Labrie EXPERT Maintenance Manual

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XPERT

AINTENANCE

ANUAL

Table of Contents

Troubleshooting

Summary of Contents for Labrie EXPERT

Page 1 XPERT AINTENANCE ANUAL...
Page 3 ™ XPERT AINTENANCE MANUAL...
Page 4 Liability Labrie Enviroquip Group assumes no liability for any incidental, consequential, or other liability that might result from the use of the information contained in this document. All risks and damages, incidental or otherwise, arising from the use or misuse of the information contained herein are entirely the responsibility of the user.
Page 5: Table Of Contents
Table of Contents Liability ..................ii Table of Contents ................ iii Introduction ................1 About This Manual ................................... 1 Topics Not Included in This Manual ............................ 1 About the Illustrations in this Manual ..........................1 Schematics ....................................1 Warranty Registration Form ................................2 Introducing the E ™...
Page 6 iv Table of Contents Packer Maintenance and Replacement ..........................39 Preparing Packer for Inspection ............................39 Inspecting Packer ..................................40 Preparing Packer for Removal ............................46 Accessing Packer ..................................50 Disconnecting Packer ................................73 Removing Packer Panel ................................ 81 Installing New Packer ................................89 Chute (Co-Mingle Vehicles Only) ..............................
Page 7 Table of Contents v Adjusting Arm Stowed Limit Switch ..........................214 Adjusting Arm Parked Limit Switch ..........................215 Adjusting Mid-Height Limit Switch ..........................218 Adjusting Chute Limit Switches (Co-Mingle Units) ....................219 Glass Compartment Limit Switch (optional) ......................222 Tailgate Hooks (Co-Mingle Units) ............................222 Main Control Valve ..................................
Page 8 vi Table of Contents Detecting Cylinder Internal Leaks ..........................285 Hydraulic Pressures ..................................288 Adjusting Vane Pump Relief Valves (if equipped) ....................288 Adjusting Directional Control Valve Pressure ......................290 Adjusting Body Relief Valve (Electro-Hydraulic Valve) ................... 291 Adjusting Utility Section (Optional Electric Valve only) ..................291 Adjusting Proportional Valve Pressure ........................
Page 9 Table of Contents vii Troubleshooting Harnesses ..............................348 Multiplexing ................351 Labrie’s Multiplex System ................................. 351 Main Page ....................................352 Main Menu ....................................362 Warning Buzzer ..................................373 Plugging a Computer ................................373 Replacing the CAN Bus-Based Multiplex Joystick ..................... 374 Allison Transmission Parameters ............................
Page 10 viii Table of Contents...
Page 11: Introduction
™ Parts Manual. XPERT About the Illustrations in this Manual Because Labrie Enviroquip Group is constantly updating its products, illustrations used in this manual may differ from those of the actual product and accessories, depending on the model or options that come with your vehicle.
Page 12: Warranty Registration Form
Warranty Registration Form Do not forget to complete the owner registration form and to send it to Labrie Enviroquip Group. Make sure to fill out the in-service date. This date will be used as the start date of the warranty period.
Page 13: Multiplexed System
This whole system has been designed to help you operate your unit in an efficient and easy way. Labrie’s multiplexed system is reliable and safe and it requires less wiring harnesses to operate. It can also monitor various function status of the body and display warning and caution messages.
Page 14: Service And Maintenance On The Expert
: Any time you have a problem with a Labrie unit, you should contact your Labrie authorized dealer first. They should be able to provide you with the proper help that you need, whether it is for parts or technical service.
Page 15: Expert ™ Basic Maintenance
(such as cylinders, packer and tailgate), see General Maintenance on page 27. Hydraulic Fluid and Filter Hydraulic fluid is the life blood of the Labrie refuse body. Regular maintenance of the hydraulics will ensure long, trouble-free life. As directed in this manual and all service training, the hydraulic filter needs to be replaced after the initial 50 hours of new truck operation and again every 6 months, or when the filter restriction gauge is in the yellow.
Page 16: Visual Inspection
Adjustments 1. Cushions - Most of Labrie’s arm cylinders are cushioned. These cushions provide a smooth stop at the end of the cylinder stroke, reducing impact and noise, which helps in the comfort of the drivers.
