Labrie Top Select Maintenance Manual
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Labrie Top Select Maintenance Manual

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  • Page 1 Maintenance Manual Top Select Maintenance Manual...

  • Page 2: Table Of Contents

    Contents Top Select Maintenance Guide ......1-1 CHAPTER 1 Liability ....................1-2 Important Safety Notions ................1-3 General Precautions ................1-5 General Responsibilities of the Employer ............1-7 General Responsibilities of the Employee ............1-8 Summary of Daily Maintenance ..............1-9 Fire Hazard ..................... 1-9 Lockout/Tagout Procedure ................
  • Page 3 Contents Monthly Visual Inspection............... 1-26 Visual Inspection on the Loading Bucket............1-27 Visual Inspection on the Roof................1-29 Visual Inspection on the Tailgate ..............1-30 Visual Inspection on the Body .................1-31 Visual Inspection on the Chassis..............1-33 Loading Container Maintenance ............1-35 General Maintenance on the Loading Container..........1-35 Bucket Swing Out Procedure ................1-36 Container Rollers Replacement or Cleaning ...........1-37 Sliding Shoe Replacement Procedure ............1-39...
  • Page 4 Contents Gear Pump Inspection Procedure ..............1-80 Main Relief Valve Pressure Adjustment ............1-80 Pressure and RPM Chart (since January 2000) ..........1-82 Body Hoist Replacement Procedure............1-83 Air System Maintenance .................1-87 Surface Finishing and Painting ...............1-89 Preventive Maintenance .................1-90 Maximizer Maintenance..........2-1 CHAPTER 2 General Cleanliness................2-2 Maximizer Daily Cleaning................
  • Page 5 Contents Hydraulic and Pneumatic Schematics....5-1 CHAPTER 5 Pneumatics Top Select 1000 and Options ..........5-2 Pneumatics Top Select 2000 and Options ..........5-3 Pneumatics Brake System ..............5-4 Pneumatics Brake System (Inter cab) ............ 5-5 Hydraulics Top Select 1000 With Maximizer .......... 5-6 Hydraulics Top Select 2000 With Maximizer ..........

  • Page 6: Top Select Maintenance Guide

    Top Select CHAPTER 1 Maintenance Guide Only body and Maximizer components maintenance guidelines are outlined in this manual. For maintenance on the chassis, refer to the chassis manufacturer’s service manual. Top Select Maintenance Manual...

  • Page 7: Liability

    Top Select Maintenance Guide Liability Labrie Environmental Group assumes no liability for any incidental, consequential or other liability from the use of this information. All risks and damages, incidental or otherwise, arising from use or misuse of the information contained herein are entirely the responsibility of the user.

  • Page 8: Important Safety Notions

    SERIOUS INJURY OR DEATH CAUTION NDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY CAUTION NDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN PROPERTY DAMAGE Top Select Maintenance Manual...
  • Page 9 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 Labrie Plus for any technical support you may require.

  • Page 10: General Precautions

    4. The operator of the Top Select unit shall make sure that any people or obstructions are far away from the loading bucket before moving it.
  • Page 11 SUCH AS TELEVISION TUBES FLUORESCENT TUBES CANS UNDER PRESSURE HE OPERATOR MUST WEAR SAFETY EQUIPMENT SUCH AS SAFETY GLASSES GLOVES AND PROTECTIVE FOOTWEAR AT ALL TIMES For any additional information, please contact Labrie Plus. 1-800-231-2771 (24 hours) Top Select Maintenance Manual...

  • Page 12: General Responsibilities Of The Employer

    8. At the end of this chapter, the owner will find a preventive maintenance chart. It is strongly recommended that he follow it and keep a record of all work done on each unit. Top Select Maintenance Manual...

  • Page 13: General Responsibilities Of The Employee

    Top Select Maintenance Guide WARNING EFORE DOING ANY MAINTENANCE ON THE VEHICLE ALL SAFETY REGULATIONS MENTIONED IN 2.0, “ THE OPERATOR MANUAL SECTION MUST BE RESPECTED ESPECIALLY THE LOCKOUT ” TAGOUT PROCEDURE CAUTION AINTENANCE AND REPAIRS CARRIED OUT ON THIS VEHICLE MUST ONLY BE DONE BY...

  • Page 14: Summary Of Daily Maintenance

    1.3.3 Summary of Daily Maintenance For the Top Select maintenance, there are basic steps to be performed daily. Any other necessary maintenance operations are clearly presented further on in this guide. You must first be familiar with all the precautions in this manual before going any further.

  • Page 15: Lockout/Tagout Procedure

    Top Select Maintenance Guide 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).
  • Page 16 ARKING BRAKE FIGURE 1-2. Parking brake ASTER SWITCH FIGURE 1-3. Master switch DANGER EFORE PERFORMING ANY TYPE OF WELDING SOAK WITH WATER ALL REMAINING RESIDUES STUCK BETWEEN THE MAXIMIZER AND THE BODY TO PREVENT FIRE 1-11 Top Select Maintenance Manual...

