Right Hand General Maintenance - Superior Truck Equipment Inc.

Right Hand General Maintenance - Superior Truck Equipment Inc.
GENERAL MAINTENANCE
AUTOMIZER RIGHT-HANDTM
Release date: December 2006
Part #55472 rev. 1
1-2
AUTOMIZER RIGHT-HANDTM
1-3
FOREWORD
Here is the new Labrie Parts and Service manual for the
AUTOMIZERTM side-loading unit. We sincerely hope that
you will find it easy to use.
We have designed it in a way that will allow you to easily
make it available to drivers, mechanics, and to Parts
Department personnel.
Any time that you have a problem with a Labrie unit, you
should contact your local distributor first. He should be able
to provide you with the proper help required (parts or
technical advice).
FIRST THINGS FIRST:
DO NOT FORGET TO COMPLETE THE OWNER
REGISTRATION FORM AND TO SEND IT TO LABRIE
ENVIRONMENTAL GROUP, MAKING SURE TO INDICATE
THE “IN SERVICE DATE”. THIS DATE WILL BE USED TO
START THE WARRANTY PERIOD. OTHERWISE, THE
DATE OF DELIVERY FROM THE FACTORY WILL BE
USED.
GENERAL MAINTENANCE
1-4
AUTOMIZER RIGHT-HANDTM
1-5
GENERAL MAINTENANCE
AUTOMIZER RIGHT-HANDTM
Table of Contents
1.0
GENERAL MAINTENANCE .......................................................................... 1 - 9
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
GENERAL PRECAUTIONS .......................................................................... 1 - 10
GENERAL RESPONSIBILITIES OF THE EMPLOYER ............................... 1 - 12
GENERAL RESPONSIBILITIES OF THE EMPLOYEE ............................... 1 - 13
FIRE HAZARD ............................................................................................... 1 - 14
“LOCKOUT/TAGOUT” PROCEDURE ......................................................... 1 - 15
BODY SAFETY PROP .................................................................................. 1 - 16
TAILGATE SAFETY PROP ........................................................................... 1 - 17
SHUTDOWN PROCEDURE ......................................................................... 1 - 18
PRIOR TO START UP .................................................................................. 1 - 18
GENERAL CLEANLINESS ............................................................................ 1 - 20
CLEANING THE HOPPER AREA ................................................................. 1 - 21
PACKER MAINTENANCE ............................................................................. 1 - 24
1.12.1 GENERAL MAINTENANCE .........................................................................
1.12.2 LIMIT SWITCH ADJUSTMENT ...................................................................
1.12.3 REPLACING SLIDING SHOES AND WEAR PAD .....................................
1.12.4 SLIDING SHOE REPLACEMENT ...............................................................
1.12.5 WEAR PAD REPLACEMENT .....................................................................
1.12.6 PACKER REMOVAL ....................................................................................
1.12.7 FLOOR GUIDE REPLACEMENT PROCEDURE ........................................
1.12.8 PACKER ROLLER REPLACEMENT ...........................................................
1.12.9 FLOATING PANEL REMOVAL AND WEAR PAD REPLACEMENT ...........
1.12.10 PACKER CYLINDER REPLACEMENT .......................................................
1.12.11 CRUSHER PANEL MAINTENANCE ............................................................
1.13
-
24
26
30
30
34
38
42
45
46
48
50
TAILGATE AND BODY HINGES MAINTENANCE ....................................... 1 - 51
1.13.1
1.13.2
1.13.3
1.13.4
1.13.5
1.14
1
1
1
1
1
1
1
1
1
1
1
TAILGATE LOCKING MECHANISM ............................................................
TAILGATE SEAL AND HINGES INSPECTION ...........................................
BODY/CHASSIS HINGES INSPECTION ...................................................
BODY RAISED LIMIT SWITCH ..................................................................
TAILGATE LIMIT SWITCH ADJUSTMENT .................................................
1
1
1
1
1
-
51
51
52
52
53
HYDRAULIC SYSTEM MAINTENANCE ...................................................... 1 - 54
1.14.1 GENERAL MAINTENANCE ......................................................................... 1 - 54
1.14.2 HYDRAULIC CYLINDER INSPECTION PROCEDURES ........................... 1 - 55
GENERAL MAINTENANCE
1-6
GENERAL MAINTENANCE
AUTOMIZER RIGHT-HANDTM
Table of Contents
1.14.3 MAIN HYDRAULIC VALVE .........................................................................
1.14.4 PROPORTIONAL VALVE ............................................................................
1.14.4APROPORTIONAL VALVE PRESSURE ADJUSTMENT ...............................
1.14.5 HYDRAULIC TANK INSPECTION PROCEDURE .......................................
1.14.6 HYDRAULIC OIL REPLACEMENT PROCEDURE .....................................
1.14.7 FILTER ELEMENT REPLACEMENT PROCEDURE ...................................
1.14.8 STRAINER CLEANING PROCEDURE .......................................................
1.14.9 DUAL VANE PUMP .....................................................................................
1.14.10 PRESSURIZING THE TANK SYSTEM ........................................................
1.14.11 PUMP INSPECTION ...................................................................................
1.15
-
56
57
59
61
64
66
67
69
70
71
HYDRAULIC PRESSURE ADJUSTMENT ................................................... 1 - 72
1.15.1
1.15.3
1.15.4
1.15.5
1.16
1
1
1
1
1
1
1
1
1
1
BODY FUNCTION MAIN RELIEF VALVE ADJUSTMENT ..........................
ARM FUNCTIONS ADJUSTMENT PROCEDURE .......................................
GRABBER LOAD SENSE RELIEF .............................................................
ARM SPEED ADJUSTMENT ......................................................................
1
1
1
1
-
72
77
79
81
BODY HOIST INSPECTION AND REPLACEMENT PROCEDURE ........... 1 - 82
1.16.1 BODY HOIST INSPECTION ....................................................................... 1 - 82
1.16.2 BODY HOIST REPLACEMENT ................................................................... 1 - 84
1.17
ARM GENERAL MAINTENANCE ................................................................. 1 - 86
1.17.1 DAILY INSPECTION ...................................................................................
1.17.2 GRABBER LIMIT SWITCH .........................................................................
1.17.3 GRABBER AUTO-CLOSING .......................................................................
1.17.4 ADJUSTING THE GRABBER AUTO-CLOSING SYSTEM ..........................
1.17.5 AUTO-CLOSING PRESSURE SWITCH ADJUSTMENT ............................
1.17.6 GRAB PACK .................................................................................................
1.18
1.19
1.20
1.21
1
1
1
1
1
1
-
86
88
89
90
92
93
AIR SYSTEM MAINTENANCE ..................................................................... 1 - 94
SURFACE FINISHING AND PAINTING ........................................................ 1 - 95
ALLISON TRANSMISSION PROGRAMMING PARAMETERS .................... 1 - 96
AUTOMIZER PREVENTIVE MAINTENANCE CHART ................................ 1 - 97
AUTOMIZER RIGHT-HANDTM
1-7
GENERAL MAINTENANCE
1-8
AUTOMIZER RIGHT-HANDTM
1-9
1.0
GENERAL MAINTENANCE
DANGER, WARNING, CAUTION notations
appear throughout this manual and on labels
on and inside of the vehicle.
DANGER
The word DANGER precedes
information, which indicates an
hazardous situation, which if not
avoided, WILL result in death or
serious injury of the user or others.
WARNING
The word WARNING precedes
information, which indicates a
potentially hazardous situation, which
if not avoided, COULD result in
personal injury or death of the user or
others.
CAUTION
The word CAUTION precedes
information, which indicates a
potentially hazardous situation or
unsafe practice, which if not avoided,
MAY result in minor to moderate
injury to user or damage to the
equipment.
The word NOTE also appears in this manual
and precedes information, which is vital to
the proper operation and maintenance of
the vehicle equipment.
In spite of our efforts to build a vehicle that
is as safe as possible, the operator’s
safety certainly depends on the
precautionary measures taken while
operating or servicing the vehicle. If in
doubt,ask your supervisor or contact the
Labrie Service and Warranty Department
for any technical support you may require.
For maintenance of the chassis itself, refer
to the chassis manufacturer’s service
manual. Only body and packer components
are outlined in this manual.
Establish and apply a periodic inspection
program to keep moving parts in good
working order, properly adjusted and safe.
It is recommended that a brief inspection
be done by the operator EVERY DAY and
any detected malfunctions must be reported
for correction BEFORE using the
equipment.
Once a month, inspect the chassis and the
body for breaks, cracks or any potential
problems. Any defects found must be
repaired without delay. To ensure the good
working order of the equipment, particular
attention should be paid to structural
components in order to prevent
deterioration due to corrosion; touch-ups
and/or complete paint jobs should be done
when necessary.
GENERAL MAINTENANCE
1-10
1.1
GENERAL PRECAUTIONS
It is the employer’s responsibility to be
assured that their employees are qualified
and capable of operating this equipment.
THE FOLLOWING IS GENERAL SAFETY
AND OPERATIONAL PRECAUTIONS,
WHICH SHOULD BE ADHERED TO BY
OPERATORS (AND/OR MAINTENANCE
PERSONNEL) AT ALL TIMES.
1. Do not operate this vehicle before having
read and completely understood this
manual and the safety labels on the
vehicle. Maintenance personnel must
also read and understand the
Maintenance Manual for this vehicle
(and the maintenance related
information in this manual). In case of
any doubt, see your supervisor for
clarification.
2. The AutomizerTM units equipped with
the Right-HandTM arm are primarily
designed to be operated by only one
person.
3. The operator of the unit must have a
clear view of the operation of the lifting
arm at all times. The operator must be
able to stop the motion of the arm at
any time, in order to prevent injury to
surrounding people, damage to property
or to the lifting arm itself.
4. The operator of the Right-Hand TM arm
shall make sure that any people or
obstructions are far away from the arm
before moving it. Failure to do so may
result in unit and / or property
damages, personal injury or even
death.
AUTOMIZER RIGHT-HANDTM
4.
(cont’d)
If, however, Labrie’s customer elects
to operate the unit with more than one
worker, the following safety items shall
be installed to protect the co-worker
from hazardous situations.
For example, an additional set of
sustained manual pressure controls for
each additional worker shall be
provided. The actuation of the controls
shall take place concurrently in order to
operate the Right-HandTM arm. The
sustained manual pressure control shall
be located so that the co-worker
pressing it, is not in the path of the arm
and has a clear and full view of the point
of operation.
In such a case, Labrie must be
informed of every and all units with a
Right-Hand TM arm operated by more
than one worker. Labrie will then
determine and supply, at the customer’s
expense, the required safety items.
For additional information, please
contact the Customer Support Center
at 1-800-231-2771.
Failure to do so may result in unit
and / or property damages, personal
injury or even death.
1-11
5. At the beginning of every working day,
inspect the body, the packing system
and any system that might endanger
the safety of the public and/or the
operator.
6. Verify that the mirrors, brakes,
accelerator pedal, steering wheel and
turn signals are in good working order.
7. Do not operate this equipment if there
are any signs of damage or incomplete
repairs.
8. Report any doubts and any equipment
safety service requirements to your
supervisor.
DANGER
14.Do not get into the hopper compartment
or try to repair anything behind the
packer when it is working or when the
hydraulic pump is still running. Personnel
authorized to get into the hopper MUST
first complete the lockout/tagout
procedures required by the employer.
15.NEVER stand underneath a raised arm/
grabber, since no arm cylinder is
equipped with a holding valve. Should a
hydraulic component break, such as an
hydraulic hose, failure to stay away
from the arm may result in personal
injury or even death.
9. Keep both hands on the steering wheel
at all times for better control.
10.Do not leave the driving position until
the vehicle is completely stopped and
the parking brake applied.
11.When the vehicle is parked, the parking
brake must be applied.
12.For any work, cleaning or inspecting
being done between the body and the
chassis, the body safety prop MUST be
used. The vehicle must also be on level
ground.
13.Watch and be sure that there are no
people at the rear of the vehicle when
opening and closing the tailgate(s) and/
or when raising the body.
GENERAL MAINTENANCE
1-12
1.2
GENERAL RESPONSIBILITIES
OF THE EMPLOYER
(Ref. ANSI Z 245.1 1999 Standards).
It is the employer’s responsibility to be
familiar with and ensure that operation is in
accordance with safety requirements and
codes including all applicable regulations,
including the Occupational Safety and
Health Act (OSHA) and the American
National Standards Institute (ANSI).
It is also the employer’s responsibility to
properly maintain all mobile equipment to
meet provincial/state and federal safety
standards. The employer also has the
following responsibilities:
1. Supply adequate instructions and
training for the safe use of the vehicle
before assigning the employee to such
equipment.
2. The employer must keep the vehicle
maintained and properly adjusted to
meet the manufacturer’s standards and
recommendations. If in doubt, contact
the manufacturer or any authorized
representative.
3. The employer must keep a record of
any breakdowns, malfunctions of the
vehicle, records of inspection and
maintenance.
AUTOMIZER RIGHT-HANDTM
4. Any breaks or malfunctions that can
affect the safe usage of the vehicle
must be repaired before the vehicle is
to be used again.
5. Meet the appropriate lighting
requirements for working at night (if
permitted).
6. On a regular basis, accompany the
operator of the vehicle and take
measures to insure the smooth and
safe operation of the vehicle. Respect
all safety measures.
7. Make sure that the backup alarm works
properly while vehicle is in reverse,
while the body is rising or while the
tailgate is opening.
1-13
1.3
GENERAL RESPONSIBILITIES
OF THE EMPLOYEE
1. The employee must enforce all of the
safety requirements for mobile
equipment supplied by the employer.