Page 17: Our Office Addresses And Phone Numbers
E-mail (Customer Service): service@labriegroup.com For technical support and parts ordering, the serial number of your vehicle is required. Therefore, MPORTANT Labrie Enviroquip Group recommends you to keep record of the information found on the VIN plate, which is located in the cab.
Page 18 8 Introduction...
Page 19: Safety
Safety It is mandatory to read the entire Operator’s Manual before performing any maintenance task on this vehicle. Conventions Danger! Indicates a hazardous situation which, if not avoided, will result in serious injury or death. Warning! Indicates a hazardous situation which, if not avoided, could result in serious injury or death.
Page 20: Responsibilities
Out and Tagging Out the Vehicle on page 14). Warning! With your safety in mind, Labrie Enviroquip Group would like to remind you that ONLY qualified personnel should service the hydraulic, electrical and pneumatic systems on your refuse truck. They must also be knowledgeable about how to operate the truck and its equipment.
Page 21: Employee Responsibilities
Safety 11 Employee Responsibilities It is the responsibility of the employee:  To enforce all safety measures to meet the requirements set by the employer.  To operate the E ™ only after having received instructions and training. XPERT  To immediately report any damage or malfunction to the vehicle or equipment to the employer or supervisor.
Page 22: General Precautions
Enviroquip Group customers choose to operate the vehicle with more than one operator, additional safety items shall be installed to protect the second operator from hazardous situations. In such cases, Labrie Enviroquip Group must be informed of every and all units that will be operated MPORTANT by more than one operator.
Page 23 Operator’s Manual before attempting to perform any type XPERT of work on the unit. Labrie Enviroquip Group will not bear any responsibility for malfunction, injury or damage resulting from improper maintenance or repairs by the end user.
Page 24: Welding
14 Safety Welding Danger! Remove paint before welding or heating. Do not weld near lines that are pressurized or contain flammable fluids. Caution! Disconnect all batteries and electronic modules prior to welding on packer body. Fire The employer must inform and train all personnel on the measures that must be taken in case of a vehicle and/or loaded body catching fire.
Page 25: Prior To Start Up
Safety 15 Switch off the hydraulic pump. Turn off the engine, remove the key from the ignition, store it in a safe and controlled area (preferably on yourself), and tape over the ignition switch. Turn off and lock the master switch. Chock all wheels.
Page 26 16 Safety Figure 2-3 Suction line shut-off valve : The model of hydraulic tank may vary according to the options installed on the vehicle. Warning! Failure to fully open the shut-off valve will cause immediate damage to the pump, even if the pump is turned off.
Page 27: Shutting Down The Vehicle
Safety 17 Figure 2-5 Pump switch • A green switch means the pump is active. • A blue switch means the pump is not active. Shutting Down the Vehicle If the vehicle has to be stored for an extended period of time, follow the chassis manufacturer’s shutdown and maintenance requirements.
Page 28: Body Safety Prop
18 Safety Body Safety Prop Safety props prevent heavy body parts from moving inadvertently. The body safety prop ensures that an empty body will not lower when you are working underneath it. Danger! Always set the body safety prop when performing maintenance underneath a raised body.
Page 29: Putting The Body Safety Prop Back In Place
Safety 19 Figure 2-8 Body Up/Down switches Body Up Body Down switch switch Release the safety prop using the safety prop release handle (see Figure 2-9) and tilt it backwards. Figure 2-9 Body safety prop release handle Lower the body slowly until it rests properly on the safety prop using the Body Down switch on the in-cab control panel (see Figure 2-8).
Page 30: Tailgate Safety Prop
20 Safety The release handle must click. Using the Body Down switch on the in-cab control panel (see Figure 2-8), slowly lower the body until it rests properly on the chassis. Tailgate Safety Prop The tailgate safety prop is used to support and keep the tailgate open during inspection or maintenance procedures.
Page 31 Safety 21 Figure 2-11 Safety pin (in storage position, left; in locking position, right) Start the engine. Turn ON the pump (see Figure 2-5). Danger! Prior to raising the tailgate, make sure that no one is standing behind the vehicle and that the truck body is empty.
Page 32: Putting The Tailgate Safety Prop Back In Place (Standard Units)
22 Safety Figure 2-13 Pulling safety prop upward (left) and setting it down (right) Slowly lower the tailgate onto the safety prop using the Tailgate Down switch on the in-cab control panel (see Figure 2-12). : If the tailgate is not resting properly on the safety prop, see Tailgate Safety Prop Adjustment on page 26 to correct the problem.