  • Page 17: Body Safety Prop

    Top Select Maintenance Guide UGGESTED OCKOUT AGOUT ROCEDURE 1. Apply the parking brake. Figure 1-2, on page 2. Turn off the pump switch on the console (PTO switch). 3. Turn off the engine. 4. Remove the key from the ignition switch.
  • Page 18 4. Once finished with repairs or inspection, slightly raise the body to release the safety prop, bring it back to its vertical position and then lower the body. DANGER O NOT USE PROPS WITH A LOADED BODY EVER STAND UNDER A RAISED AND LOADED BODY 1-13 Top Select Maintenance Manual...

  • Page 19: Loading Bucket Safety Pin

    Top Select Maintenance Guide 1.3.7 Loading Bucket Safety Pin The loading bucket can be locked and secured at the end of its tracks (Figure 1-5 Figure 1-6) to allow access to the chassis components. The upper parts of the unit should be accessed by maintenance personnel only and must be reached only with a guarded platform that meets OSHA regulations about elevated working stations.
  • Page 20 6. Install front and rear safety pins in the tracks. Make sure they are firmly held in place. 7. When service is completed, remove the safety pins and slowly lower the bucket to its down position. FIGURE 1-6. Safety pin for bucket in full dump position 1-15 Top Select Maintenance Manual...

  • Page 21: Tailgate Safety Prop

    Top Select Maintenance Guide 1.3.8 Tailgate Safety Prop 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 opened for such purpose.

  • Page 22: 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. To shut down the Top Select: 1. Park on a hard level surface. 2. Apply the parking brake.

  • Page 23: Prior To Start Up

    Top Select Maintenance Guide RAIN AIR FIGURE 1-8. Drain air tank 1.3.10 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...
  • Page 24 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. THER CHASSIS NOT MODIFIED BY ABRIE MAY HAVE A DIFFERENT CONFIGURATION THAN THE ONE ILLUSTRATED HEREIN FIGURE 1-11. Air pressure gauge 1-19 Top Select Maintenance Manual...
  • Page 25 Top Select Maintenance Guide WARNING AKE SURE THAT THE MAIN VALVE ON THE HYDRAULIC TANK IS FULLY OPEN BEFORE STARTING 1-10). I THE ENGINE IGURE F IT IS NOT OPEN IT WILL RESULT IN IMMEDIATE DAMAGE TO THE PUMP EVEN IF THE...

  • Page 26: General Cleanliness

    Keep clean the contact surface between the body and chassis. Labrie recommends to clean the chassis after every unloading.

  • Page 27: Body Daily Cleaning

    The loading bucket: separators and the container cleanup procedure. Cleaning the chassis: cleanup of this section and precautions to be taken. The Maximizer area: if the Top Select is equiped with a Maximizer, body cleaning is not quite the same as for partitions.
  • Page 28 General Cleanliness AILY LEANING ROCEDURE 1. Apply suggested Lockout/Tagout procedure. For a Top Select with a Maximizer, go section 2.1.1 on page 2. Start the truck’s engine. 3. Open the tailgate enough to set the safety prop in place. FIGURE 1-12. Tailgate safety prop 4.

  • Page 29: Loading Bucket Daily Cleaning

    6. When most of the water has evacuated from the bucket, put the separators back in place. 7. If the Top Select has two loading buckets, proceed to clean the other side. WARNING E CAREFUL NOT TO USE PRESSURIZED WATER ON CYLINDER HEADS...

  • Page 30: Chassis Daily Cleaning

    4. Clean between body and frame with pressurized water, clean rear of cab. 5. Start truck, lift body, remove safety prop. 6. Lower body. 7. Clean all the exterior with water and soap. Rinse. 1-25 Top Select Maintenance Manual...

  • Page 31: Monthly Visual Inspection

    The visual inspection should take you about half an hour once you are accustomed to it. This inspection takes place once a month, after cleaning up. If performed along with the preventive maintenance, it will help you keep the Top Select in good condition. This inspection is divided in five procedures: The loading bucket •...

  • Page 32: Visual Inspection On The Loading Bucket

    Two rails; look for dirt or any small object that could cause premature wear. There • should not be grease in the rails, such coating will help glass, grit and other deposits stick inside and cause premature use of the rollers. Clean with pressure steam or solvent. 1-27 Top Select Maintenance Manual...
  • Page 33 46. Check the ball joint for unusual wear. Look inside the bucket at the ball joint’s level and inspect the pin joint. 3. Move the second bucket if you have a Top Select 2000. FIGURE 1-16. Automatic latch inspection 1-28...

  • Page 34: Visual Inspection On The Roof

    The roof consists of two cylinders per roof or side, rods to lift the buckets, two moving panels and a fixed one for the Top Select 1000. A safety pin system can secure the roof for maintenance or inspection when the buckets are up.

  • Page 35: Visual Inspection On The Tailgate

    Top Select Maintenance Guide FIGURE 1-18. Spillage deflector 8. Inspect all lifting beam welds. 1.5.3 Visual Inspection on the Tailgate Always set the safety prop before opening the tailgate. To perform the visual inspection on the tailgate: 1. Perform visual inspection procedure preparation, see section 1.5 on page...

