLE 46 2 1 3 GREASE 46 LABRIE OPTIMIZER CHAPTER 2 0 Table of contents...

Page 45: ...45 LUBRICATION...

Page 46: ...ingoilsmaybeusedinthe Optimizer ShellTellus32orT 32 2 1 2 MOTOR OIL FOR VEHICLE Refertochassismanufaturer smaintenance manual 2 1 3 GREASE Any lithium base commercial multi purpose greasemaybeused For...

Page 47: ...47 LUBRICATION...

Page 48: ...OPTIMIZERTM 48 LUBRICATION CHART ON SIDE OF THE TRUCK...

Page 49: ...49 TROUBLESHOOTING...

Page 50: ...TIMIZER CHAPTER 3 0 Table of contents 3 0 TROUBLESHOOTING SECTION 52 3 1 TROUBLESHOOTING TABLE 52 3 2 INTERNAL LEAK DETECTION FOR CYLINDERS 55 3 3 TAILGATE LOCKING MECHANISM TROUBLESHOOTING 56 3 4 MAI...

Page 51: ...51 TROUBLESHOOTING...

Page 52: ...stoohigh 4 Oil level in reservoir too low 5 Contaminatedoil 3 Setthepressureatthereliefvalve to2500PSI 2 See section 2 0 for proper oil to use 2 NOTTHEPROPERGRADEOF OIL ie Too thin in hot temperatures...

Page 53: ...he hose 5 Openthevalvecompletely 2 Check if the relief valve is workingproperly 3 After any repairs was the hydraulicsproperlycleaned 2 Isthehydraulicoilclean 2 Invisibleminiatureparticles 1 Have the...

Page 54: ...No electrical power reaches thesolenoidvalve 1 Checkforpowersourceonthe solenoid valve located in the console 2 Adjustorreplacethelimitswitch 1 Openthetailgatecompletly 1 Thetailgateisnotfullyopened...

Page 55: ...pressure on the piston end 10 If oil leaks out of end A there is an internal leak Replace damaged parts INTERNAL LEAK DETECTION FOR CYLINDERS 3 2 INTERNALLEAKDETECTION FOR CYLINDERS 1 2 3 4 5 6 FIGURE...

Page 56: ...s working The pressure burst goes to the holding valve into port D1 and then out to the cylinder by port U1 This will keep the tailgate cylinders pressurized and the tailgate closed when packing mater...

Page 57: ...57 TROUBLESHOOTING Main relief Gauge port Velocity fuse FIGURE 3 3 Gauge 1 Gauge 2...

Page 58: ...elf If the tailgate seems to unlock by itself when using the packer the power bleed inside the valve might not work on the right side of the hydraulic cylinder Apply the following procedure FIGURE 3 4...

Page 59: ...Figure 3 3 and verify that it is cleanandthattheplungerismoving freely A new velocity fuse may be necessary Problem 2 Tailgate is LOWERING by itself One other problem that may be found on the tailgat...

Page 60: ...OPTIMIZERTM 60 3 4 MAINHYDRAULICSCHEMATIC...

Page 61: ...61 TROUBLESHOOTING Intentionally left blank...

Page 62: ...ULIC SYSTEMS PARTS AND DIAGRAMS 64 4 1 HYDRAULIC HOSES AND PIPES ON CHASSIS 64 4 1 1 HOW TO ORDER 64 4 1 2 HYDRAULIC PIPING TANK TO PUMP PETERBILT A320 4 2 65 4 2 PUMPS VALVES AND HYDRAULIC TANK 67 4...

Page 63: ...63 HYDRAULIC...

Page 64: ...ways specify the following a Body serial number eg FL98HHA b Type of body 40 cubic yards This capacity determines the length of the body therefore the type of hydraulic pipes hoses hoists and pumps c...

Page 65: ...65 HYDRAULIC 4 1 2 HYDRAULIC PIPING TANK TO PUMP PETERBILT A320 4 2...

Page 66: ...TUBINGASSY 1 8 60662 BODYRETURNHOSE 1 9 60685 SUPPORT HYDRAULICTUBINGASSY 1 10 73335 TANKSUCTIONHOSE 1 11 76842 PACKERRETURNHOSE 1 12 76857 SUPPORT 1 13 76859 HYDRAULICHOSE 1 14 76880 HYDRAULICHOSE 1...

Page 67: ...67 HYDRAULIC 4 2 PUMPS VALVESANDHYDRAULICTANK 4 2 1 HYDRAULICTANK...

Page 68: ...4 CIB00061 TANKCAP 1 5 HYF02157 ADAPTORREDUCED 1 6 HYF03010 45 DEGREEFITTING 1 7 HYF06275 TFITTING 1 8 HYF07825 90 DEGREEFITTING 1 9 HYF08810 ADAPTORREDUCED 1 10 HYF20015 SCHROEDERRETURNFILTER 1 11 H...

Page 69: ...69 HYDRAULIC 12 11 10 9 8 7 6 5 5 4 4 3 2 1 4 2 2 MUNCIEHYDRAULICPUMP NOTE FITTINGS VARY ACCORDING TO TRUCK CONFIGURATION...

Page 70: ...E 2 3 HYF07870 HYDRAULICFITTING 1 4 HYF13100 90 DEGREE FITTING 2 5 HYF13800 FITTING 2 6 HYF25015 ADAPTOR 1 7 HYP01175 MUNCIE LIVE PACK PUMP 1 8 HYS02500 TYRONEADAPTOR 1 9 QUB00700 BOLT 1 10 QUY00200 Y...

Page 71: ...71 HYDRAULIC 4 2 3 MAINVALVE 17 16 1 10 15 3 2 11 9 7 5 6 12 4 18 19 8 14 13...

Page 72: ...OR 3 7 HYF05167 90 ADAPTOR 1 8 HYF05168 90 ADAPTOR 1 9 HYF05185 ADAPTOR 4 10 HYF07100 45 ADAPTOR 1 11 HYF08000 90 ADAPTOR 2 12 HYF08050 90 ADAPTOR 2 13 HYF08110 90 ADAPTOR 1 14 HYF10050 SAFETY CAP 1 1...

Page 73: ...73 HYDRAULIC Intentionally Left Blank...

Page 74: ...74 BODY AIR SYSTEMS LABRIE OPTIMIZER CHAPTER 5 0 Table of contents 5 0 BODY AIR SYSTEMS PARTS AND DIAGRAMS 75 5 1 INTRODUCTION 75 5 2 GENEREAL PNEUMATIC DIAGRAM 77...

Page 75: ...BODY AIR SYSTEMS 75 5 0 BODY AIR SYSTEMS PARTS AND DIAGRAMS 5 1 INTRODUCTION This section contains a diagram presenting the pneumatic system of an Optimizer TM body...

Page 76: ...76 BODY AIR SYSTEMS...

Page 77: ...77 BODY AIR SYSTEMS 5 2 GENERALPNEUMATICDIAGRAM...

Page 78: ...OPTIMIZERTM 78 Intentionally Left Blank...

Page 79: ...ELECTRICAL LABRIE OPTIMIZER CHAPTER 6 0 Table of contents 6 0 ELECTRICAL SYSTEMS 80 6 1 ELECTRICAL SCHEMATICS 80 6 2 DELASTEK MODULE 80...

Page 80: ...assistance call Labrie Environmental Group Customer Support Center at 1 800 231 2771 6 2 DELASTEK MODULE All the electrical systems are controlled by a module located inside the cab console Figure 6 1...

Page 81: ...81 NOTES...

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