Page 33: Setting The Tailgate Safety Props (Co-Mingle Units)
Safety 23 Figure 2-14 Raising tailgate safety prop Release your grip on the safety prop to set it in its home position. Figure 2-15 Setting safety prop in its home position With the Tailgate Down switch on the in-cab control panel (see Figure 2-12), close the tailgate completely.
Page 34 24 Safety The safety props can be easily set when the tailgates are slightly open. Danger! Always use the appropriate tailgate safety prop when working under a raised tailgate. The prop must be installed even if the tailgate is in fully raised position. To set either tailgate safety prop on a co-mingle unit, apply the following procedure: Make sure the corresponding body compartment is empty.
Page 35: Putting The Tailgate Safety Prop Back In Place (Co-Mingle Units)
Safety 25 ICC bumper Support Figure 2-16 Tailgate Selector switch Tailgate Selector switch With the Tailgate Up switch on the in-cab control panel (see Figure 2-12), raise the selected tailgate about 3 feet (enough to lift and rotate the safety prop). Pull the safety prop upward and set it down (see Figure 2-13).
Page 36: Tailgate Safety Prop Adjustment
26 Safety With the Tailgate Down switch on the in-cab control panel (see Figure 2-12), close the tailgate completely. light indicator should turn OFF. TAILGATE OPEN Put the corresponding safety pin back in place. If the other tailgate needs to be open, select it using the Tailgate Selector switch on the in-cab control panel (see Figure 2-16), then repeat the last 2 procedures: “Setting the Tailgate Safety Props (Co- Mingle Units)”...
Page 37: General Maintenance
 Clean the contact surface between the body and the chassis. Labrie Enviroquip Group recommends cleaning the chassis after every unloading.  Remove any stacked garbage in the hopper area.
Page 38: Expert ™ Preventive Maintenance Chart
28 General Maintenance ™ Preventive Maintenance Chart XPERT Component/System Task Daily Weekly Monthly Yearly Page Limit/proximity Proper adjustment of all See page 201 switches limit/proximity switches is imperative Check and clean area around limit/proximity switches Packer and related Lubricate packer and See page 250 parts related parts.
Page 39 General Maintenance 29 Component/System Task Daily Weekly Monthly Yearly Page Hydraulic system Check oil level in tank, See page 276 and refill if necessary Check if the shut-off see Figure valve on the hydraulic 5-27 tank is open Check ground for overnight leaks Check cylinders, pump, See page 284...
Page 40: Hopper
30 General Maintenance Hopper The area behind the packer SHOULD be cleaned out EVERY DAY. The packer will not work properly if waste accumulates in this area; this could cause severe damage to the packer and other related parts. Cleaning the Hopper This section explains how to properly clean the hopper section of the truck body.
Page 41 General Maintenance 31 If needed, disengage the speed-up system by turning OFF any of the two Speed-Up switches on the control panel: Speed-Up ON/Speed-Up Auto (see Figure 3-2). Both switches must be blue lighted. Figure 3-2 Speed-Up switches If the truck is equipped with a chute, as in a co-mingle type unit, place it on the left-hand side of the hopper.
Page 42 32 General Maintenance : If no right-hand side packer control station is installed, you may use the Crusher Panel Up switch on the in-cab control panel (see Figure 3-4). Keep this switch pressed until the panel is raised completely. Figure 3-4 Crusher Panel Up switch on in-cab control panel Using the arm joystick or the auxiliary arm controls below the right-hand side seat (if provided) [see Figure 3-5], fully extend the H...
Page 43 General Maintenance 33 Push the green S button (see Figure 3-7) to fully extend the packer, then push the TART YCLE red emergency S button (see Figure 3-7) when the packer is fully extended. Figure 3-7 and S buttons TART YCLE Stop button Start Cycle...
Page 44 Close both clean-out trap doors. Caution! When parking the truck overnight after cleaning the hopper, Labrie Enviroquip Group recommends leaving the truck’s clean-out traps slightly open if frost is forecast in your area. This should prevent rain accumulation at the bottom of the hopper and ice build-up around the packer cylinders.
Page 45 General Maintenance 35 B. Units with no H ™ arm ELPING : For units with a ™ arm, go to page 30. ELPING To clean the hopper of an E ™ that has no automated arm, apply the following procedure: XPERT Park the E ™...