  • Page 36: Visual Inspection On The Body

    2. Bring the loading buckets up and set the safety pin in the rails. Open the tailgate and set the safety prop. FIGURE 1-20. Loading bucket safety pin and tailgate safety prop 3. Apply the lockout/tagout procedure for the rest of the truck. 1-31 Top Select Maintenance Manual...
  • Page 37 Top Select Maintenance Guide 4. Inspect the rail stoppers. If they seem damaged, replace them both. HEN REPLACING THE STOPPERS THE TOTAL SHIM THICKNESS MUST STAY THE SAME 5. Check the roof stoppers (up to 5) and replace them if needed.

  • Page 38: Visual Inspection On The Chassis

    O NOT USE PROPS WITH A LOADED BODY EVER STAND UNDER A RAISED AND LOADED BODY FIGURE 1-23. Air hose 1.5.5 Visual Inspection on the Chassis Always set the safety prop under the body after lifting it. 1-33 Top Select Maintenance Manual...
  • Page 39 S MANUAL FOR MORE DETAILS SINCE MOST OF THE INFORMATION ABOUT THE INSPECTION OF THE CHASSIS IS LOCATED THEREIN To perform the visual inspection on the Labrie chassis: 1. Perform visual inspection procedure preparation, see section 1.5 on page 2. Bring the chassis up high enough to set the body safety prop, see section 1.3.6 on...

  • Page 40: Loading Container Maintenance

    Call factory for any structural problem that may endanger the operator’s safety. FTER THE LOCK NUT IS PROPERLY TORQUED TACK WELD MAIN NUT AND LOCK NUT TOGETHER ODEL WITH A ODEL WITH A COUNTERNUT CLAMP FIGURE 1-25. Different types of linkages 1-35 Top Select Maintenance Manual...

  • Page 41: Bucket Swing Out Procedure

    Top Select Maintenance Guide LIDING SHOE AILS FIGURE 1-26. Bucket up 1.6.2 Bucket Swing Out Procedure There are at least two reasons to have the bucket taken out the rails: to change the rollers and to remove the bucket. To safely perform this:...

  • Page 42: Container Rollers Replacement Or Cleaning

    1.6.3 Container Rollers Replacement or Cleaning The container rollers should be checked on a daily basis. Replace them as soon as they stop rolling properly. 1-37 Top Select Maintenance Manual...
  • Page 43 Top Select Maintenance Guide To replace or clean the rollers: 1. Perform the bucket swing out procedure, see section 1.6.2 on page 2. Rollers move freely so all you have to do is pull them to take them out. FIGURE 1-29. Sliding out the rollers 3.

  • Page 44: Sliding Shoe Replacement Procedure

    3. Perform the Lockout/Tagout procedure. 4. With the same ladder you use to install the safety pins, gain access to the sliding shoe located in the rear of the bucket. 5. Remove the T-nuts and then the sliding shoe. 1-39 Top Select Maintenance Manual...

  • Page 45: Replacing The Bucket Rod Ends

    Top Select Maintenance Guide FIGURE 1-31. Loading bucket and sliding shoe 6. Clean up both sides thoroughly around the holes to remove rust or remaining paint from the screws. Look at the surface and remove dirt stuck around that could prevent the proper operation of the sliding shoe.
  • Page 46 2. Place a jack under the bucket. FIGURE 1-32. A jack under the bucket 3. On the upper end of the rod, remove the lock bolt and then the pin. FIGURE 1-33. Removing the lock bolt, rod and rod end 1-41 Top Select Maintenance Manual...

  • Page 47: Ajusting The Length Of The Bucket Rods

    HE TOLERANCE FOR THE HORIZONTAL LEVEL OF THE BUCKET IS INCH Depending on the model of your Top Select, there either one of two types of rod installed. The adjustment on the two types of rod is different. To adjust the length of the rod: 1.
  • Page 48 N THE MODEL WITH A LOCK NUT IT IS NECESSARY TO CUT THE WELD OF THE NUT 4. Turn the rods to adjust the length until both rods convey the horizontal alignment of the bucket. 1-43 Top Select Maintenance Manual...

  • Page 49: Bucket Limit Switches Adjustment

    Top Select Maintenance Guide DANGER HE ROD END MUST ALWAYS BE INSERTED A MINIMUM OF ONE INCH IN THE ROD 5. Tighten the lock nuts or clamp. 6. Remove the jacks or any other means you used to set the bucket straight.

  • Page 50: Limit Switch Arm Adjustment

    1.6.8 Limit Switch Arm Adjustment There are three limit switches in the Top Select’s body. The first one is for the loading bucket movement, the second one is used to signal the tailgate movement and the third one is used to find out if the body is rising.

  • Page 51: Optional Automatic Cart Latches Adjustment

    Top Select Maintenance Guide 1.6.9 Optional Automatic Cart Latches Adjustment On a daily basis verify all components on latch mechanism. See that the latch goes all the way up. A failure may lead to an operator injury if a fully-loaded roller cart falls off when loading.