2. Equipment is to be operated only after
having received instructions and training
in accordance to Operator Manual.
3. The employee has the responsibility to
report any damages or malfunctions of
the vehicle to his employer or his
supervisor without any delay. The
employer will then take the necessary
measures prior to the re-operation of
the vehicle to insure its safe operation.
4. The employee must make sure that
there is nobody near the vehicle before
activating any of the controls and must
be prepared to stop anything in case of
danger.
WARNING
BEFORE DOING ANY
MAINTENANCE ON THE VEHICLE,
ALL SAFETY REGULATIONS
MENTIONED IN THE OPERATOR
MANUAL, SECTION 2.0, MUST BE
RESPECTED, ESPECIALLY THE
“LOCKOUT/TAGOUT”
PROCEDURE (ANSI Z 245.1 1999).
CAUTION
MAINTENANCE AND REPAIRS
CARRIED OUT ON THIS VEHICLE
MUST ONLY BE DONE BY
QUALIFIED PERSONNEL WHO IS
FAMILIAR WITH THE EQUIPMENT.
LABRIE ENVIRONMENTAL GROUP
DECLINES ANY RESPONSIBILITY
FOR FAILURES RESULTING
UNPROPER REPAIRS PERFORMED
BY THE END USER.
CAUTION
MAINTENANCE PERSONNEL
SHALL NOT DO ANY
MAINTENANCE ON THE
EQUIPMENT IF THEY ARE NOT
WELL ACQUAINTED WITH THE
OPERATIONS OF THE EQUIPMENT
AS WELL AS ALL SAFETY
PRECAUTIONS OF SUCH
OPERATIONS. REFER TO THE
OPERATOR MANUAL BEFORE
ATTEMPTING TO PERFORM ANY
TYPE OF WORK ON THE UNIT.
GENERAL MAINTENANCE
1-14
1.4
FIRE HAZARD
ABC TYPE
FIRE EXTINGUISHER
If, for any reason, the maintenance
personnel has to work on equipment that
has not been unloaded, for any type of
work, a fire extinguisher (Figure #1.1) should
be made readily available and close to this
vehicle. Anytime a loaded vehicle is inside
a garage, there shall be a fire extinguisher
very close nearby.
The employer must inform and train all
personnel about the measures to be taken
in case of a truck and/or a loaded body
catching on fire. The employer must also
inform its employees of an appropriate
place to drop the load near the maintenance
facility (Preferably away from traffic,
surface drains and ditches).
FIGURE #1.1
DANGER
DO NOT PERFORM ANY REPAIR
OR MAINTENANCE ON A VEHICLE
THAT HAS NOT BEEN UNLOADED.
AUTOMIZER RIGHT-HANDTM
1-15
1.5
“LOCKOUT/TAGOUT”
PROCEDURE
PARKING
BRAKE
It is the employer’s responsibility to establish
and apply a “lockout/tagout procedure” for
any inspection, repairs or maintenance
being done on the vehicle, whether it is on
the road or at the shop. Before the “lockout/
tagout” procedure is applied, the body
must be unloaded.
FIGURE #1.2
SUGGESTED “LOCKOUT /
TAGOUT” PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
•
•
•
•
•
•
Apply
the
parking
brake
(Figure #1.2).
Turn off the pump switch on the
console (PTO switch).
Shut off the engine.
Remove the key from the ignition
switch.
Put the key in a safe controlled
area.
Put adhesive tape on the ignition
switch keyhole.
If installed, turn off the master
switch (Figure #1.3).
Put an “Off Service” tag on steering
wheel.
Put an “Off service” sign in the
windshield.
Block any system that could move
by gravity with a proper and visible
safety prop (open tailgate, raised
body, etc.).
Release any residual pressure in
the hydraulic and pneumatic
system.
Block wheels on both sides to
prevent movement of vehicle.
Disconnect the following items if
any type of welding is required:
Battery*;
ABS* (Anti-lock brake system);
Electronic transmission (ECU)*;
Electronic engine module (ECM)*;
Intermittent wiper module*;
All multiplex modules.
MASTER
SWITCH
FIGURE #1.3
*
Refer to the chassis manufacturer
service manual to locate electronic
components.
GENERAL MAINTENANCE
1-16
1.6
BODY SAFETY PROP
BODY SAFETY PROP
INSTALLATION PROCEDURE
1.
Make sure the body is empty.
2.
Lift the body until the safety prop
is clear to be tilted under the body.
3.
Pull the handle (Figure #1.5) to
release the safety prop, then pull
down the safety prop.
4.
Slowly lower the body so it rests
properly on the prop (Figure #1.6).
5.
Once finished with repairs or
inspection, slightly raise the body
and bring back the safety prop to
its vertical position then lower the
body.
SAFETY PROP
HANDLE
FIGURE #1.5
DANGER
DO NOT USE PROP WITH A
LOADED BODY. NEVER STAND
UNDER A RAISED AND LOADED
BODY.
BODY SAFETY
PROP
FIGURE #1.6
AUTOMIZER RIGHT-HANDTM
1-17
1.7
TAILGATE SAFETY PROP
SAFETY PINS
The tailgate safety prop is used to support
and keep the tailgate open during inspection
or when maintenance is carried out on the
vehicle. It is mandatory to install the safety
prop each time the tailgate is open for such
purpose.
The safety prop can be easily installed
when the tailgate is slightly open. Apply the
following procedure to install the safety
prop.
TAILGATE SAFETY PROP
INSTALLATION PROCEDURE
1.
Make sure there is no garbage
inside the body.
2.
Remove both the tailgate safety
pins.
3.
Start the engine.
4.
Turn the PTO switch ON and open
the tailgate about 3 feet high.
5.
Remove the safety prop lock pin
and raise the prop in a position
where both locking holes are
aligned together (Figure #1.7).
6.
Insert the lock pin to maintain the
safety prop in place.
7.
Lower the tailgate so it rests on
the safety prop.
SAFETY PROP
FIGURE #1.7
DANGER
ALWAYS USE THE TAILGATE
SAFETY PROP WHEN WORKING
UNDER A RAISED TAILGATE. THE
SAFETY PROP MUST BE
INSTALLED EVEN IF THE
TAILGATE IS IN THE FULLY
RAISED POSITION.
DANGER
ENSURE THAT NO ONE IS
STANDING BEHIND THE TRUCK
AND THERE IS NO WASTE
MATERIAL IN THE BODY.
GENERAL MAINTENANCE
1-18
1.8
SHUTDOWN PROCEDURE
If the vehicle has to be stored for an
extended period; follow the chassis
manufacturer shutdown requirements as
well as the maintenance requirements and
perform the following procedure.
SHUTDOWN PROCEDURE
1.
Park on a hard level surface.
2.
Apply the parking brake.
3.
Make sure all moving parts are in
the stored position (tailgate, arm,
body, crusher panel, packer, etc.).
4.
Turn hydraulics, electrical and
engine “OFF”.
5.
Turn off the master switch.
6.
Drain the air tanks (Figure #1.8).
1.9
PRIOR TO START UP
Before starting the vehicle, ensure that no
system will engage and start to operate as
you are starting the engine. All electrical
components should be turned OFF and the
hydraulic pump disengaged (Figure #1.9).
The main valve on the hydraulic tank
should be open (Figure #1.10 & #1.11).
Refer to section 3.1.8 “Engaging the
hydraulic system” in the Operator Manual.
Once the engine is started, wait for the air
pressure to build up to at least 70 PSI. Do
not operate or move the vehicle until
the air pressure has reached 70 PSI.
PUMP
SWITCH
LIGHT
AIR TANK
DRAIN
VALVE
FIGURE #1.9
FIGURE #1.8
AUTOMIZER RIGHT-HANDTM
1-19
MAIN HYDRAULIC TANK (2 DIFFERENT TYPES)
BALL VALVE
(OPEN)
FIGURE #1.10
Note: The hydraulic tank model can vary according to the options installed on the
truck.
GENERAL MAINTENANCE
1-20
SUCTION LINE MOUNTED VALVE
1.10
GENERAL CLEANLINESS
Cleanliness is part of the safety. Ensure
the equipment will work properly by
removing any stacked garbage in the
hopper area. Clean all truck lights, warning
lights and safety stickers, so you and the
surrounding pedestrians and vehicles will
be safe around the truck at all times.
Keep clean the contact surface between
the body and chassis. Labrie recommends
to clean the chassis after every unloading.
Make sure that the side step and/or the
hopper step (if installed) are clean and free
of any slippery material.
BALL VALVE
(OPEN)
WARNING
KEEP THE RIGHT AND LEFT-HAND
SIDE CAB FLOOR DRY AND CLEAN
TO PREVENT ANY RISK OF
SLIPPING AND ACCIDENT.
FIGURE #1.11
CAUTION
MAKE SURE THE MAIN VALVE ON
THE HYDRAULIC TANK IS FULLY
OPEN BEFORE STARTING THE
ENGINE (FIGURE #1.10 & #1.11). IF
NOT OPEN, IMMEDIATE DAMAGE
WILL OCCUR TO THE PUMP EVEN
IF THE PUMP SWITCH IS TURNED
“OFF”.
AUTOMIZER RIGHT-HANDTM
DANGER
USE A STEPLADDER TO WORK
ON HIGHER PARTS OF THE
VEHICLE. REMEMBER THAT THE
ROOF IS NOT MEANT TO BE
WALKED ON. BE VERY CAUTIOUS
IF YOU HAVE TO WORK ON THE
ROOF AREA.
1-21
1.11
CLEANING THE HOPPER AREA
The area behind the packer should be
cleaned out every day. The packer will not
work properly if waste accumulates in this
area; it could even cause severe damage
to the packer and other related parts.
This section indicates the cleaning
procedure of the hopper section.
DANGER
FIGURE #1.12
APPLY THE “LOCKOUT/TAGOUT”
PROCEDURE TO PREVENT ANY
ENGINE START-UP.
HOPPER CLEANING
PROCEDURE
1.
Park the vehicle in a proper place,
where the vehicle can be cleaned
out. Make sure to park the vehicle
on a safe and level ground.
2.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
3.
Start the engine and engage the
hydraulic pump (PTO ON).
4.
Extend the arm, fully extend the
packer (Figure #1.12) and push on
the red button (Figure #1.13) to
stop the packer in this position.
The hopper door MUST be closed
in order to move the packer.
5.
Turn off the hydraulic pump and
the engine.
EMERGENCY
STOP BUTTON
FIGURE #1.13
Continued on next page. . .
GENERAL MAINTENANCE
1-22
1.11
CLEANING THE HOPPER
AREA (cont’d)
HOPPER CLEANING
PROCEDURE
6.
Open the clean out traps on each
side of the hopper (Figure #1.15).
7.
Climb inside the hopper using the
step-ladder (Figure #1.14).
8.
Tilt down the floating panel over
the packer to gain access to the
rear area of the packer
(Figure #1.17).
CLEAN OUT
TRAP
FIGURE #1.15
STEP
LADDER
HANDLE
Unlock the floating panel,
and pull the handle in order
to clean behind packer.
FIGURE #1.16
Install safety pin to prevent
the floating panel from
falling back.
FIGURE #1.14
WARNING
PREVENT HANDS OR FINGERS
FROM BEING CAUGHT AT THE
PINCH POINT OF THE FLOATING
PANEL. INSTALL THE SAFETY
PIN.
AUTOMIZER RIGHT-HANDTM
FIGURE #1.17
1-23
HOPPER CLEANING
PROCEDURE
9.
Remove all accumulated dirt under
the cylinder brackets and side rails
(Figure #1.18) using a scraper or
pressurized water.
10. Rake small piece of garbage
towards the clean out traps
(Figure #1.19). Finish cleaning the
area with pressurized water.
11. Perform a visual inspection of the
following components, checking
for proper working order and/or
alignment:
•
•
•
•
•
•
Rollers;
Cylinders pins;
Hoses, pipes and connections;
Proper tightness of bolts;
Check for excessive wear of the
floor and sidewalls of the hopper;
Check cylinders and hoses for
leaks;
FIGURE #1.19
HOPPER CLEANING
PROCEDURE
12. After cleaning and inspecting,
raise the floating panel.
13. Exit the hopper, retract the step
ladder.
14. Start the engine, engage the
hydraulic system and fully retract
the packer.
SIDE
RAIL
15. Retract the arm along the truck.
PACKER
CYLINDER
ROLLER
FIGURE #1.18
GENERAL MAINTENANCE
1-24
1.12
PACKER MAINTENANCE
PACKER INSPECTION
PROCEDURE
1.12.1 GENERAL MAINTENANCE
The AutomizerTM packing system has a
heavy-duty guiding system using high
strength steel wear plates. Because of the
intensive use of the packer, (1000 to 3000
cycles per day), Labrie recommends that a
visual inspection of the packer and its
components to be performed daily by the
operator. A weekly inspection and
maintenance done by maintenance
personnel is also mandatory.
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine, engage the
hydraulic system.
3.
Fully extend the packer and stop it
using the emergency red button.
Greasing all moving parts on a daily basis
is very important and the proper adjustment
of the limit switches is imperative, especially
on units equipped with multi-cycle options.
Refer to the “Lubrication” section for
detailed diagrams of greasing points and
lubrication schedule.
4.
Check the follower panel hinges
and see if there is no wear on the
panel’s surface (Figure #1.20).
5.
Inspect the wear pad (nylon strip)
at the bottom of the floating panel
(Figure #1.20). This wear pad
wipes out dirt each time the packer
goes back and forth. Replace this
wear pad before it is worn down to
the top of its holding screw.
DO NOT GREASE THE SIDE RAILS:
Abrasive material sticks to the grease and
can cause premature wear of the rollers
and/or the side rails.