Page 46 36 General Maintenance : If no right-hand side packer control station is installed, you may use the Crusher Panel Up switch on the in-cab control panel (see Figure 3-4). Keep this switch pressed until the panel is raised completely. Push the green S button (see Figure 3-7) to fully extend the packer, then push the TART YCLE...
Page 47 General Maintenance 37 Finish cleaning the area with pressurized water. Perform a visual inspection of the area behind the packer through the clean-out traps. Check for possible leaks in the hydraulic system and wear signs on mechanical parts such as: rollers, cylinder pins, hoses, pipes,, connections, and hopper floor and sidewalls.
Page 48 Close both clean-out trap doors. Caution! When parking the truck overnight after cleaning the hopper, Labrie Enviroquip Group recommends leaving the truck’s clean-out traps slightly open if frost is forecast in your area. This should prevent rain accumulation at the bottom of the hopper and ice build-up around the packer cylinders.
Page 49: Packer Maintenance And Replacement
™ packing system relies on a heavy-duty guiding system and high-strength steel wear XPERT plates. Because the packing system is put to such intensive use (1,000 to 3,000 cycles a day), Labrie Enviroquip Group recommends that operators perform a visual inspection of the packer and its components every day.
Page 50: Inspecting Packer
40 General Maintenance Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Inspecting Packer A. Inspecting Packer - Standard Units W/ Loading Arm : For standard units w/o loading arm, go to page 41;...
Page 51 General Maintenance 41 Check the packer for vertical and horizontal movements. See Testing for Excessive Wear on page 128 for correct procedure. If the packer shows vertical or horizontal movement, wear pads need to be replaced. Extensive wear on the hopper floor also suggests that sliding shoes require immediate replacement (see Sliding Shoes on page 127).
Page 52 42 General Maintenance Figure 3-17 Side rail and roller Side rail Roller Check out for leaks on hydraulic hoses and tubes. Tighten leaking connections and/or replace defective hoses. Verify cylinder rods: Make sure that cylinder rod ends are clear of debris. 5 a.
Page 53 General Maintenance 43 Figure 3-18 Extended packer Chute Scraper Follower Hinge panels Inspect the scraper (nylon strip) at the bottom of the automated arm assembly (see Figure 3-18). This nylon strip wipes out dirt every time the packer goes back and forth. Replace this scraper before it is worn down to the top of its holding screws (see Lower Wear Pad on page 165).
Page 54 44 General Maintenance D. Inspecting Packer - Co-Mingle Units W/O Loading Arm To inspect the packer: Check the follower panel hinges and verify that there is no wear on the panel surface (see Figure 3-19). Figure 3-19 Extended packer Scraper Chute Hinges Follower...
Page 55 General Maintenance 45 Should you find oil leaks, the cylinder must be replaced immediately. During the warranty period, do not attempt to change cylinder seals and packing. MPORTANT Check the packer for vertical and horizontal movements. See Testing for Excessive Wear on page 128 for correct procedure.
Page 56: Preparing Packer For Removal
46 General Maintenance Tighten leaking connections and/or replace defective hoses. Danger! Defective or worn-out hoses can burst and cause a major fire. Hydraulic leaks can also cause fire due to hot pressurized hydraulic fluid flowing inside pipes and hoses. Do not underestimate these fire hazards.
Page 57 General Maintenance 47 Follow these steps before proceeding with the removal of the packer panel: Start the engine and engage the hydraulic pump. Fully raise the crusher panel (if installed). Using the joystick, extend the automated arm to get better access to the hopper area. Danger! Secure the area around the path of the automated arm when performing maintenance or repair.
Page 58 48 General Maintenance Fully raise both crusher panels (if installed). : The E ™ may be equipped with a dual split crusher panel, or a single split crusher panel XPERT which would be located either on the right-hand side or on the left-hand side of the hopper (see Figure 3-22).
Page 59 General Maintenance 49 D. Preparing Packer for Removal - Co-Mingle - W/O Loading Arm Follow these steps before proceeding with the removal of the packer panel: Start the engine and engage the hydraulic pump. Fully raise both crusher panels (if installed). : The E ™...