  • Page 52: Replacing The Rod Ends Of The Mobile Roof

    1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes. Refer to “1.3.5 Lockout/Tagout Procedure” on page DANGER HIS PROCEDURE REQUIRES A MINIMUM OF TWO PERSONS ERFORM THIS PROCEDURE ON ONE ROD AT A TIME 2. Completely lift the loading bucket. 1-47 Top Select Maintenance Manual...
  • Page 53 Top Select Maintenance Guide 3. Install the loading bucket safety pin. See section 1.3.7 on page DANGER LWAYS WEAR A SAFETY HARNESS WHEN PERFORMING ANY MAINTENANCE ON THE ROOF 4. On the one end remove the snap ring and the pin.

  • Page 54: Adjusting The Length Of The Mobile Roof Rods

    To replace the loading bucket hydraulic cylinders: 1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes. Refer to “1.3.5 Lockout/Tagout Procedure” on page 1-49 Top Select Maintenance Manual...
  • Page 55 Top Select Maintenance Guide DANGER HIS PROCEDURE REQUIRES A MINIMUM OF TWO PERSONS ERFORM THIS PROCEDURE ON ONE CYLINDER AT A TIME 2. Raise the bucket to the fullest. 3. Install the loading bucket safety pins. See section 1.3.7 on page 4.

  • Page 56: Removing The Roof Mechanism Pivot

    3. Use a jack or any safe device that can support the roof on one end near the pivot. AVE ROOF REST ON A JACK FIGURE 1-45. Roof need to safely rest on a jack 1-51 Top Select Maintenance Manual...

  • Page 57: Adjusting The Loading Bucket Cylinder Cushion

    Top Select Maintenance Guide 4. On the side facing out the body, remove the pivot bolt and pin. OLT AND PIN FIGURE 1-46. Pivot bolt, pin and pillow block 5. Use any safe lifting device to safely lift the roof high enough to clear the pillow block area.
  • Page 58 USHION DOWN OLDING VALVE USHION UP FIGURE 1-47. Bucket hydraulic cylinder Lower the bucket and test by lifting it and using the body guides as reference. • ½ HE TOLERANCE FOR THE HORIZONTAL ALIGNMENT IS INCH 1-53 Top Select Maintenance Manual...
  • Page 59 Top Select Maintenance Guide DANGER LWAYS TURN OFF THE ENGINE AND THE HYDRAULIC SYSTEM WHEN PERFORMING TASKS ON THE ROOF DANGER LWAYS INSTALL THE BUCKET SAFETY PIN WHEN THE BUCKET IS RAISED AND YOU OPERATE THE CYLINDER ADJUSTMENTS CAUTION O NOT FORGET TO REMOVE THE BUCKET SAFETY PINS WHEN YOU NEED TO TEST THE CYLINDERS BY MOVING THE BUCKET ¼...
  • Page 60 CCW decreases the cushion. OOSEN AND HOLD FIX URN TO ADJUST CUSHION FIGURE 1-49. Upper cushion adjusment Once the adjustment is done, you must tighten the lock nut. • 9. If adjustment is needed on the lower end: 1-55 Top Select Maintenance Manual...
  • Page 61 Top Select Maintenance Guide On the cylinder, locate the adjustment point near the base. • USHION DOWN OLDING VALVE USHION UP FIGURE 1-50. Bucket hydraulic cylinder location of adjusment points Adjust the cushion by loosening and holding fix the lock nut and then turning the •...
  • Page 62 FIGURE 1-52. Loading bucket cushion adjustment screw and holding valve 11. Remove the safety pin and perform a few cycles to test the adjustment. DANGER LWAYS TURN OFF THE ENGINE AND THE HYDRAULIC SYSTEM WHEN PERFORMING TASKS ON THE ROOF 1-57 Top Select Maintenance Manual...

  • Page 63: Loading Bucket Partition Adjustment

    Top Select Maintenance Guide DANGER HERE MUST NOT BE ANYBODY ON THE ROOF OR IN THE BODY WHEN THE ENGINE IS ON AND THE HYDRAULIC SYSTEM ENGAGED 12.Repeat the adjustment on both cylinders to obtain the desired cushion. 1.6.15 Loading Bucket Partition Adjustment The loading bucket is equipped with “readily movable”...
  • Page 64 ULTIPLE PARTITIONS CONFIGURATION REQUIRES THE BODY TO BE DIVIDED ACCORDING TO THE NUMBER OF PARTITIONS IN THE BUCKET UP TO SEVEN PARTITIONS LIGN THE BODY AND LOADING BUCKET PARTITIONS SO THAT NO CROSS CONTAMINATION CAN OCCUR WHEN UNLOADING THE SIDE BUCKET 1-59 Top Select Maintenance Manual...

  • Page 65: Tailgate And Body Maintenance

    Top Select Maintenance Guide Tailgate and Body Maintenance 1.7.1 Tailgate Locking Mechanism (single tailgate) It is important to lubricate the tailgate hinges and the locking mechanism with multipurpose grease as per the lubricating schedule (section 3.1 on page Also, inspect the welding around hinges. The proper working order of the following components is also to be checked: ...