DANGER
FLOATING
PANEL
WEAR PAD
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
Any problems found on the packing system
must be corrected immediately.
Labrie’s Service Department is available
for any type of technical support. Apply the
following step-by-step inspection procedure
to prevent breakdowns and to reduce
maintenance expenses.
AUTOMIZER RIGHT-HANDTM
HINGES
FOLLOWER
PANELS
FIGURE #1.20
1-25
PACKER INSPECTION
PROCEDURE (cont’d)
6.
Visually inspect both hopper side
rails
and
packer
rollers
(Figure #1.21 & #1.22) for
premature wear. If necessary,
refer to section 1.12.8 “Packer
Roller
Replacement”
or
section 1.12.5 “Wear pad
replacement.
7.
See that there are no leaks on
hydraulic hoses and pipes. Tighten
leaking connections and/or
replace the defective hose.
8.
Cylinder rod ends must be clear of
any dirt.
PACKER INSPECTION
PROCEDURE (cont’d)
9.
Verify cylinder rods for scratches
that may cause the cylinder to leak
oil. In this case, the cylinder must
be replaced immediately. DURING
THE WARRANTY PERIOD; DO NOT
ATTEMPT TO CHANGE CYLINDER
SEALS AND PACKING.
10. Check for vertical and horizontal
movement of the packer. If the
packer seems to play sideways or
even up and down, the packer wear
pads need to be replaced.
Extensive wear of the hopper floor
also suggests that the sliding
shoes
require
immediate
replacement.
Refer
to
section 1.12.3 to section 1.12.5.
11. Make sure there is no knocking
noise when the packer reaches
the end of the cylinder’s stroke.
A knocking noise will indicate that
both limit switches require
adjustment. Refer to section 1.12.2
“Limit switch adjustment”.
SIDE
RAIL
12. In order to verify if hydraulic
cylinders are internally leaking,
(insufficient packing force) refer
to troubleshooting; section 3.13
“Internal Leak Detection”.
FIGURE #1.21
PACKER
ROLLER
FIGURE #1.22
GENERAL MAINTENANCE
1-26
1.12.2 LIMIT SWITCH ADJUSTMENT
The packer limit switches were properly
adjusted at the factory for optimal operation
of the packer. If a daily cleaning is not
properly done behind the packer, it is
possible that the limit switches will no
longer stop the packer, creating a knocking
noise when the packer reaches the end of
a stroke (bottoming out). The packer may
also not retract far enough to touch the limit
switch preventing the automatic cycle to
work properly.
After a certain period of time, a misalignment
of the components may occur due to the
frequent back and forth movement of the
packer. An adjustment might be necessary
to prevent the cylinders from completely
extending and retracting to the end of their
strokes.
There are two limit switches that control
the packer’s extension and the retraction
limits. Both limit switches are located at
the front end of the body, between the cab
and the body (Figure #1.23 & #1.24). The
limit switch that stops the packer during
extension (packer extend) is located on the
left-hand side (Figure #1.23). The other
limit switch, (packer retract) is located on
the right-hand side of the vehicle (Figure
#1.24).
PACKER EXTEND
LIMIT SWITCH
FIGURE #1.23
PACKER RETRACT
LIMIT SWITCH
FIGURE #1.24
DANGER
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
NOTE : Optional proximity switches can
also be installed on the vehicle but the
adjustment procedure remains the same
(see Figure # 1.24A).
AUTOMIZER RIGHT-HANDTM
3/16”
PROXIMITY
SWITCH
CYLINDER
FINGER
FIGURE #1.24A
1-27
1.12.2
LIMIT SWITCH ADJUSTMENT (Cont’d)
PACKER LIMIT SWITCH
ADJUSTMENT PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine, engage the
hydraulic pump.
3.
Press the green button on the
packer control station in order to
extend the packer about 1 inch
back from the fully extended
position (Figure #1.25).
4.
Push the red button when the
packer reaches the proper
position. The red button ensures
there will be no accidental start up
of the packer when adjusting the
limit switch.
1”
FIGURE #1.25
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
Continued on next page. . .
GENERAL MAINTENANCE
1-28
1.12.2
LIMIT SWITCH ADJUSTMENT (Cont’d)
PACKER LIMIT SWITCH
ADJUSTMENT PROCEDURE
5.
Locate the limit switch on the lefthand side of the vehicle
(Figure #1.26).
6.
Adjust the limit switch lever so it is
“active” when the packer cylinder
finger is in the position shown
on figure #1.27 (Limit switch is
“clicked”). The lever may require
to be bent or twisted to properly
activate the limit switch at this
exact position.
CYLINDER
FINGER
LEVER
FIGURE #1.27
PACKER “EXTEND”
LIMIT SWITCH
FIGURE #1.26
AUTOMIZER RIGHT-HANDTM
1-29
1.12.2
LIMIT SWITCH ADJUSTMENT (Cont’d)
PACKER LIMIT SWITCH
ADJUSTMENT PROCEDURE
7.
8.
To adjust the ”packer retract” limit
switch, retract the packer to 1”
before the fully retracted
position (Figure #1.28), using the
yellow button on the packer
control station.
Push the red button when the
packer reaches the right position.
PACKER LIMIT SWITCH
ADJUSTMENT PROCEDURE
9.
Locate the limit switch on the righthand side of the vehicle
(Figure #1.29).
10. Adjust the limit switch lever so it is
“active” when cylinder finger is in
the position shown on figure #1.29
(Limit switch is “clicked”). The
lever may require to be bent or
twisted to properly activate the
limit switch at this exact position.
11. Test the packer for a full cycle.
Make sure that there is no knocking
noise at both ends of the packer
cylinder stroke.
CYLINDER
FINGER
PACKER “RETRACT”
LIMIT SWITCH
1”
FIGURE #1.28
FIGURE #1.29
NOTE: If the vehicle is equipped with
proximity switches, loosen the proximity
switch on the bracket and move it over the
trigger lever to get the yellow light found on
the proximity switch to turn ON (Figure
#1.24A). The green light on the proximity
switch must be ON too.The gap between
the proximity switchand the trigger lever
must beadjusted to 3/16 of an inch.
GENERAL MAINTENANCE
1-30
1.12.3 REPLACING SLIDING SHOES AND
WEAR PAD
Use a pry bar to move the packer up and
down and from side to side and if the
packer has a vertical movement greater
than 3/16” or a side movement greater
than 1/8”, verify both packer’s sliding shoes
as well as wear pads (Figure #1.30) under
the side rails.
Two different types of steel are used on
the packer guiding system: the AR-425
and the AR-500 type steel. The sliding
shoes are made of AR-425 type steel to
wear out before the floor guides, which are
made of AR-500. Refer to Body Parts
section for replacement part numbers.
To keep the packer in good working order
and to prevent breakdowns, replace the
sliding shoes and wear pads before
extensive wear or damage appears on the
hopper floor and walls.
1.12.4
SLIDING SHOE REPLACEMENT
SLIDING SHOE
REPLACEMENT PROCEDURE
1.
Note that it is not necessary to
remove the packer to perform this
procedure.
2.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
3.
Start the engine and engage the
hydraulic system.
4.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
SLIDING SHOE
FIGURE #1.30
AUTOMIZER RIGHT-HANDTM
1-31
1.12.4
SLIDING SHOE REPLACEMENT
(cont’d)
View from behind the packer
(packer fully retracted)
SLIDING SHOE
REPLACEMENT PROCEDURE
5.
If the packer is not fully retracted,
press the yellow button on the
packer control station to retract it.
6.
Turn the hydraulic pump and the
engine off.
7.
Behind the packer, remove the
welds from both wear shoes
(Figure #1.31), using a grinder or
cutting tools.
8.
Start the engine; engage the
hydraulic pump and extend the
packer about 18 inches before the
end of the stroke (Figure #1.31).
9.
Turn the hydraulic pump and the
engine off.
Remove
welding here
FIGURE #1.31
18”
10. Remove all retaining bolts (3) from
each sliding shoe (Figure #1.33).
FIGURE #1.32
NOTE:
In order to move the packer (retract or
extend) for a short distance, press on the
green (or yellow) button and then push
immediately the red button to stop the
packer. Pull out the red button and repeat
the process until the packer reaches the
desired position.
RETAINING
BOLTS
FIGURE #1.33
Continued next page. . .
GENERAL MAINTENANCE
1-32
1.12.4
SLIDING SHOE REPLACEMENT
(cont’d)
SLIDING SHOE
REPLACEMENT PROCEDURE
11. Tack weld a piece of steel tubing
to the floor rail and to the front of
the
both
sliding
shoes
(Figure #1.34).
12. Then start the engine, engage the
hydraulic pump and slowly retract
the packer by pressing the yellow
button and the red button.
13. The sliding shoes will come out
from under the packer as it is
retracting (Figure #1.35).
14. Remove the old sliding shoe and
tubing. Make sure to remove the
welds on the floor guide using a
grinder.
SLIDING
SHOE
WELDS
FLOOR
GUIDE
FIGURE #1.34
AUTOMIZER RIGHT-HANDTM
SLIDING
SHOE
FIGURE #1.35
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
1-33
1.12.4
SLIDING SHOE REPLACEMENT
(cont’d)
SLIDING SHOE
REPLACEMENT PROCEDURE
15. Align the new sliding shoe in front
of the packer and slowly extend
the packer to make the sliding shoe
go under the packer.
16. When the sliding shoes are back
in place, tighten all retaining bolts
(Figure #1.36).
17. If the wear pads at the top of the
packer need to be replaced, refer
to section 1.12.5 “Wear Pad
Replacement”.
SLIDING SHOE
REPLACEMENT PROCEDURE
18. Retract the packer.
19. Weld both sliding shoes to the
packer (Figure #1.37).
20. Test the packer for proper
operation.
21. If the packer is binding, to find out
where the interference is, apply
primer paint on the floor guide.
22. Run the packer a few times .
23. The location where the paint comes
off indicate the surface to be
ground.
View from behind the packer
(packer fully retracted)
BOLTS (3)
FIGURE #1.36
WELD
HERE
FIGURE #1.37
GENERAL MAINTENANCE
1-34
1.12.5 WEAR PAD REPLACEMENT
Apply the following procedure to remove
and change the wear pads.
Replacement of the wear pads at the top of
the packer (Figure #1.38) is required when
vertical movement of the packer is greater
than 3/16” (Check with a pry bar).
WEAR PAD
REPLACEMENT PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine and engage the
hydraulic pump.
3.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
4.
If the packer is not fully retracted,
press the yellow button on the
packer control station to retract it.
5.
Turn the hydraulic and the engine
off.
6.
Remove the hopper side panel
(Figure #1.39).
7.
Remove both side rail shields.
8.
Remove the lower bolts (4) of left
side wall to be able to remove the
left side rail (Figure #1.42-43).
This section will provide the full procedure
to remove and change both wear pads at
the top of the packer.
PACKER
WEAR PAD
FIGURE #1.38
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
AUTOMIZER RIGHT-HANDTM
1-35
1.12.5
WEAR PAD REPLACEMENT (cont’d)
WEAR PAD
REPLACEMENT PROCEDURE
9.
HOPPER WALL
BOLTS
Remove stitch welds to release
the side rails.
10. Remove both side rails.
SIDE PANEL
FIGURE #1.42
HOPPER WALL
BOLTS (4)
FIGURE #1.39
Note : The model of the side
panel varies according to the
options installed.
FIGURE #1.43
Continued next page. . .
GENERAL MAINTENANCE
1-36
1.12.5
WEAR PAD REPLACEMENT (cont’d)
FIGURE #1.44
PLASTIC
SHIELD
FCAW
1/4”
1-6
Stitch welds that hold the
rail into position, should be
cut out in order to release
the side rail.
SIDE RAIL
FIGURE #1.45
Left-hand side spacers :
Always re-install otherwise damage
could occur to the roller assembly.
FIGURE #1.46
AUTOMIZER RIGHT-HANDTM
1-37
1.12.5
WEAR PAD REPLACEMENT (cont’d)
WEAR PAD
REPLACEMENT PROCEDURE
11. When both side rails are removed,
start the engine and engage the
hydraulic pump.
12. Extend the packer about 12 inches
before the end of the stroke
(Figure #1.47).
13. Turn the hydraulic pump and the
engine off.
WEAR PAD
REPLACEMENT PROCEDURE
14. Remove and replace both wear
pads (Figure #1.45) and retract the
packer.
15. Reinstall the side rails.
16. Stitch weld the rails along the top
edge of the hopper wall
(Figure #1.44).
17. Reinstall the side rail shields.
18. Reinstall the hopper side wall
19. Reinstall the deflector cover back
in place.
12”
PACKER
WEAR SHOE
FIGURE #1.47
NOTE:
In order to move the packer (retract or
extend) for a short distance, press on the
green (or yellow) button then immediately
push the red button to stop the packer. Pull
the red button and repeat the process until
the packer reaches the desired position.
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
FIGURE #1.48
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
GENERAL MAINTENANCE
1-38
1.12.6
PACKER REMOVAL
SIDE PANEL
PACKER REMOVAL
PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine and engage the
hydraulic pump.
3.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
4.
If the packer is not fully retracted,
press the yellow button on the
packer control station to retract it.
5.
Turn the hydraulic and the engine
off.
6.
Remove the hopper side panel
(Figure #1.49).
7.
Remove both side rail shields.
8.
Remove the lower bolts (4) of left
side wall to be able to remove the
left side rail (Figure #1.52-53).
DANGER
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
AUTOMIZER RIGHT-HANDTM
FIGURE #1.49
Note : The model of the side panel
varies according to the options
installed.