Page 60: Accessing Packer
50 General Maintenance Using the joystick, extend both automated arms to get better access to the hopper area. Danger! Secure the area around the path of the automated arms when performing maintenance or repair. Fully retract the packer by pressing the yellow button on the packer control station. Danger! Do not enter the hopper while the packer is moving.
Page 61 General Maintenance 51 Figure 3-25 R-pin holding anti-spill guard in place Remove the deflector panel. Use a ¾-inch wrench to remove the 4 bolts that hold the panel. Figure 3-26 Deflector panel Remove the transversal beam by taking out the 4 bolts (2 on each side) that retain it. Figure 3-27 Transversal beam Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-28].
Page 62 52 General Maintenance Figure 3-28 Side rail Bolts that hold the upper part of the side rail in place Side rail Start the engine and engage the hydraulic pump. Extend packer to mid-stroke position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 63 General Maintenance 53 Enter the hopper and proceed with the removal of both floating panels (see Figure 3-30). Warning! Beware of the floating panel pinch points. Keep your fingers and hands away from them. Figure 3-30 Floating panels To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-31).
Page 64 54 General Maintenance Figure 3-32 Floating panel assembly LHS floating panel Carriage bolt Bolts (2) Central cover Carriage bolt RHS floating panel Transversal beam Bolts (2) 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-32).
Page 65 General Maintenance 55 Retract packer to mid-stroke position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). NEXT‘: DISCONNECTING PACKER: See “B.
Page 66 56 General Maintenance Remove the hopper divider (see Figure 3-36). There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-38).
Page 67 General Maintenance 57 Figure 3-39 Divider guard Remove the chute (see Figure 3-40). To perform this task, apply the following steps: Use a suitable lifting device (e.g. sling or cable) to hold the chute in place. 4 a. Start de truck and engage the hydraulic pump. 4 b.
Page 68 58 General Maintenance Figure 3-41 Protective panels : On some trucks, especially those with a single split crusher panel, the crusher panel deflector also needs to be removed (see Figure 3-42). Once the protective covers are removed, you will be able to access the area where the chute cylinder and the rear end section of the chute shaft are.
Page 69 General Maintenance 59 Figure 3-43 Chute cylinder and related parts Grease Plate Plate fitting holding bolt holding bolt Hydraulic hoses Pillow block Plate Chute cylinder Cotter pin Chute lever Chute shaft Remove the cylinder pin that secures the cylinder rod to the chute lever (see Figure 3-43). 4 h.
Page 70 60 General Maintenance Figure 3-44 Bolts holding pillow block in The rear section of the chute shaft is now free and unattached. Next: Disconnecting the front section of the chute shaft. Remove the flange bearing that is bolted to the automated arm assembly to free the chute 4 m.
Page 71 General Maintenance 61 Also remove the 3 carriage bolts located at the center of the automated arm assembly (see Figure 3-46). In order to access these bolts and remove them, lift the arm cover open. Figure 3-46 Deflector panel Arm cover Remove these 3 carriage bolts Deflector panel...
Page 72 62 General Maintenance Figure 3-48 Side rail Bolts that hold the upper part of the side rail in place Side rail Start the engine and engage the hydraulic pump. Extend the packer to mid-stroke position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 73 General Maintenance 63 Figure 3-50 R-pin holding anti-spill guard in place Remove the hopper divider (see Figure 3-51). There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-53).
Page 74 64 General Maintenance Figure 3-53 5/8” nut Remove the divider guard. 4 bolts are to be taken out to remove the divider guard (2 on each end). Figure 3-54 Divider guard Remove the chute (see Figure 3-55). To perform this task, apply the following steps: Use a suitable lifting device (e.g.
Page 75 General Maintenance 65 Figure 3-55 Chute : The E ™ may be equipped with a dual split crusher panel, or a single split crusher panel XPERT which would be located either on the right-hand side or on the left-hand side of the hopper (see Figure 3-23).
Page 76 66 General Maintenance Figure 3-57 Hopper rear side Crusher panel deflector Protective cover Crusher panel Remove the cotter pin (see Figure 3-58) that holds the cylinder pin in. 4 g. Figure 3-58 Chute cylinder and related parts Grease Plate Plate fitting holding bolt holding bolt...