  • Page 66: Tailgate And Hinges Inspection

    Having the tailgate slightly raised and resting on the safety prop allows you to have better access to the different parts of the cylinder. 3. Disconnect the hydraulic hoses. 4. On the cylinder base, remove the lock bolt and the pin. 1-61 Top Select Maintenance Manual...
  • Page 67 Top Select Maintenance Guide FIGURE 1-58. Tailgate hydraulic hoses and cylinder base pin 5. Attach the cylinder head to a safe lifting device. FIGURE 1-59. Tailgate cylinder head attached 6. On the cylinder head, remove the lock bolt and pin to release the cylinder.

  • Page 68: Tailgate Limit Switch Adjustment

    1.7.4 Tailgate Limit Switch Adjustment Standard Top Select 1000 and 2000 units are equipped with a limit switch locoated at the bottom right-hand side of the tailgate. When the tailgate is unlocked, the cylinder releases the limit switch lever that activates the backup alarm and a warning buzzer inside the cab.

  • Page 69: Body Chassis Hinges Inspection

    Any crack must be reported and repaired by qualified personnel. Contact Labrie Plus for technical support if required. Keep the contact surface clean between the body and chassis. Labrie recommends cleaning after every unloading. FIGURE 1-62. Clean area between chassis and body 1.7.6...

  • Page 70: Body Partitions Adjustment

    O NOT OPERATE THIS EQUIPMENT IF THERE ARE ANY SIGNS OF DAMAGE OR INCOMPLETE REPAIRS 1.7.7 Body Partitions Adjustment The Labrie Top Select can be equipped with up to seven (7) air-operated opening body partitions, giving eight (8) adjustable compartments for recyclable materials. 1-65 Top Select Maintenance Manual...
  • Page 71 Top Select Maintenance Guide Body partition adjustment procedure: 1. Make sure the body is empty before performing this procedure. 2. Open the tailgate and set the tailgate safety prop. 3. Apply the lockout/tagout procedure before entering the body to adjust partition.
  • Page 72 DISCONNECT THE PARTITION PNEUMATIC HOSE LOCATED ON THE ROOF AND PLUG IT INTO ANOTHER PNEUMATIC COUPLER ACH PARTITION IF MORE THAN ONE HAS ITS OWN PNEUMATIC HOSE HERE MAY BE MORE THAN ONE COUPLER FOR A PARTITION 1-67 Top Select Maintenance Manual...
  • Page 73 Top Select Maintenance Guide N THIS CASE THE COUPLERS ARE CONNECTED TO THE SAME CONTROL CONSOLE Partition pneumatic hose FIGURE 1-67. Partition pneumatic hose Partition pneumatic hose disconnected FIGURE 1-68. Disconnecting the hose 7. Slide the partition to desired position.

  • Page 74: Hydraulic System Maintenance

    Make sure that connections between all hoses and pipes are tightened, and there are no oil leaks. DANGER PPLY THE OCKOUT AGOUT PROCEDURE AT ALL TIMES WHEN MAINTENANCE OR INSPECTION IS PERFORMED ON THE VEHICLE 1-69 Top Select Maintenance Manual...

  • Page 75: Main Hydraulic Valve

    3. Inspect the rod surface for unusual wear or scratches. 4. On the hoist cylinder, inspect the air bleeder for any leaks. Tighten if necessary. 1.8.3 Main Hydraulic Valve To obtain more information regarding specific options, contact Labrie Plus. 1.8.4 Cycle Time For All Hydraulic Functions 650 RPM (G...

  • Page 76: Hydraulic Tank Inspection Procedure

    Verify that the oil in the reservoir is clean and always at approximately 3/4 of the level gage. The oil must be clean and not colored. CAUTION 180 °F (82 °C) AXIMUM TEMPERATURE FOR HYDRAULIC OIL MUST NEVER EXCEED 1-71 Top Select Maintenance Manual...
  • Page 77 Top Select Maintenance Guide FIGURE 1-70. Hoist To perform the inspection of the hydraulic tank: 1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes, see section 1.3.5 on page 2. Replace the filter element after 50 hours of service. See section 1.8.8 on page...

  • Page 78: Hydraulic Fluid Replacement Procedure

    1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes, see section 1.3.5 on page 2. Start the engine and engage the hydraulic pump. 3. Retract all cylinders (roof, loading buckets, tailgate, etc.). 1-73 Top Select Maintenance Manual...
  • Page 79 Top Select Maintenance Guide ITH THE LOADING BUCKET HYDRAULIC CYLINDER COMPLETELY RETRACTED THE LOADING BUCKET IS FOUND COMPLETELY LOWERED O ACCESS THE HYDRAULIC TANK RAISE THE BUCKET FEET AND BLOCK IT AVOIDING ANY MOVEMENT 4. Disengage the hydraulic pump and stop the engine.