1-39
1.12.6
PACKER REMOVAL (Cont’d)
HOPPER WALL
BOLTS (4)
PACKER REMOVAL
PROCEDURE (cont’d)
9.
Remove stitch welds to release
the side rails.
10. Remove both side rails.
11. When both side rails are removed,
start the engine and engage the
hydraulic pump.
12. Extend the packer about 12 inches
before the end of the stroke
(Figure #1.54).
FIGURE #1.52
HOPPER WALL
BOLTS (4)
13. Turn the hydraulic pump and the
engine off.
14. Remove the floating panel from
the hopper. Refer to section 1.12.9
“Floating
Panel
Removal
Procedure”.
15. Remove the access cover to reach
the cylinder pins (Figure #1.54).
FIGURE #1.53
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
NOTE:
In order to move the packer (retract or
extend) for a short distance, press on the
green (or yellow) button then immediately
push the red button to stop the packer. Pull
the red button and repeat the process until
the packer reaches the desired position.
12”
ACCESS
COVER
FIGURE #1.54
Continued next page. . .
GENERAL MAINTENANCE
1-40
1.12.6
PACKER REMOVAL (Cont’d)
PACKER ROLLER
ASSEMBLY
PACKER REMOVAL
PROCEDURE
16. Remove both cylinder pins
(Figure #1.56). Note that the
greasing hoses must be
disconnected from the cylinder
pins.
The cylinder pins top plate are
provided with two (2) threaded
holes to be used as a puller by
inserting two (2) 1/2 NC bolts.
FOLLOWER
PANELS
17. After removing the two cylinder
pins, start the engine and retract
the hydraulic cylinders (see
Figure #1.44).
FIGURE #1.55
18. Remove all packer roller
assemblies from the follower
panels (Figure #1.55).
GREASING HOSES
(Located under the
follower panel)
ACCESS
COVER
CYLINDER PINS
FIGURE #1.56
AUTOMIZER RIGHT-HANDTM
1-41
1.12.6
PACKER REMOVAL (cont’d)
DANGER
PACKER REMOVAL
PROCEDURE
19. Fold the follower panels over the
packer.
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
20. Weld the follower panels to the
packer.
21. Attach the packer to a lifting device
(Fork lift) in order to extract it
from the hopper.
22. Re-install the new packer into the
hopper checking the alignment of
the packer with the floor guides.
23. Install a new wiper blade on each
side of the packer (Figure #1.58).
These wiper blades may require to
be adjusted to fit between the new
packer and the hopper walls.
FIGURE #1.57
24. Once the packer is installed in the
hopper, install roller assemblies
and reverse the procedure to
reconnect the hydraulic cylinders
and re-install both side rails.
25. Stitch weld the rails along the top
edge of the hopper wall (Figure
#1.44).
WIPER BLADE
(PLASTIC)
26. Once finished re-assembling the
removed components, lubricate
and check for proper operation of
the packer.
FIGURE #1.58
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
GENERAL MAINTENANCE
1-42
1.12.7 FLOOR GUIDE REPLACEMENT
PROCEDURE
After years of hard work, the floor guides
inside the hopper may require replacement.
The following step-by-step procedure will
help removing and replacing the floor guides
inside the hopper.
FLOOR GUIDE
REPLACEMENT PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine and engage the
hydraulic system.
3.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
4.
Remove the packer from the
hopper (refer to section 1.12.6
“Packer Removal Procedure”).
5.
Retract the hydraulic cylinders
and move them out of the way.
6.
Mark the exact location of both
floor guides to ensure the proper
positioning of the new ones.
7.
Using a grinder or cutting tool,
remove the floor guides by cutting
the stitch welds (Figure #1.59).
AUTOMIZER RIGHT-HANDTM
1-43
1.12.7
FLOOR GUIDE REPLACEMENT
PROCEDURE (Cont’d)
STITCH
WELDS
FLOOR GUIDES
FIGURE #1.59
GENERAL MAINTENANCE
1-44
1.12.7
FLOOR GUIDE REPLACEMENT
PROCEDURE (Cont’d)
View from behind the packer
(packer fully extended)
FLOOR GUIDE
REPLACEMENT PROCEDURE
8.
Clean the hopper floor and wall
surfaces.
9.
Position new guides onto the
hopper floor (do not tack or weld
yet).
10. Bring the packer over the hopper,
using a proper lifting device.
PACKER SITTING
ON THE
FLOOR GUIDE
FIGURE #1.60
11. Lower the packer on the floor
guides, and align them with the
packer.
WELD HERE ON
BOTH SIDES OF THE
FLOOR GUIDE
12. Once the packer sits on the floor
guides, center the packer (and the
floor guides) in the hopper making
sure they are parallel to the hopper
wall (Figure #1.60).
13. Tack weld the floor guides to the
hopper floor (Figure #1.61).
14. Adjust the packer wipers on both
sides (UHMW plastic).
15. Connect the packer cylinders
(refer to section 1.12.6 “Packer
Removal Procedure”).
FIGURE #1.61
WELD HERE ON BOTH
SIDES OF THE FLOOR
GUIDE
16. Retract slowly the packer under
the rails until the end of the packer
stroke. Keep the packer centered
with the hopper, re-install the side
rails then tack the floor guides to
the hopper floor (Figure #1.62).
FIGURE #1.62
AUTOMIZER RIGHT-HANDTM
1-45
1.12.7
FLOOR GUIDE REPLACEMENT
PROCEDURE (Cont’d)
FLOOR GUIDE
REPLACEMENT PROCEDURE
17. Extend the packer to the middle of
the hopper; verify the alignment
with the hopper side rails.
18. Stitch weld the floor guides going
towards the back of the vehicle
(Figure #1.63).
1.12.8 PACKER ROLLER REPLACEMENT
Packer rollers need to be replaced when
damaged, showing excessive wear or flat
spots.
PACKER ROLLER
REPLACEMENT PROCEDURE
1.
Lower the floating panel.
2.
19. Then fully extend the packer to
finish welding under the packer
(Figure #1.64).
Unbolt the roller assembly
(Figure #1.65).
3.
Clean the roller axle.
20. Check for proper operation.
4.
Install a new roller.
5.
Bolt assembly in place.
6.
Check full cycle for smooth
operation.
FOLLOWER PANEL
FCAW
3/8”
3-12
WELD HERE ON
BOTH SIDES OF THE
FLOOR GUIDE
FIGURE #1.63
WELD HERE ON
BOTH SIDES OF THE
FLOOR GUIDE
ROLLER
ASSEMBLY
FIGURE #1.65
FCAW
3/8”
3-12
FIGURE #1.64
GENERAL MAINTENANCE
1-46
1.12.9
FLOATING PANEL REMOVAL AND
WEAR PAD REPLACEMENT
FLOATING PANEL
FLOATING PANEL REMOVAL AND
WEAR PAD REPLACEMENT
PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine and engage the
hydraulic system.
3.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
4.
Fully extend the packer then press
the red emergency stop button to
keep it at this position.
5.
Disengage the hydraulic pump and
shut the engine “OFF”.
6.
Remove the floating panel axis pin
on both side of the hopper
(Figure #1.67).
WEAR PAD
FIGURE #1.66
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
Continued next page. . .
AUTOMIZER RIGHT-HANDTM
1-47
1.12.9
FLOATING PANEL REMOVAL AND
WEAR PAD REPLACEMENT (Cont’d)
WARNING
PREVENT HANDS OR FINGERS
FROM BEING CAUGHT AT THE
PINCH POINT OF THE FLOATING
PANEL.
FLOATING PANEL REMOVAL AND
WEAR PAD REPLACEMENT
PROCEDURE
7.
Remove the floating panel from
the hopper using a lifting device.
8.
Remove retaining screws holding
the nylon wear pad (Figure #1.66).
9.
Install the new wear pad and bring
back the floating panel in place.
DANGER
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
10. Check for even contact of wear
pad with packer blade and the
follower panels.
REMOVE
FLOATING PANEL
AXIS
FIGURE #1.67
GENERAL MAINTENANCE
1-48
1.12.10 PACKER CYLINDER REPLACEMENT
PACKER CYLINDER
REPLACEMENT PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine, engage the
hydraulic pump.
3.
Then using the joystick, extend
the automated arm to give a better
access to the hopper area.
4.
Fully extend the packer.
5.
Disengage the pump and stop the
engine.
6.
Remove the floating panel (refer
to section 1.12.9).
7.
Open
the
access
cover
(Figure #1.68), remove both
cylinder pins and retract the
packer.
8.
Remove the roller assemblies on
the follower panels (See
section 1.12.8).
DANGER
SECURE THE AREA AROUND THE
PATH OF THE ARM WHEN
PERFORMING MAINTENANCE OR
REPAIR.
AUTOMIZER RIGHT-HANDTM
ACCESS
COVER
CYLINDER
PINS
ROLLER
ASSEMBLY
FIGURE #1.68
DANGER
DO NOT CLIMB INTO THE
HOPPER WHILE THE PACKER IS
MOVING.
1-49
1.12.10 PACKER CYLINDER REPLACEMENT
(Cont’d)
PACKER CYLINDER
REPLACEMENT PROCEDURE
9.
Fold the follower panels over the
packer (Figure #1.69).
CAUTION
PACKER CYLINDERS MUST BE
REMOVED WITH A LIFTING
DEVICE.
10. Retract the cylinders.
11. Remove the hydraulic hoses from
the cylinders (Use absorbent
material to catch oil spills).
12. Go in the hopper to attach and
secure the cylinder to a lifting
device.
13. Remove the piston side pin that
holds the cylinder in front of the
body. Protect the limit switch
during the removal of the cylinder.
14. Remove cylinder fingers used for
the limit switches installed on both
cylinders and keep them for the
new cylinder.
FIGURE #1.69
15. Replace the faulty cylinder with a
new one. Contact the Labrie’s
Service
Department
for
replacement under warranty.
16. Install the cylinder fingers on the
new cylinders. The limit switches
may require to be re-adjusted
afterwards; refer to section 1.12.2
“Limit switch adjustment”.
17. Reinstall the piston pin, then the
hydraulic hoses.
18. Extend the cylinders, install the
pins and the roller assemblies and
unfold the follower panels.
19. Grease the cylinder pins and check
for proper operation.
GENERAL MAINTENANCE
1-50
1.12.11 CRUSHER PANEL MAINTENANCE
CRUSHER PANEL MAINTENANCE
PROCEDURE
1.
Grease the cylinder heads of the
crusher panel by using the
greasing points.
2.
Grease also the crusher panel
bushings.
GREASING POINT
CYLINDER AXLE
GREASING POINT (BUSHINGS)
GREASING POINT
CYLINDER HEAD
CYLINDER AXLE
AUTOMIZER RIGHT-HANDTM
1-51
1.13
TAILGATE AND BODY HINGES
MAINTENANCE
1.13.1 TAILGATE LOCKING MECHANISM
It is important to lubricate the tailgate
hinges and the locking mechanism with
multipurpose grease as per the lubricating
schedule (Refer to section 2.1
“Recommended Lubricants”).
1.13.2 TAILGATE SEAL AND HINGES
INSPECTION
Tailgate hinge pins must not have any sign
of wear or metal fatigue. The retaining
bolts must be kept tight (Figure #1.71).
The tailgate rubber seal must not show any
sign of damage. Replace the seal if
necessary.
RETAINING
BOLT
Also, inspect the welds around hinges. The
proper working order of the following
components is also to be checked:
(Figures #1.70 to #1.73)
•
•
•
•
•
•
Tailgate hydraulic cylinders
Cylinder pins and circlips
Tailgate hinges and pins
Wear on the locking mechanism
Wear on the tailgate lock pins
Tailgate rubber seal
TAILGATE
HINGE AND PIN
FIGURE #1.71
CAUTION
EXCESSIVE WEAR MIGHT BE
DANGEROUS AND HARMFUL TO
THE PROPER WORKING ORDER
OF THE TAILGATE.
CYLINDER
RETAINING RING
LOCKING
MECHANISM
FIGURE #1.72
TAILGATE
LOCK PIN
RUBBER
SEAL
SAFETY PINS
FIGURE #1.70
FIGURE #1.73
GENERAL MAINTENANCE
1-52
1.13.3 BODY/CHASSIS HINGES INSPECTION
1.13.4 BODY RAISED LIMIT SWITCH
Monthly lubrication of the body-chassis
hinges should be done. Also, inspect for
cracks or corrosion. Any crack must be
reported, and repaired by QUALIFIED
personnel. Contact the Labrie Service
Department for technical support, if
required.
A limit switch located on the truck chassis
(Figure #1.76) activates the backup alarm
and a warning buzzer sounds as soon as
the body is about one foot above the
chassis. Adjust the limit switch accordingly.
VIEW FROM BEHIND THE
REAR MUD GUARD
This safety feature is provided to warn
people around, that the truck is unloading
and to tell the operator that the body is still
raised.
DANGER
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
BODY HINGES
FIGURE #1.74
TRUCK
CHASSIS
DANGER
DO NOT OPERATE THIS
EQUIPMENT IF THERE IS ANY
SIGN OF DAMAGE OR
INCOMPLETE REPAIRS.
ARM
LIMIT SWITCH
FIGURE #1.76
FIGURE #1.75
AUTOMIZER RIGHT-HANDTM
1-53
1.13.5 TAILGATE LIMIT SWITCH
ADJUSTMENT
AutomizerTM units are equipped with a limit
switch located at the top of the left-hand
side tailgate cylinder (Figure #1.77. When
the tailgate is unlocked, the cylinder
releases the limit switch lever that activates
the backup alarm and a warning buzzer
inside the cab.
As the cylinder head is moving down, the
limit switch trigger lever is released and
the warning buzzer and the backup alarm
should be heard.
LIMIT SWITCH
Apply the following procedure to adjust the
limit switch located next to hydraulic cylinder
(tailgate unlocked).
LIMIT SWITCH ADJUSTMENT
PROCEDURE (Tailgate
unlocked)
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5
“Lockout/Tagout procedure”).
2.
Start the engine and engage the
hydraulic system.
3.
Open the tailgate using the lever
on the console and listen if the
warning buzzer and the backup
alarm start to beep as you move
the lever.
4.
Adjust the trigger lever of the
limit switch so the limit switch
will “click”, as the cylinder head
is moving down
(Figure #1.77 & #1.78).
TRIGGER
LEVER
FIGURE #1.77
WARNING
CYLINDER HEAD
ENSURE THAT NO ONE IS
STANDING BEHIND OR NEAR THE
TAILGATE WHEN ADJUSTMENT
PROCEDURE IS CARRIED OUT.
FIGURE #1.78
GENERAL MAINTENANCE
1-54
1.14
HYDRAULIC SYSTEM MAINTENANCE
1.14.1
GENERAL MAINTENANCE
In order to keep the hydraulic system efficient and reliable, the following care must be
taken:
HYDRAULIC SYSTEM GENERAL INSPECTION PROCEDURE
1)
For new vehicle, change the return filter element after 50 hours of use, and twice a
year afterwards (See section 1.14.7 “Filter replacement procedure”).
2)
Clean the strainer inside the tank after the first 50 hours of use, and once a year
afterwards. (See section 1.14.8 “Strainer cleaning procedure”).
3)
Hydraulic oil must be replaced at least once a year or when contaminated.
(See section 1.14.6 “Hydraulic oil replacement procedure”).
4)
When maintenance is carried out, protect all hoses, fittings and pipes or any other
holes from dirt that would eventually get into the oil. Use plugs to block hoses that
are not connected.
5)
Monthly inspect and adjust (If necessary) the oil pressure of the hydraulic system.
(See section 1.15 “Hydraulic pressure adjustment).
6)
On a daily basis, inspect the hydraulic lines and connections for leaks, and correct
if necessary;
7)
Inspect the pump for leaks or unusual noise;
8)
The ball valve on the hydraulic tank must be completely open before engaging the
pump or starting the engine (See section 1.9 “Prior to Start up”).
Labrie Environmental Group requires that
the hydraulic fluid and return oil filter be
changed and the strainer cleaned before
changing the hydraulic pump.
year. The hydraulic fluid must be changed
annually. Hydraulic fluid contamination can
cause severe damage to the hydraulic
components.
Manufacturer’s warranty on hydraulic
pumps provided or sold by Labrie
Environmental Group could be declared
void if the hydraulic fluid and return oil filter
are not changed and if the strainer is not
cleaned prior to replacing the hydraulic
pump.
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 hydraulic fluid change
frequency. Labrie trucks are now equipped
with an “oil sampler coupler”. See section
2.1.6 of the Lubrication manual.
Therefore, it is mandatory to change the
return oil filter and clean the strainer after
the first 50 hours of use and then once a
Note that proofs of maintenance and/or
fluid samples could be requested when
filing warranty claims concerning the
hydraulic system or pump.
AUTOMIZER RIGHT-HANDTM
1-55
1.14.2 HYDRAULIC CYLINDER INSPECTION
PROCEDURES
To maintain proper working order and
extend cylinder life, it is essential to inspect
the hydraulic cylinders at least once a
month. Make sure that connections
between all hoses and pipes are tightened,
and there are no oil leaks.
DANGER
Check that all cylinder caps are firmly
tightened and there are no leaks. All leaks
must be repaired immediately by replacing
damaged or faulty cylinders. Lubricate and
inspect all cylinders’ mounting points (pins,
retaining bolts, etc.).
WARNING
VERIFY THAT THE BALL VALVE
ON THE SUCTION LINE IS
COMPLETELY OPEN BEFORE
STARTING THE ENGINE.
APPLY THE LOCKOUT / TAGOUT
PROCEDURE AT ALL TIMES WHEN
MAINTENANCE OR INSPECTION IS
CARRIED OUT ON THE VEHICLE.
GENERAL MAINTENANCE
1-56
1.14.3 MAIN HYDRAULIC VALVE
VALVE SECTION DESCRIPTION:
The Automizer TM side-loading unit is
equipped with a directional control valve
which is assembled as follows, from top to
bottom (Figure #1.79).
For further details, refer to the hydraulic
system Parts and Diagram section, or see
the simplified diagram for the packing
system in the troubleshooting section. The
pressure adjustment procedure is outlined
in section 1.15 “Hydraulic Pressure
Adjustment”.
Body hoist: 3 way, 3 position, operated
with an air actuator.
Packer: 4 way, 3 position, operated
with an air actuator.
Tailgate: 4 way, 3 position, operated
with an air actuator.
NOTE: An electro-hydraulic actuator is
also available.
To get more information regarding specific options, refer to the proper section of the
manual included with the vehicle documentation or contact the Labrie Service Department.
MAIN HYDRAULIC VALVE
TAILGATE
PACKER
BODY HOIST
FIGURE #1.79
AUTOMIZER RIGHT-HANDTM
1-57
1.14.4 PROPORTIONAL VALVE
VALVE SECTION DESCRIPTION:
AutomizerTM units use an extra valve stack
to control the arm, the chute and the crusher
panel (if equipped) (Figure #1.80). This
valve is on/off or proportional type, meaning
that the amount of flow coming out of it will
be according to the position of the spool.
This feature (proportional control) allows
infinite control of the speed and the
movement of the arm. The arm is powered
by a dual vane pump (see section 1.14.9
“Dual Vane Pump”).
• Inlet/Outlet cover:
(Provided with main relief valve)
• Crusher panel section (optional):
(Not proportional, with load sense relief)
• Chute section (Co-Mingle units):
(Not proportional, with load sense relief)
• Grabber section (Open/Close):
(Not proportional, with load sense relief)
• Grabber section (Up/Down):
(Proportional, no load sense relief)
• Telescopic arm section (Extend/
Retract):
(Proportional, no load sense relief)
Each section of the valve is actuated by an
electrical coil, located under the valve. The
proportional valve sections are described as
follow from right to left on figure #1.81.
PROPORTIONAL VALVE
CRUSHER
PANEL (if
equipped)
INLET/OUTLET
COVER
CHUTE (CoMingle units
TELESCOPIC ARM
(Extend / Retract)
GRABBER
(Open /Close)
GRABBER
(Up / Down)
FIGURE #1.80
GENERAL MAINTENANCE
1-58
INLET/OUTLET
COVER
ELECTRIC
COILS
FIGURE #1.81
NOTE: 5-SECTION VALVE SHOWN. NON CO-MINGLE UNITS ARE USUALLY EQUIPPED WITH A 3 OR 4-SECTION VALVE.
AUTOMIZER RIGHT-HANDTM
1-59
1.14.4APROPORTIONAL VALVE PRESSURE
ADJUSTMENT
The following step by step pressure
adjustment procedure explains how to
adjust the pressure of each function of the
Right-Hand TM arm. Note that the dump
valve pressure (if equipped) must be set
properly before making any adjustments to
the proportional valve of the Right-Hand TM
arm. Refer to section 1.15 of the General
Maintenance section for adjustment
procedure of the dump valve.
The lockout/tagout procedure explained in
section 1.5 of the General Maintenance
section will apply each time maintenance
has to be done on the vehicle. Also, refer
to the hydraulic pressure table to adjust
each function of the arm. Make sure to
identify all function levers on the valve and
its adjustment screw before performing
the procedure.
Note that a helper may be needed to
perform the pressure adjustment of the
arm. Use any precaution necessary around
the vehicle to work safely at all times.
Secure the arm’s working area using barrier
tape or barricades.
DANGER
STAY OUT OF THE PATH OF THE
ARM WHILE MANUALLY MOVING
THE ARM. SERIOUS INJURY OR
EVEN DEATH MAY RESULT.
PROPORTIONAL VALVE MAIN
RELIEF ADJUSTMENT
PROCEDURE
1.
Apply the lockout / tagout
procedure.
2.
Before making any adjustments,
secure the arm’s working area
using safety tape or barricades.
3.
Remove any residual hydraulic
pressure in the system by moving
the levers back and forth.
4.
Connect a 0-4000PSI gauge on the
quick coupler located on the
proportional valve (see pictures
on next page).
5.
Make sure the transmission is in
Neutral.
6.
Start the engine.
7.
Engage the hydraulic system
(Pump switch “ON”).
8.
Retract and maintain the arm to
the end of its stroke using the
corresponding lever in order to
make the hydraulic pressure to
rise on the pressure gauge.
9.
Adjust the main relief valve to 2000
PSI using the adjustment screw
(see pictures on next page) turning
the hex key clockwise or counter
clockwise.
GENERAL MAINTENANCE
1-60
QUICK
COUPLER
CONTROL
LEVER
0-4000PSI PRESSURE
GAUGE
(Part# HYF00910)
QUICK COUPLER
(Part# HYF10195)
MAIN RELIEF VALVE
ADJUSTMENT SCREW
AUTOMIZER RIGHT-HANDTM
1-61
1.14.5 HYDRAULIC TANK INSPECTION
PROCEDURE
Verify that the oil in the reservoir is clean
and always at the appropriate level. The
oil must be clean and not colored.
HYDRAULIC TANK
INSPECTION PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Clean the strainer and replace the
filter element inside the tank after
the first 50 hours of service. Refer
to section 1.14.8 “Strainer
cleaning procedure”.
3.
Change the return filter element,
twice a year (after the first 50
hours). Refer to section
section 1.14.7 “Filter element
replacement procedure”.
4.
Ensure the proper operation of
the filler cap (Figure #1.83). See
that the filler cap has no
obstruction.
5.
The hydraulic oil must be clean
and not colored as well as in
sufficient quantity (level at 3/4 of
the oil level gauge, with all
cylinders retracted).
6.
NOTE: The whole system requires
between 50 to 60 gallons of oil.
CAUTION
MAXIMUM TEMPERATURE FOR
HYDRAULIC OIL IS 180°F.
3/4 OF OIL
LEVEL
GAUGE
OIL GAUGE
AND TEMPERATURE
FIGURE #1.82
GENERAL MAINTENANCE
1-62
HYDRAULIC TANK
OIL TEMP/LEVEL
GAUGE
Front View
SUCTION LINE
FILLER
BREATHER
CAP
BALL
VALVE
Rear view
FILTER ELEMENT
HOUSING
FIGURE #1.83
AUTOMIZER RIGHT-HANDTM
1-63
FILTER
SUCTION
BREATHER CAP
SAFETY VALVE
OIL TEMP./
LEVEL GAGE
FILLER
CAP
ACCESS
PANEL
FIGURE #1.83A
GENERAL MAINTENANCE
1-64
1.14.6
HYDRAULIC OIL REPLACEMENT
PROCEDURE
HYDRAULIC OIL
REPLACEMENT PROCEDURE
1.
2.
3.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
Start the engine, engage the
hydraulic pump and disable the
speed-up system.
Retract all cylinders (Packer,
crusher panel, tailgate etc.).
4.
Disengage the hydraulic pump and
stop the engine.
5.
Clean around the filler cap and
remove it. Be cautious; some
hydraulic tanks are pressurized
(3 to 5 PSI). Open slowly.
HYDRAULIC FLUID REPLACEMENT
PROCEDURE
6.
Use a clean container of at least 60
gallons to drop the old oil into.
7.
To drop the oil, close the ball valve
and remove the drain plug under
the tank. Use a container with a
minimum capacity of 60 US gallons
to collect the oil.
8.
Completely drain the tank.
9.
Once emptied, reinstall the drain
plug.
10. Remove the strainer by removing
the bolts (see Figure 1.89) and
clean it (once a year, see section
1.14.8).
11. Clean inside the hydraulic tank
with a clean and dry cloth in order
to remove any metal particles or
debris accumulated at the bottom
• To clean the interior of the an
WARNING
HIGHLY
CONTAMINATED
HYDRAULIC FLUID MUST BE
CHANGED PROMPLY TO AVOID
ANY DAMAGE ON THE HYDRAULIC
SYSTEM.
aluminum tank (see Figure #1.83),
insert the hand in the hole where
the strainer was fixed. This allows
to clean one half of the tank. To
clean the other half, remove the
entire filter at the rear side of the
tank (see Rear view of Figure
#1.83), insert the hand inside, and
clean with the cloth.
• To clean the steel tank (see Figure
WARNING
IT IS NOT RECOMMENDED TO MIX
DIFFERENT BRAND NAMES AND/
OR GRADES OF OIL IN THE SAME
RESERVOIR.
AUTOMIZER RIGHT-HANDTM
#1.83A), remove the access panel
by removing the retaining screw.
Insert the hand inside and clean
the interior with the dry and clean
cloth.
1-65
HYDRAULIC FLUID REPLACEMENT
PROCEDURE (Cont’d)
12. Change the return filter element
(twice a year).
13. Refill the tank until oil reaches
the 3/4 of the oil gauge
(Figure #1.82). Use a high quality
oil, that has good performance in
cold weather(if applicable), such
as SHELL TELLUS T32 or
equivalent (See section 2
“Lubrication” for specifications).
The whole system will require
between 50 and 60 gallons.
14. The oil must be clean and free of
any dirt, metallic particles or sand
etc.) The use of a filtering screen
is strongly recommended while
filling the tank with new oil.
15. If the suction line has been
replaced, fill the line until the oil
reaches the pump to avoid
cavitation (see section 3.5 of
Troubleshooting).