  • Page 80: Strainer Cleaning Procedure

    ). U OME HYDRAULIC TANKS ARE PRESSURIZED NSCREW THE FILLER CAP SLOWLY 7. Drain the hydraulic tank using the drain plug underneath, refer to section 1.8.6 on page 8. Once empty, reinstall the drain plug. 1-75 Top Select Maintenance Manual...
  • Page 81 Top Select Maintenance Guide FIGURE 1-73. Hydraulic tank 9. Remove both hose clamps from the suction hose and slide the hose over the pipe until it clears the ball valve (slide towards the front of the vehicle). YDRAULIC TANK UCTION HOSE...

  • Page 82: Filter Element Replacement Procedure

    50 hours of operation. Then, change the element twice a year (see the preventive maintenance chart at the end of this section). This will keep the oil clean, extend component life expectancy and reduce breakdowns. 1-77 Top Select Maintenance Manual...
  • Page 83 Top Select Maintenance Guide WARNING HANGE RETURN FILTER ELEMENT AFTER THE FIRST HOURS OF OPERATION To replace the hydraulic filter: 1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes, see section 1.3.5 on page 2.

  • Page 84: Hydraulic Gear Pump Systems

    Hydraulic Gear Pump Systems Hydraulic Gear Pump Systems The Top Select is offered with a gear type hydraulic pump. This type of system requires the engine to run at 1500 RPM for the Maximizer operation, if applicable. The other functions require the engine to run at idle. The main pressure setting is 2000 psi.

  • Page 85: Gear Pump Inspection Procedure

    Top Select Maintenance Guide 1.9.1 Gear Pump Inspection Procedure If the pump is adequately maintained, it will provide a satisfactory output. If the pump is noisy, perform the following inspections. HE RETURN PRESSURE OF THE OIL FLOW FROM THE PUMP TO THE RESERVOIR MUST...
  • Page 86 7. When finished, hold the adjustment screw and tighten the lock nut. DANGER PPLY THE OCKOUT AGOUT PROCEDURE AT ALL TIMES WHEN MAINTENANCE OR INSPECTION IS PERFORMED ON THE VEHICLE 1-81 Top Select Maintenance Manual...

  • Page 87: Pressure And Rpm Chart (Since January 2000)

    Top Select Maintenance Guide 1.9.3 Pressure and RPM Chart (since January 2000) Types of pump: Front mounted pump and pump mounted on transmission Types of body: Low body, high body and Maximizer RPM A RESURE AND DJUSTMENT ABBLE : TSR, TSLR, TSRHL...

  • Page 88: Body Hoist Replacement Procedure

    3. Go inside the body and remove the access cover to the anchor pin of the hoist. FIGURE 1-81. Cover providing access to the hoist 4. Purge any residual oil in the cylinder that may be adding pressure by turning the bleeder valve. 5. Remove the anchor pin. 1-83 Top Select Maintenance Manual...
  • Page 89 Top Select Maintenance Guide FIGURE 1-82. Hoist anchor pin 6. Cautiously lean the hoist against the cab. CAUTION SE A RAG OR ANY PIECE OF CLOTH TO CUSSION THE HOIST CYLINDER AGAINST THE CAB AND AVOID ANY DAMAGE TO BOTH 7.
  • Page 90 1. Attach the new hoist cylinder to the overhead bridge crane and move it to its position on the vehicle. 2. Attach the base pillow blocks. 3. Attach the oil hose. 4. Completely lower the body with the overhead bridge crane and free it from the crane. 1-85 Top Select Maintenance Manual...
  • Page 91 Top Select Maintenance Guide 5. Install the anchor pin. 6. Turn on the engine and the hydraulic system. 7. Operate the hoist cylinder control until oil comes out of the bleeder valve without any bubbles. 8. Immediately secure the bleeder valve.

  • Page 92: Air System Maintenance

    To perform maintenance on the air dryer, refer to the chassis manufacturer maintenance manual. DANGER PPLY THE OCKOUT AGOUT PROCEDURE AT ALL TIMES WHEN MAINTENANCE OR INSPECTION IS PERFORMED ON THE VEHICLE The main hydraulic valve which controls the body functions, is activated by air actuators. 1-87 Top Select Maintenance Manual...
  • Page 93 Top Select Maintenance Guide FIGURE 1-86. Air actuators 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.

  • Page 94: Surface Finishing And Painting

    Dupont Black Urethane Primer #373p27678 to get a minimum thickness of 2 mils (dry). Finishing coat: Dupont Emron Elite Paint 2-mil-deep single coat At the end of the painting process, the product must have a minimum of 4-mil thickness. 1-89 Top Select Maintenance Manual...

  • Page 95: Preventive Maintenance

    Top Select Maintenance Guide 1.13 Preventive Maintenance ELECT REVENTIVE AINTENANCE HART OMPONENT ERIFICATION ECTION SYSTEM AILY EEKLY ONTHLY YEAR  Hydraulic Check oil level in tank 1.8.5 system refill if necessary  Check if the gate valve 1.8.3 is open on main tank ...
  • Page 96  Operator’s Check for proper controls operation.  Air tanks Drain. 1.11  Air system Check for leaks 1.11  Safety Check for proper systems operation (tailgate alarm and special devices 1-91 Top Select Maintenance Manual...
  • Page 97 Top Select Maintenance Guide 1-92 Top Select Maintenance Manual...