16. Start the engine and check again.
GENERAL MAINTENANCE
1-66
1.14.7 FILTER ELEMENT REPLACEMENT
PROCEDURE
To protect new components of the hydraulic
system, the return filter element must be
changed after the first 50 hours of
operation of the vehicle. Then, change the
element twice a year (see the preventive
maintenance chart at the end of this
section).
The filter restriction indicator located at
front of the tank (Figure #1.84) will indicate,
when the engine is running, if the filter
requires to be changed. Replace the filter
when the indicator is in the yellow zone,
before it reaches the red zone. This will
keep the oil clean, extend component life
expectancy and reduce breakdowns.
FILTER
RESTRICTION
INDICATOR
HYDRAULIC FILTER
REPLACEMENT PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Prepare a pan or a bucket to
recuperate oil that will spill out of
the filter housing (2 gallons of oil).
3.
Remove the four (4) bolts of the
filter head cover of the hydraulic
tank (Figure #1.85); This in-tank
return filter system has a selfclosing trap that is closing as you
remove the cartridge therefore
preventing the whole tank to empty
itself.
4.
Change
the
filter
element with a new one (Figure #1.86).
5.
Reinstall the filter head cover.
WARNING
FIGURE #1.84
CHANGE RETURN FILTER
ELEMENT AFTER THE FIRST 50
HOURS OF OPERATION.
FILTER ELEMENT
FILTER HEAD
COVER
COVER RETAINING
BOLTS (4)
FIGURE #1.85
AUTOMIZER RIGHT-HANDTM
FIGURE #1.86
1-67
1.14.8
STRAINER CLEANING PROCEDURE
STRAINER CLEANING
PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Start the engine, engage the
hydraulic pump.
3.
Retract all cylinders (packer,
crusher panel, tailgate etc.).
4.
Raise the body and install the
safety prop.
STRAINER CLEANING
PROCEDURE
5.
Disengage the hydraulic pump and
turn off the engine.
6.
Clean around the filler cap and
remove it. Be cautious; some
hydraulic tanks are pressurized
(3 to 5 PSI). Open slowly.
7.
Drain the hydraulic tank using the
drain plug under the tank (Refer to
section 1.14.6 “Hydraulic oil
replacement procedure”).
8.
Once emptied, reinstall the drain
plug.
STRAINER
FIGURE #1.87
GENERAL MAINTENANCE
1-68
1.14.8
STRAINER CLEANING PROCEDURE
(Cont’d)
Strainer / ball valve
assembly
STRAINER CLEANING
PROCEDURE
9.
Remove the hose clamp from the
suction hose (Figure #1.88) and
slide the hose over the pipe until it
clears the ball valve (slide towards
the frame of the vehicle).
HOSE CLAMP
10. Remove the strainer from the tank
port (Figure #1.89).
11. Once the strainer is removed,
clean it using solvent, and inspect
for damage; replace if necessary.
FIGURE #1.88
12. Replace the seal if necessary and
re-install the strainer.
13. Refer to the hydraulic fluid
replacement procedure for filling
up the tank and ensure there is no
leak.
Bolts
(4)
Seal
Strainer
AUTOMIZER RIGHT-HANDTM
FIGURE #1.89
1-69
1.14.9 DUAL VANE PUMP
The AutomizerTM is equipped with a dual
vane pump. One of the vane pump sections,
known as the body vane pump, powers all
the body functions (i.e.: tailgate, body
hoist, packer, etc.) through the directional
control valve.
The second vane pump section, known as
the arm vane pump, powers the automated
arm functions and some other options
through the proportional valve.
DUAL VANE PUMP
2
1
FIGURE #1.90
1: VANE PUMP SOLENOID VALVE
2: FLOW REGULATOR
PUMP SWITCH
The dual vane pump is activated by two
electric solenoid valves (one for each
section) mounted on the pump
(Figure #1.90). The electric signal, which
activates the solenoid, is sent by the pump
switch on the console (Figure #1.91).
When the pump switch is turned “ON”, the
transmission electronic control unit (ECU),
monitors the vehicle speed and the engine
RPM and then allows (or not) the vane
pump to engage. The air pressure MUST
be at least of 70 PSI in order to engage the
pump. If the vehicle is exceeding 15 mph
(25 km/h) or if the engine speed exceeds
900 RPM , the vane pump will not engage.
After the pump is engaged, it will stay
engaged at any engine speed under 2300
RPM. Refer to section 1.19 “Allison
Transmission Programming Parameters”.
The arm vane pump is capable of delivering
a flow of 15 gallons per minute at 900 RPM
(idle speed). A flow regulator at the pump
outlet limits the flow to the valve at 15
GPM. All excess flow is sent back directly
to the pump inlet. When the pump is not
engaged, all the oil returns to the inlet.
The body vane pump is capable of delivering
a flow of 23 GPM at 900 RPM (idle). A flow
regulator at the pump outlet limits the flow
to the valve at 45 GPM. All excess flow is
sent back to the hydraulic tank. When the
pump is not engaged, all the oil returns to
the hydraulic tank.
FIGURE #1.91
GENERAL MAINTENANCE
1-70
1.14.10 PRESSURIZING THE TANK SYSTEM
Cavitation is defined as the formation of air
pockets in a moving fluid. The presence of
air in the hydraulic oil produces cavitation
inside the pump, generating excessive wear
and noise. Cavitation forms after replacing
hydraulic components or after flushing the
hydraulic system.
To prevent cavitation in the hydraulic
system, air pressure of 3 to 3.5 PSI is
applied to the hydraulic tank. A gauge and
a pressure regulator are installed to adjust
the air pressure inside the tank. This gauge
is located inside the frame rail on the
curbside of the chassis (Figure #1.92).
This gauge can be accessed only when
body is raised. To adjust the pressure
regulator, turn it’s knob until the pressure
reaches 3 to 3.5 PSI.
The hydraulic tank is also equipped with
a 5-PSI relief valve (Figure #1.93) and a 5PSI pressurized screw on filler cap.
PRESSURE
REGULATOR
5 PSI RELIEF
VALVE
FIGURE #1.93
5 PSI
BREATHER CAP
FIGURE #1.94
DANGER
INSTALL BODY SAFETY PROP
BEFORE PERFORMING ANY
WORK UNDER BODY.
PRESSURE
GAUGE
FIGURE #1.92
WARNING
DO NOT EXCEED 5 PSI OF AIR
PRESSURE INSIDE THE TANK.
AUTOMIZER RIGHT-HANDTM
1-71
1.14.11 PUMP INSPECTION
HYDRAULIC PUMP
The hydraulic pump (Figure #1.95) is
powered by the truck’s engine through a
drive shaft. On a daily basis, the pump
should be visually inspected. Follow this
procedure.
PUMP INSPECTION PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to section 1.5 “lockout/
tagout procedure”).
2.
Start the engine, engage the
hydraulic pump.
3.
The pump should turn freely
without any excessive noise or
vibrations.
4.
Open the cab grille (if necessary).
5.
Inspect the pump (under) and
connections for any oil leak.
6.
If an electrical problem occurs with
the pump, refer to section 3.3
“Troubleshooting guide.
FIGURE #1.95
WARNING
IF THE UNIT HAS TO BE DRIVEN
AWAY FOR REPAIRS ON THE
HYDRAULIC SYSTEM, REMOVE
THE DRIVE SHAFT BETWEEN THE
ENGINE AND THE PUMP BEFORE
RESTARTING THE ENGINE.
GENERAL MAINTENANCE
1-72
1.15
HYDRAULIC PRESSURE
ADJUSTMENT
Ball-end Hex Key (Metric & SAE)
1.15.1 BODY FUNCTION MAIN RELIEF
VALVE ADJUSTMENT
The vane pump that controls the body
function may have its own relief valve. This
relief valve has to be set before the main
relief valve on the directional control valve.
The pressure chart below gives the proper
adjustment pressure for body function.
Use this chart to adjust the relief of the
pump. A 0-4000 pressure gauge
(Figure #1.96) as well as a set of ball-end
Hex key (Figure #1.97) is required to
perform the pressure adjustment
procedure.
0-4000 PSI PRESSURE
GAUGE
(HYF00910)
FIGURE #1.97
PRESSURE CHART FOR 27/21 CU.YD
BODY with 4-inch dia. packer cylinders
1. Body vane pump relief valve (if
equipped) is set at 3300 PSI (2200
PSI FOR 21 CU.YD Body) at idle
speed.
QUICK CONNECT
(HYF10195)
2. Body function main relief valve is
set at 3000 PSI (2000 PSI FOR 21
CU.YD Body) at idle speed.
FIGURE #1.96
RELIEF VALVE
AUTOMIZER RIGHT-HANDTM
FIGURE #1.98
1-73
1.15.1
BODY FUNCTION MAIN RELIEF
VALVE ADJUSTMENT(cont’d)
0-4000 PSI
PRESSURE GAUGE
(HYF00910)
Apply the following procedure in order to
adjust the vane pump relief valve.
BODY VANE PUMP RELIEF VALVE
(IF EQUIPPED) ADJUSTMENT
PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Apply
the
lockout/tagout
procedure.
Ensure safety around the vehicle
at all times.
Install the 0-4000 PSI pressure
gauge on the quick connect fitting
located on the body functions
valve (Figure #1.99).
Start the engine and engage the
hydraulic system (Pump switch
“ON”).
Release the vane pump relief (if
equipped).
Tighten the main relief valve
adjustment screw to be able to
adjust the vane pump relief valve
(if equipped).
Activate the tailgate until the
cylinder reaches the end of its
stroke (close the tailgate).
Adjust the vane pump relief valve1
(if equipped) according to the
pressure chart.
Once the body vane pump relief
valve is adjusted, back out the
Main Relief .
QUICK CONNECT
(HYF10195)
FIGURE #1.99
FIGURE #1.100
When the vane pump is adjusted to the
proper pressure, adjust the relief of the
body function valve according to the
pressure chart.
1
The flow control that controls the flow for
all body functions is the one on the closest
section of the input shaft.
GENERAL MAINTENANCE
1-74
MAIN RELIEF VALVE PRESSURE
ADJUSTMENT
1.
Make sure the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the Lockout/Tagout
procedure).
2.
Start the engine.
3.
Engage the hydraulic system.
4.
Hook a 0-4000 PSI pressure gage
on the quick connect located on
the hydraulic valve.
5.
Back out the main relief and close
the tailgate completely. Hold the
lever in order to make the pressure
build up in the system.
6.
At the same time, check the
pressure on the gage.
7.
Adjust the main relief as needed
by loosening the lock nut and
turning the adjustment screw.
0-4000 PSI
PRESSURE GAGE
PRESSURE ADJUSTMENT TABLE
PUMP
VANE PUMP
CHASSIS
CYLINDER
BORE(PACKER)
MAIN
RELIEF
PRESSURE
(± 50 PSI)
DUMP VALVE
PRESSURE (IF
EQUIPPED) (± 50
PSI)
6X4
4 INCHES
3000 [email protected]
IDLE
3300 [email protected]
IDLE
4X2
4 INCHES
2000 [email protected]
IDLE
2200 [email protected]
IDLE
AUTOMIZER RIGHT-HANDTM
1-75
BODY RELIEF VALVE
ADJUSTMENT (ELECTROHYDRAULIC VALVE)
1.
2.
3.
4.
5.
Once the body vane pump relief
valve is adjusted, back out the
Main Relief (F).
Install the pressure gauge at the
valve inlet cover (E).
Activate the “close tailgate”
function.
If it doesn’t work, adjust the utility
section of the valve.
Set the pressure at IDLE to 2000
PSI for a single axle or to 3000 PSI
for tandem chassis.
UTILITY SECTION ADJUSTMENT
6.
Install a pressure gauge at the
valve inlet cover (letter E on the
schematic).
7. Back out the Pilot Generation Relief
Valve (A) as well as the Pressure
Reducing Valve (B)
8. Disconnect the BODY UP coil (C).
9. Activate the BODY UP hydraulic
function in order to energize the
Build-Up solenoid.
10. Set the Pilot Generation Relief
Valve(A) that is located on the righthand side of the valve bank, behind
the coil, to 420 PSI (plus or minus
30 PSI) with the engine at IDLE. If
you’re not able to do so, turn the
main relief (F) on 1 turn.
11. Reconnect the BODY UP coil.
12. Remove the pressure gauge from
the valve inlet cover and install it
on the UTILITY VALVE SECTION
TEST PORT (D).
13. Activate the TAILGATE CLOSE (B)
function and hold. Set the Pressure
Reducing Valve at 550 PSI (plus or
minus 50 PSI) with the engine at
MAX RPM.
14. Test the valve. The valve should
shift sharply.
NOTE: Refer to the schematic on the next
page to identify the valve parts.
1.15.2 ARM VANE PUMP RELIEF VALVE
ADJUSTMENT (cont’d)
Usually, there is no arm vane pump relief
valve. If there’s one on your truck, raise the
pressure to it’s maximum by tightening
completely the relief valve.
NOTE: The arm vane pump is located at
the front of the pump.
GENERAL MAINTENANCE
AUTOMIZER RIGHT-HANDTM
C
(BEHIND)
D
B
F (MAIN RELIEF)
A
E
B
1-76
1-77
PROPORTIONAL VALVE
1.15.3 ARM FUNCTIONS ADJUSTMENT
PROCEDURE
The operating pressure of the arm
(retract / extend) and the grabber (up and
down movement) are the same as the main
relief: 2000 PSI (refer to section 1.14.4A).
No adjustment is required for these
functions. Only the grabber (close) requires
proper adjustments to prevent crushing the
roller carts. Refer to section 1.15.4 to
adjust the grabber’s load sense relief valve.
MAIN RELIEF
FIGURE #1.101
The table on the next page presents the
operating pressure and the cycle times for
each function of the arm. Note that speed
of the arm is controlled by the amount of
hydraulic fluid (flow) sent to the cylinder.
The flow is limited mechanically by two
movement restrictors located on each
section. To adjust the cycle time of the arm
refer to section 1.15.5 “Arm Speed
Adjustment Procedure”.
Install the control lever here
to retract the telescopic
arm.
FIGURE #1.102
GENERAL MAINTENANCE
1-78
GRABBER LOAD
SENSE RELIEF
MOVEMENT
RESTRICTORS
FIGURE #1.103
FIGURE #1.104
ARM OPERATING PRESSURE AND CYCLE TIMES
Arm function
Pressure setting
Cycle Time
Arm Extend / Retract
2000 PSI
10 sec.
Grabber Up / Down
2000 PSI
8 sec.
Grabber Close
1200 PSI (load sense)1
Less than 2 sec.
Grabber Open
2000 PSI + ¼ turn
Less than 2 sec.
Table 1
1
Reference value that varies according to use. This pressure can be adjusted according
to client’s needs.
AUTOMIZER RIGHT-HANDTM
1-79
1.15.4 GRABBER LOAD SENSE RELIEF
GRABBER LOAD SENSE
RELIEF ADJUSTMENT
PROCEDURE
The section of the proportional valve that
controls the grabber is located on the
right-hand side of the valve and it is equipped
with a load sense relief valve that allows
pressure adjustment of the grabber. To
adjust the load sense relief apply the
following procedure.
1.
Apply the lockout / tagout
procedure.
2.
Before making any adjustments,
secure the area around the path of
the arm.
3.
Remove all residual hydraulic
pressure in the system by moving
the manual levers back and forth.
4.
Make sure that all hoses are tight
and not leaking.
5.
Connect a pressure gauge
(0-4000PSI) to the quick connect
on proportional valve.
6.
Put the transmission in Neutral.
7.
Start the engine, and engage the
hydraulic pump.
8.
Using the first lever on the lefthand side of the proportional
valve, close the grabber .
9.
Adjust the relief valve of the
“grabber close” side of the valve
section at 1200PSI 1 (screw or
unscrew depending on the gauge
readout).
DANGER
DO NOT STAND DIRECTLY IN THE
PATH OF THE ARM WHILE
CARRYING OUT THESE
ADJUSTMENTS.
GRABBER LOAD
SENSE RELIEF
FIGURE #1.105
10. Open the grabber and adjust the
pressure of the “grabber open”
load sense relief valve at 2000 PSI
+ ¼ turn
1
FIGURE #1.106
Reference value that varies according to
use. This pressure can be adjusted
according to client’s needs.
GENERAL MAINTENANCE
1-80
“Grabber close” relief
adjustment screw
“Grabber open” relief
adjustment screw
AUTOMIZER RIGHT-HANDTM
Main Relief Valve
1-81
1.15.5 ARM SPEED ADJUSTMENT
The arm speed is controlled by the amount
of hydraulic fluid that is being sent to the
arm’s cylinder. The arm control valve spools
can let a certain flow of hydraulic oil,
depending on the section of the valve*. The
flow is limited by a mechanical movement
restrictor or stopper (Figure #1.107).
Note:
No arm speed adjustment is required unless
replacing the valve or a section of it.
MOVEMENT
RESTRICTORS
SPEED ADJUSTMENT
PROCEDURE
1.
Apply
the
procedure.
2.
Secure the arm’s working area
using barrier tape or barricades.
3.
Put the transmission to neutral.
4.
Start the engine and engage the
hydraulic system (Pump switch
“ON”).
5.
Clearly identify the stopper screw
on the valve that corresponds to
the proper function (boom
extension/retraction, grabber
open/close). Move the lever to
evaluate the speed of the arm then
release the lever.
6.
Loosen the lock nut.
7.
Screw in the restrictor adjustment
only one eighth (1/8th) of a turn at
a time to see a significant change
of the arm’s speed.
8.
Move the lever again to evaluate
the arm’s speed. Repeat until cycle
times are properly set (see cycle
time on page 7).
9.
Tighten the lock nut.
FIGURE #1.107
DANGER
APPLY THE “LOCKOUT/TAGOUT”
PROCEDURE AT ALL TIMES.
lockout/tagout
DANGER
*
Limiting the stroke of the spools is
limiting the amount of oil (flow) going
through them. Controlling the flow
of oil means controlling the speed of
the arm.
DO NOT STAND DIRECTLY IN THE
PATH OF THE ARM WHILE
CARRYING OUT THESE
ADJUSTMENTS.
GENERAL MAINTENANCE
1-82
1.16
BODY HOIST INSPECTION AND
REPLACEMENT PROCEDURE
Because of its frequent use, the body hoist
needs to be inspected to ensure the proper
operation at all times. The following section
presents a typical inspection procedure of
the body lifting cylinder.
1.16.1 BODY HOIST INSPECTION
The body hoist should be visually inspected
every week as part of regular maintenance.
Check for leaks, cracks and loose parts
that could cause breakdown. When the
body is raised, at the top of each cylinder’s
section, you will see a steel gland (figure
#1.109) which must be inspected as well.
Apply the following procedure for complete
inspection of the hoist.
BODY HOIST INSPECTION
PROCEDURE
BODY HOIST
FIGURE #1.108
DANGER
APPLY THE “LOCKOUT/TAGOUT”
PROCEDURE AT ALL TIMES.
1.
Park the vehicle on a safe and
level ground.
2.
Check the overhead clearance and
fully raised the body.
3.
Install the body safety prop.
4.
Apply the
procedure.
5.
Check the cylinder for scratch or
leaks.
6.
At the cylinder base, make sure
that the pivots are greased and
the bolts are tight.
lockout/tag
CYLINDER
GLAND
FIGURE #1.109
AUTOMIZER RIGHT-HANDTM
out
1-83
1.16.1
BODY HOIST INSPECTION (cont’d)
BODY HOIST INSPECTION
PROCEDURE
7.
Check the gland on each stage of
the cylinder.
8.
If the gap between the gland and
the tube is higher than 1/8 inch:
You
must
call
Labrie
Environmental Group Customer
Support Center immediately at 1800-231-2771.
9.
In the event that the gap between
the tube and the gland is bigger
than 1 inch:
Less that 1/8”
gap here.
FIGURE #1.110
Safety pin
You must stop using the vehicle
immediately and repair the
cylinder. Refer to section 1.16.2
“Body hoist replacement”.
10. Make sure that the gland safety
pins are in place.
11. When the inspection is completed,
retract the safety prop and lower
the body.
FIGURE #1.111
DANGER
INSPECTION OF THE CYLINDER
GLAND EVERY WEEK IS
MANDATORY. UNSCREWED
GLAND FROM THE BODY HOIST
WILL CAUSE THE SEPARATION OF
THE HYDRAULIC CYLINDER AND A
SUDDEN DROP OF THE BODY.
THIS TYPE OF ACCIDENT CAN
LEAD TO SERIOUS INJURIES AND/
OR IMPORTANT DAMAGES OR
EVEN DEATH.
GENERAL MAINTENANCE
1-84
1.16.2
BODY HOIST REPLACEMENT
TOP OF THE BODY HOIST
BODY HOIST REPLACEMENT
PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Remove the locknut at the top of
the cylinder cover (Figure #1.112).
3.
Start the engine and engage the
hydraulic pump.
4.
Lift the body to get enough space
to lower the safety prop under the
body (Figure #1.113).
5.
Install the safety prop and using a
lifting device secure the cylinder
to prevent the cylinder from tilting
on the cab or falling onto the
chassis.
6.
Start the engine, engage the
hydraulic system and lower the
body cylinder using the lever on
the console.
7.
Disengage the hydraulic system
and stop the engine.
LOCKNUT
FIGURE #1.112
SAFETY
PROP
DANGER
DO NOT USE THE SAFETY PROP
WITH A LOADED BODY. UNLOAD
THE BODY PRIOR DOING ANY
REPAIRS.
AUTOMIZER RIGHT-HANDTM
FIGURE #1.113
1-85
1.16.2
BODY HOIST REPLACEMENT (cont’d)
HYDRAULIC
FITTING
BODY HOIST REPLACEMENT
PROCEDURE
8.
Disconnect the hydraulic hose and
fitting (Figure #1.114).
9.
Remove the cylinder base pillow
blocks (Figure #1.115).
10. Replace the cylinder.
FIGURE #1.114
11. Reinstall the cylinder base pillow
blocks on both sides and
reconnect the hydraulic hose.
12. Start the engine and engage the
hydraulic pump.
13. Slowly raise the cylinder until it
reaches the top of the cover where
the lock nut will be tightened. Note
that the cover must be aligned
with the threaded rod at the top
end of the cylinder.
14. When the threaded rod passes
through the cover, install the
locknut.
BASE PIILLOW
BLOCKS
FIGURE #1.115
15. Lubricate the cover and the base
pillow blocks (Figure #1.115 & # 1.116).
16. Lift the body, store the safety prop
and check for proper operation.
COVER
PILLOW
BLOCKS
FIGURE #1.116
GENERAL MAINTENANCE
1-86
1.17
ARM GENERAL MAINTENANCE
To keep the arm in good working order,
reduce down time and risk of accidents, a
preventive maintenance program must be
implemented and followed thoroughtly.
Maintenance personel must be familiar
with the operation of the arm, the safety
around it and the maintenance procedure
described in this section as well.
1.17.1 DAILY INSPECTION
On a daily basis, perform a visual inspection
of the arm, looking for leaks, crack or
premature wear of the moving parts.
REFER TO LUBRICATION SECTION FOR
DETAILED GREASING POINTS.
Apply the following inspection procedure.
ARM INSPECTION PROCEDURE
1.
Make sure to park the vehicle on a
safe and level ground.
2.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
3.
Start the engine and engage the
hydraulic pump (PTO ON).
4.
Fully extend the arm.
5.
Raise the body and install the
safety prop.
6.
Turn off the hydraulic pump and
the engine.
7.
Perform a visual inspection of the
following items.
•
•
•
•
•
•
•
•
Mounting bolts (Fig. 1.117 - 1.118);
Rollers and bearings (Fig. 1.119);
Bolt locks (Fig. 1.120);
Pivots;
Chains and gears;
Grabber arm;
Hoses and connections (Fig. 1.121);
Cylinders;
8.
Check for loose nuts and bolts.
9.
Check limit switches. See
section 1.17.2 “Limit switch
adjustment procedure”.
DANGER
DO NOT STAND DIRECTLY IN THE
PATH OF THE ARM WHILE
CARRYING OUT THESE
ADJUSTMENTS.
DANGER
APPLY THE “LOCKOUT/TAGOUT”
PROCEDURE AT ALL TIMES
10. Lubricate moving parts as per the
lubrication chart. See Lubrication
section.
AUTOMIZER RIGHT-HANDTM
1-87
MOUNTING BOLTS
(Over the chassis)
FIGURE #1.117
BOLT LOCKS
FIGURE #1.120
MOUNTING BOLTS
(Under the chassis)
HOSES
FIGURE #1.118
ROLLERS AND
BEARINGS
FIGURE #1.119
FIGURE #1.121
BOLTS
FIGURE #1.122
GENERAL MAINTENANCE
1-88
1.17.2 GRABBER LIMIT SWITCH
5.
On each side of the grabber, you will find
limit switches (Figure #1.123 and 1.124).
According to the grabber model, there can
be only one limit switch on the grabber.
When the operator extends the arm or
closes the grabber, these limit switches
trigger the warning lights on the dashboard.
If one of the limit switches is misaligned,
the warning lights on the dashboard may
continue to flash even if the grabber is fully
open and the arm fully retracted.
It is important that the these limit switch
are working at all times. Otherwise, the
operator may not be aware that the arm is
not fully retracted. This may result an
accident causing injuries and arm or
property damage.
Extend the arm (or close the
grabber) and see if the warning
light start to flash when the arm is
moving out. If not, adjust the lever
accordingly.
LIMIT SWITCH
LEVER
FIGURE #1.123
To adjust limit switches apply the following
procedure.
ARM LIMIT SWITCH
ADJUSTMENT PROCEDURE
1.
Park the vehicle on a safe and
level ground.
2.
Fully retract the arm.
3.
Fully open the grabber.
4.
See if the warning lights on the
dashboard are flashing; if they are
still flashing at that point, bend
the limit switch lever in such way
that the grabber finger will trigger
the limit switch (click sound) and
stop the warning lights. One or
both levers may require to be bent
to stop warning lights.
AUTOMIZER RIGHT-HANDTM
GRABBER
FINGER
LIMIT SWITCH
FIGURE #1.124
DANGER
DO NOT STAND DIRECTLY IN THE
PATH OF THE ARM WHILE
CARRYING OUT THESE
ADJUSTMENTS.
1-89
1.17.3 GRABBER AUTO-CLOSING
The automated arm is equipped with a
system that will close the grabber if the
operator raises the grabber without closing
it. The “Grabber Auto-Closing System” will
automatically close the grabber at a preset
height, preventing collision between the
grabber and the hopper wall.
In addition, if the vehicle is parked for a
long period of time with the grabber inside
the hopper, the grabber cylinder may leak
pressure, causing the grabber to open
itself by gravity if the joystick is out of the
central position. As soon as the hydraulic
system is brought online (pump switch
On), the system will close the grabber
automatically before the operator can move
the arm.
AUTO-CLOSING
LIMIT SWITCH
FIGURE #1.125
How it works:
The system acts as though the operator
would press the “Close Grabber” button on
the joystick.
The “Auto-Closing System” is activated by
a limit switch located on the left side of the
arm (Figure #1.125). When the grabber is
halfway up (Figure #1.126), a signal is sent
to the proportional valve coil to close the
grabber.