  • Page 98: Maximizer Maintenance

    The Maximizer is an optional equipment. This is why you are finding it in a separate section of the Parts & Service manual. Maintenance of the Maximizer is quick and easy, but there are basic rules to respect. Top Select Maintenance Manual...

  • Page 99: General Cleanliness

    Keep clean the contact surface between the body and chassis. Labrie recommends to clean the chassis after every unloading.

  • Page 100: Maximizer Daily Cleaning

    NSTALL TAILGATE SAFETY PROP BEFORE ENTERING THE BODY 2.1.1 Maximizer Daily Cleaning If the Top Select has the Maximizer option, perform the following procedure. To daily clean the Maximizer: 1. Bring the Maximizer panel towards the cab, full stroke. 2. Open the tailgate and set the tailgate safety prop.
  • Page 101 TO ACCESS THE CYLINDER AREA FIGURE 2-1. Accessing the Maximizer cylinder head 10.Climb out of the back, slightly raise the body and release the Maximizer swing door to evacuate the water. 11. Finish cleaning with pressurized water. Top Select Maintenance Manual...

  • Page 102: Maximizer General Maintenance

    Maximizer General Maintenance Maximizer General Maintenance The Top Select’s Maximizer packing has a heavy-duty guiding system using high-strength steel wear plates. Labrie recommends that a visual inspection of the Maximizer and its components to be performed daily by the operator. A weekly inspection and maintenance done by maintenance personnel is also mandatory.

  • Page 103: Maximizer Monthly Visual Inspection

    Maximizer Maintenance Maximizer Monthly Visual Inspection This section indicates the general visual inspection procedure for the Top Select Maximizer. Before performing any of the visual inspections, apply the following procedure. To prepare the vehicle for the visual inspection: 1. Park the vehicle on a safe level ground where it can be cleaned.
  • Page 104 FIGURE 2-2. Maximizer 5. Inspect the rails, make sure the rails do not suffer from premature use from glass grit. AXIMIZER RAILS FIGURE 2-3. Maximizer rails Top Select Maintenance Manual...
  • Page 105 Maximizer Maintenance EMOVE BOLTS AND LIFT PANEL TO ACCESS THE CYLINDER AREA FIGURE 2-4. Accessing the Maximizer cylinder head 6. To verify if hydraulic cylinders are internally leaking, refer to “Hydraulic Cylinder Inspection” on page Top Select Maintenance Manual...

  • Page 106: Pressure Adjustment

    4. While a second person is operating the Maximizer at end of stroke (toward the tailgate) adjust the screw to set the pressure read on the pressure gauge: towards the tailgate, the pressure should read 1400 psi and towards the front the pressure should read 2000 psi. Top Select Maintenance Manual...
  • Page 107 Maximizer Maintenance 5. Lock the adjustment screw and make sure the pressure is still on the proper setting while the second person is operating the joystick. 2-10 Top Select Maintenance Manual...

  • Page 108: Replacing The Maximizer Cylinder

    4. Move the separator close to the cab to clear the cylinder gard. 5. Use a zip cutter to cut through the guard tacks lined along the cylinder. FIGURE 2-6. Zip cut the guard tacks 2-11 Top Select Maintenance Manual...

  • Page 109: Removing The Cylinder

    3. Remove the head pin. 4. Completely retract the cylinder. 5. Disconnect all hydraulics from the cylinder. 6. At the cylinder base, remove the bolt retaining the pin to the pillow block. 7. Remove the pin. 2-12 Top Select Maintenance Manual...

  • Page 110: Installing A New Cylinder

    6. Have a second person move the control to extend the cylinder while you ensure its alignment with the Maximizer. 7. Install the cylinder head pin that locks the cylinder to the Maximizer. 8. Tack weld the gard using the weld code indicated in the following figure. 2-13 Top Select Maintenance Manual...
  • Page 111 UARD WELD 1/8 - 10 FIGURE 2-9. Maximizer cylinder guard 9. Make sure the cylinder is tightly secured on both ends and move the Maximizer back and forth a few times to inspect its performance. 2-14 Top Select Maintenance Manual...

  • Page 112: Replacing The Maximizer

    6. Lift the Maximizer and move it as far as you can towards the exterior of the truck, the beam at the back will eventually block you. 7. Bring the forklift to set the Maximizer on it, once the Maximizer rests safely on the forklift remove the chains and pull it out. 2-15 Top Select Maintenance Manual...
  • Page 113 AXIMIZER RAILS FIGURE 2-10. Maximizer rails 4. Move the Maximizer to meet the head and align the two structures. 5. Weld the head to the rest of the Maximizer. 2-16 Top Select Maintenance Manual...