To prevent unnecessary pressure build-up
in the system, a pressure switch is used to
control the hydraulic pressure inside the
cylinder. The pressure switch will cut the
signal sent by the limit switch to the
proportional coil before the pressure
reaches the maximal setting.
If the pressure drops below the maximal
setting, the pressure switch will allow the
signal again to maintain the pressure inside
the cylinder keeping the grabber closed.
GRABBER
CLOSED
FIGURE #1.126
AUTO-CLOSING
PRESSURE SWITCH
FIGURE #1.127
Continued next page. . .
GENERAL MAINTENANCE
1-90
1.17.3
GRABBER AUTO-CLOSING (cont’d)
To make sure the “Grabber Auto-Closing”
is working properly, apply the following
procedure.
GRABBER AUTO-CLOSING
INSPECTION PROCEDURE
1.17.4 ADJUSTING THE GRABBER AUTOCLOSING SYSTEM
The Grabber Auto-Closing system is
controlled by a limit switch located on the
left side of the arm (figure 1.128). To
adjust the system apply the following
procedure.
GRABBER AUTO-CLOSING
ADJUSTMENT PROCEDURE
1.
Make sure the vehicle is parked on
a safe and level ground.
2.
Secure the area around the path of
the arm.
1.
Make sure the vehicle is parked on
a safe and level ground.
3.
Start the engine and engage the
hydraulic pump.
2.
Secure the area around the path of
the arm.
4.
Lower the grabber arm and fully
open the grabber.
3.
Start the engine and engage the
hydraulic pump.
5.
Raise the grabber arm and see if
the grabber closes automatically
when it reaches the middle of its
stroke. If the grabber does not
close, refer to section 1.17.4
“Adjusting The Grabber AutoClosing System.
4.
Extend the arm.
4.
Fully open the grabber.
5.
Raise the grabber arm halfway.
6.
The arm lever on the grabber arm
should release the roller of the
limit switch. At this point, a 12-volt
signal should reach the coil on the
proportional valve to close the
grabber.
DANGER
APPLY THE “LOCKOUT/TAGOUT”
PROCEDURE AT ALL TIMES.
ARM LEVER
DANGER
LIMIT SWITCH
ROLLER
DO NOT STAND DIRECTLY IN THE
PATH OF THE ARM WHILE
CARRYING OUT THESE
ADJUSTMENTS.
FIGURE #1.128
AUTOMIZER RIGHT-HANDTM
1-91
1.17.4
ADJUSTING THE GRABBER AUTOCLOSING SYSTEM (cont’d)
GRABBER AUTO-CLOSING
ADJUSTMENT PROCEDURE
7.
If the grabber does not close,
adjust the roller on the limit switch
accordingly (click sound). Loosen
the nut at the center of the roller
arm axis
DANGER
IT IS IMPERATIVE TO BE
EXTREMELY CAREFUL DURING
THE ADJUSTMENT OF THE LIMIT
SWITCH. AS IT IS NEAR THE
GRABBER AND THE ARM,
SERIOUS INJURIES COULD
OCCUR IF YOU STAY IN THE ARM
PATH.
ROLLER ARM
AXIS NUT
ROLLER
FIGURE #1.129
8.
When the grabber is closing,
tighten the nut and perform a few
up and down cycle of the grabber.
Each time the grabber is raised,
the grabber fingers should close
automatically before reaching the
hopper.
9.
Adjust the pressure switch that
cuts the signal to the coil. See
section 1.17.5 “Auto-Closing
Pressure Switch Adjustment.
Pressure switch
adjustment screw
FIGURE #1.130
GENERAL MAINTENANCE
1-92
1.17.5 AUTO-CLOSING PRESSURE SWITCH
ADJUSTMENT
To prevent pressure build-up in the system,
the Grabber Auto-Closing System is
equipped with a pressure switch that cuts
the 12-volt signal sent by the limit switch to
the coil. This pressure switch is set at the
factory at a pressure of 800 PSI. When the
pressure in the grabber cylinder reaches
800 PSI the pressure switch will cut the
signal to the coil. To adjust the pressure
switch apply the following procedure.
GRABBER AUTO-CLOSING
ADJUSTMENT PROCEDURE
1.
Make sure the vehicle is parked on
a safe and level ground.
2.
Secure the area around the path of
the arm.
3.
Start the engine and engage the
hydraulic pump.
4.
By using the joystick, extend the
arm (from 3 to 4 inches).
5.
Raise the grabber in order to close
it (auto-closing zone).
6.
Disconnect
the
electrical
connectors from the “Extend/
Retract” and “Up/Down” sections
of the valve.
7.
Unscrew
completely
the
adjustment screw of the pressure
switch in order to obtain the
minimum pressure.
8.
Install a pressure gage on the inlet
section of the arm valve. Reduce
the safety valve pressure to 800
PSI.
AUTOMIZER RIGHT-HANDTM
9.
Manually close the grabber to put
the valve under pressure.
10. Ask another person to push on the
extend/retract buttons of the
joystick. Step 1 MUST be done
correctly in order to avoid any
movement of the arm.
11. Adjust the pressure switch by
screwing ¼ turn at a time. The
valve should be pressurized
momentarily. When you turn the
screw in ¼ turn and that pressure
stays, that means that the pressure
is the same as the relief valve, for
instance 800 PSI.
12. Readjust the relief pressure to 1200
PSI.
13. Reconnect the connectors and put
the arm in it’s normal position
(parked along the truck).
PRESSURE
SWITCH
INLET SECTION
CONNECTORS
1-93
1.17.6 GRAB PACK
The Grab Pack switch (see Figure #3.33 of
Operator Manual) enables the packer to
automatically start cycling about 4 seconds
after the grabber is closed. This will give
the arm enough time to reach the hopper
and dump the cart before the packer starts
to pack.
With a multi-cycle system, if the packer is
set to perform 3 cycles (set in factory to
3 cycles, adjustable from 2 to 8; see section
3.2.5 Multi-Cycle Control of Operator
Manual), the packer will complete all its
cycles until the next time the operator
closes the grabber. When the operator
closes the grabber, the multi-cycle function
is reset.
If the grabber is closed in the middle of a
cycle, the packer will interrupt its current
cycle, return to its fully retracted position,
and then restart the next cycle. When a
cycle is interrupted and the packer has
returned, there is no delay before the
packer restarts the next cycle. The foursecond reset will apply only when the
packer has completed all its cycles (2 to 8)
and when it has returned to its fully retracted
position.
Interrupting a cycle prevents dumping carts
directly over the packer. Piled material
over the packer could reduce the packer
efficiency.
GENERAL MAINTENANCE
1-94
1.18
AIR SYSTEM MAINTENANCE
the actuator on the main hydraulic valve.
Refer to Air System section for air diagrams.
Air system is crucial for the brakes to
operate with maximum efficiency. All air
tanks on the chassis must be drained after
each working day.
AIR TANK
DRAINAGE
VALVE
AIR
ACTUATORS
FIGURE #1.131
Some units are equipped with an air
dryer and/or alcohol evaporator (Figure
#1.138). These devices are used to reduce
water in the air system, preventing air
components to corrode or to freeze in cold
weather.
To perform maintenance on the air dryer
and alcohol evaporator, refer to the chassis
manufacturer maintenance manual.
The main hydraulic valve which controls the
body functions, is activated by air
actuators (Figure #1.132). When the
tailgate or body lever on the console is
moved, air pressure passing through the
lever will activate the corresponding air
actuator on the main valve; resulting in a
movement of the hydraulic spool inside the
valve.
The same thing occurs when the packer is
activated; when pressing the green button
on the packer control station, an electric
signal is sent to the air-valve that controls
AUTOMIZER RIGHT-HANDTM
FIGURE #1.132
At the end of each day, bleed the water
from the air filter bowl located on the cab
console (Figure #1.133). Unscrew the drain
cock and using a small rag in hand, collect
the water that will come out. This water
trap helps keep residual moisture out of
the air system.
WATER TRAP
BLEED
DRAIN COCK
FIGURE #1.133
1-95
1.18
AIR SYSTEM MAINTENANCE
(cont’d)
DANGER
To avoid affecting control of packer or
other system on the vehicle (especially
under cold weather conditions), Apply the
following procedure:
USE APPROPRIATE “LOCKOUT/
TAGOUT” PROCEDURE AT ALL
TIMES.
AIR SYSTEM MAINTENANCE
PROCEDURE
1.
Ensure that the parking brake is
applied and the vehicle is tagged
out for maintenance purposes
(refer to the section 1.5 “Lockout/
Tagout procedure”).
2.
Drain all air tanks daily.
3.
Pay a particular attention to the
dryer cartridge. On this type of
equipment the compressor works
all the time (frequent use of the
brake system). As a consequence,
a lot of moisture is injected into
the air system. See chassis
manufacturer recommendations.
4.
Twice a year lubricate the air
actuators found on the main
control valve with light oil (low
temperature). See section 3.6
“Packer
air
system
troubleshooting”.
NOTE:
For vehicle equipped with alcohol
evaporator, please refer to the chassis
manufacturer dealer for proper
maintenance.
AIR
DRYER
FIGURE #1.134
1.19
SURFACE FINISHING AND
PAINTING
Type of surface finishing recommended:
PAINTING PROCEDURE
•
SURFACE PREPARATION:
Sandblasting.
•
PRIMARY COAT:
Anticorrosive epoxy primer.
•
FINISHING COAT:
Two (2) coats industrial type paint
(or equivalent).
GENERAL MAINTENANCE
1-96
1.20
ALLISON TRANSMISSION
PROGRAMMING PARAMETERS
The Allison transmission electronic control
unit (ECU) controls several systems of the
automated unit; it prevents the pump from
over speeding (2300 RPM maximum). The
ECU also prevents the pump engagement
if the engine speed is any higher than 900
RPM. It will also shut off the pump and the
joystick (of the arm) if the vehicle is moving
faster than 15 MPH (25Km/h). The
transmission ECU also controls the autoneutral system (if equipped).
If the vehicle requires having the ECU
repaired or replaced, or a specific
programming parameters, refer to section
3.17 “Allison Transmission Programming
Parameters”.
A “Pro-link” keypad interface (Figure
#1.139) may be used to program the Allison
ECU and verify if the signals are properly
reaching the computer and verify the fault
code. To tap onto the ECU, Labrie uses the
following wires on the Allison connector:
INPUT:
#117: PUMP PACK ENABLE: Active when
the brakes are used, and when the
PTO and auto-neutral switch is
“ON”(ground signal).
#118: PTO ENABLE: Active when the PTO
switch is “ON”(+12V. signal).
#153: AUTO-NEUTRAL PACK INPUT:
Active when the brakes are used, and
when the PTO and auto-neutral
switches are “ON” (ground signal).
AUTOMIZER RIGHT-HANDTM
FIGURE #1.139
OUTPUT:
#112: PTO ENABLE OUTPUT: Active when
the PTO switch is “ON” and when all
engine and vehicle speed criteria are
respected (+12V. signal). Refer to
the programming parameter chart.
“Troubleshooting” tab, section 3.17
“Allison Transmission Programming
Parameters”.
#114: NEUTRAL SIGNAL OUTPUT: Active
when the transmission is in neutral.
This signal (ground signal) is used to
allow the fast idle engagement. For
more details, refer to the electrical
schematic.
1-97
1.21
AUTOMIZER PREVENTIVE
MAINTENANCE CHART
AUTOMIZER
PREVENTIVE MAINTENANCE CHART
COMPONENT /
SYSTEM
Hydraulic system
EACH
YEAR
VERIFICATION
SECTION
9
– Check oil level in tank and
refill if necessary.
1.14.5
9
– Check if the ball valve is
open on main tank.
1.9
9
– Check on ground for
overnight leaks.
DAILY
WEEKLY
MONTHLY
– Check cylinders, pump,
control valve and system
for leaks. Repair or replace
if required.
1.14
TWICE
A YEAR
– Replace hydraulic filter.*
1.14.7
9
– Drain, flush, clean and refill
strainer.
1.14.8
9
9
Hopper area
Visual inspection of
the following
components:
– Check pressure.
1.15
9
– Clean traps on each side.
1.11
9
– Tilt down the floating panel
and clean dirt under or
behind the packer.
1.11
9
– Rollers,
hydraulic
cylinders and cylinder
pins, hoses, pipes and
connections, wear of floor
and side of hopper.
1.11
9
Body and chassis
9
– Check for corrosion.
– Keep the contact surfaces
clean, between the body
and chassis.
1.10
* Also replace the return filter after the first 50 hours of operation
GENERAL MAINTENANCE
1-98
1.21 AUTOMIZERTM PREVENTIVE
MAINTENANCE CHART (cont’d)
AUTOMIZER
PREVENTIVE MAINTENANCE CHART
COMPONENT /
SYSTEM
DAILY
Limit switches
Lubrication
WEEKLY
MONTHLY
EACH
YEAR
9
VERIFICATION
SECTION
– Proper adjustment of the
limit switches is imperative.
1.12.2
9
– Check and clean area
around switches
9
– Lubricate packer and its
accessories.
– See lubrication chart on
side of the truck
9
Wiring system
Operator control
Air tanks
Air system
Safety systems
Automated Arm
9
9
9
– Check for damaged
harnesses and/or bad
connections.
– Check for proper operation.
– Drain.
1.18
9
– Check for leaks.
1.18
9
– Check
for
proper
operation (tailgate alarm
and special devices).
– Check all pivots.
– Check hydraulic pressure.
AUTOMIZER RIGHT-HANDTM
1.6
1.7
1.13.4
1.13.5
1.17
1-99
NOTES
GENERAL MAINTENANCE
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