  • Page 114: Replacing The Maximizer Extensible Air Hose

    3. Remove the cover on the side that will provide access to the hose. 4. Once you’ve gaind access to the hose connectors and the hose, disconnect the hose on both ends and pull it out from the side. 2-17 Top Select Maintenance Manual...
  • Page 115 4. Reinstall the cover on the connector leading to the air system. 5. Reinstall the cover on the connector leading to the Maximizer. 6. Move the Maximizer back and forth a few times to test. 2-18 Top Select Maintenance Manual...

  • Page 116: Lubrication

    Lubrication CHAPTER 3 Lubricating the Top Select as part of the regular maintenance is a very important task to ensure its efficiency and durability. Keeping the Top Select lubricated is esencial for its optimal operation. Top Select Maintenance Manual...

  • Page 117: Recommended Lubricant

    DRAIN AND REFILL WITH NEW OIL Motor oil for vehicle Refer to vehicle maintenance manual Transmission oil Refer to transmission manufacturer Mainte- nance manual for recommended type of trans- mission oil. Grease Any lithium-base commercial multi-purpose grease Top Select Maintenance Manual...

  • Page 118: Location Of Grease Fittings On Chassis

    Location of Grease Fittings on Chassis Location of Grease Fittings on Chassis BOTH ENDS BODY HOIST HINGES ENGINE PUMP BODY HINGES FRONT DRIVE SHAFT Top Select Maintenance Manual...

  • Page 119: Location Of Grease Fittings On Body

    Lubrication Location of Grease Fittings on Body BOTH ENDS ROOF HINGES AND LOADING CYLINDERS Top Select Maintenance Manual...
  • Page 120 Location of Grease Fittings on Body Top Select Maintenance Manual...

  • Page 121: Lubrication Chart

    Lubrication Lubrication Chart Top Select Maintenance Manual...

  • Page 122: Troubleshooting

    The Maximizer is an optional equipment. This is why you are finding it in a separate section of the Parts & Service manual. Maintenance of the Maximizer is quick and easy, but there are basic rules to respect. Top Select Maintenance Manual...

  • Page 123: Troubleshooting Table

    COMPLEX COMPONENTS LIKE PUMPS OR VALVES Hydraulic system off ANY ASSISTANCE OR DETAILED SERVICE CALL ABRIE Slipping clutch Oil supply O CONTROL ON ALL No flow or pressure CYLINDERS Contaminated oil or wrong type Faulty control valve Wrong relief pressure setting Top Select Maintenance Manual...

  • Page 124: Internal Leak Detection For Cylinders

    OF POWER OMPLETELY EXTEND CYLINDER ISCONNECT THE HOSE AT END LUG THE END OF THE DISCONNECTED HOSE UT PRESSURE ON THE PISTON F OIL LEAKS OUT OF END THERE IS AN INTERNAL LEAK EPLACE DAMAGED PARTS Top Select Maintenance Manual...
  • Page 125 Troubleshooting Top Select Maintenance Manual...

  • Page 126: Hydraulic And Pneumatic Schematics

    Hydraulic and Pneumatic CHAPTER 5 Schematics The following are the schematics you may need to support the maintenance on the Top Select. Top Select Maintenance Manual...

  • Page 127: Pneumatics Top Select 1000 And Options

    Hydraulic and Pneumatic Schematics Pneumatics Top Select 1000 and Options Top Select Maintenance Manual...

  • Page 128: Pneumatics Top Select 2000 And Options

    Pneumatics Top Select 2000 and Options Pneumatics Top Select 2000 and Options Top Select Maintenance Manual...

  • Page 129: Pneumatics Brake System

    Hydraulic and Pneumatic Schematics Pneumatics Brake System Top Select Maintenance Manual...

  • Page 130: Pneumatics Brake System (Inter Cab)

    Pneumatics Brake System (Inter cab) Pneumatics Brake System (Inter cab) Top Select Maintenance Manual...

  • Page 131: Hydraulics Top Select 1000 With Maximizer

    Hydraulic and Pneumatic Schematics Hydraulics Top Select 1000 With Maximizer Top Select Maintenance Manual...

  • Page 132: Hydraulics Top Select 2000 With Maximizer

    Hydraulics Top Select 2000 With Maximizer Hydraulics Top Select 2000 With Maximizer Top Select Maintenance Manual...

  • Page 133: Hydraulics Top Select 1000

    Hydraulic and Pneumatic Schematics Hydraulics Top Select 1000 Top Select Maintenance Manual...

  • Page 134: Hydraulics Top Select 2000

    Hydraulics Top Select 2000 Hydraulics Top Select 2000 Top Select Maintenance Manual...
  • Page 135 Hydraulic and Pneumatic Schematics 5-10 Top Select Maintenance Manual...
  • Page 136 3630 Stearns Drive, Oshkosh, WI 54904 Toll free: 1-800-231-2771 Telephone: 1-920-233-2770 General Fax: 1-920-232-2496 Sales Fax: 1-920-232-2498 Mailing Address: P.O. Box 2785 Oshkosh, WI 54903-2785 Parts, Service and Warranty (during business hours) 7:00 AM to 7:00 PM, Central Standard Time Technical Support Service (24 hours) Maintenance # 90406...

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