Page 77 General Maintenance 67 a) Start the engine and engage the hydraulic pump. Danger! Never enter the hopper while the hydraulic system is engaged. b) Retract the cylinder using the outside chute-operating lever/button. c) Turn OFF the hydraulic pump and stop the engine. d) Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 78 68 General Maintenance Figure 3-60 Floating panels Left side Right side floating panel floating panel To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-61). To remove the left-hand side floating panel: a) open the panel, b) slide it to the left and c) lift it Figure 3-61 Removing RHS floating panel...
Page 79 General Maintenance 69 Figure 3-62 Flange bearing and holding bolts Start the engine and engage the hydraulic pump. Fully extend the packer. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 80 70 General Maintenance 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-63). Remove the upper part of both side rails (one on each side of the hopper). 6 bolts are to be taken out to remove this section of the side rail (see Figure 3-64).
Page 81 General Maintenance 71 Figure 3-65 Anti-spill guards Figure 3-66 R-pin holding anti-spill guard in place Remove the deflector panel. Use a ¾-inch wrench to remove the 4 bolts that hold the panel. Figure 3-67 Deflector panel Deflector panel Bolts to be removed (4) Remove the transversal beam by taking out the 4 bolts (2 on each side) that retain it.
Page 82 72 General Maintenance Figure 3-68 Transversal beam Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-69]. 4 carriage bolts are to be taken out to remove this section of the side rail. Figure 3-69 Side rail Bolts that hold the...
Page 83: Disconnecting Packer
General Maintenance 73 Disconnecting Packer A. Disconnecting Packer - Standard Units W/ Loading Arm : For standard units w/o loading arm, go to page 74; for co-mingle units w/ loading arm go to page 76; for co-mingle units w/o loading arm, go to page 78; for dual Helping-Hand units, go to page 79.
Page 84 74 General Maintenance Figure 3-72 5/8-18 NF fine-threaded bolts Tighten the bolts until the cylinder pin is completely removed. Figure 3-73 Cylinder pin removed Exit the hopper. Start the engine and engage the hydraulic pump. Retract both hydraulic cylinders. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 85 General Maintenance 75 Figure 3-74 Access cover Remove these 2 bolts Disconnect the cylinder pin from the greasing hoses (see Figure 3-75). Figure 3-75 Cylinder pin Loosen these 2 bolts to Cylinder pin disconnect greasing hoses from cylinder pin Remove the cylinder pin. Take 2 5/8-18 NF, 9-inch long fine-threaded bolts and screw them in the pin head holes.
Page 86 76 General Maintenance Figure 3-77 Cylinder pin removed Exit the hopper. Start the engine and engage the hydraulic pump. Retract both hydraulic cylinders. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). NEXT: REMOVING PACKER PANEL: See “B.
Page 87 General Maintenance 77 Figure 3-79 Cylinder pin Loosen these 2 bolts to Cylinder pin disconnect greasing hoses from cylinder pin Remove the cylinder pin. Take 2 5/8-18 NF, 9-inch long fine-threaded bolts and screw them in the pin head holes. Figure 3-80 5/8-18 NF fine-threaded bolts Tighten the bolts until the cylinder pin is completely removed.
Page 88 78 General Maintenance Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). NEXT: REMOVING PACKER PANEL: See “C. Removing Packer Panel - Co-Mingle Units W/ Loading Arm” on page 84. D. Disconnecting Packer - Co-Mingle Units W/O Loading Arm Once you have gained access to the packer, you must now disconnect it.
Page 89 General Maintenance 79 Figure 3-84 5/8-18 NF fine-threaded bolts Tighten the bolts until the cylinder pin is completely removed. Figure 3-85 Cylinder pin removed Exit the hopper. Start the engine and engage the hydraulic pump. Retract both hydraulic cylinders. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 90 80 General Maintenance Figure 3-86 Access cover Remove these 2 bolts Disconnect the cylinder pin from the greasing hoses (see Figure 3-87). Figure 3-87 Cylinder pin Loosen these 2 bolts to Cylinder pin disconnect greasing hoses from cylinder pin Remove the cylinder pin. Take 2 5/8-18 NF, 9-inch long fine-threaded bolts and screw them in the pin head holes.
Page 91: Removing Packer Panel
General Maintenance 81 Figure 3-89 Cylinder pin removed Exit the hopper. Start the engine and engage the hydraulic pump. Retract both hydraulic cylinders. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). NEXT: REMOVING PACKER PANEL: See “E.
Page 92 82 General Maintenance Figure 3-90 Marking down arm stopper location Remove both side panels (one on each side of the hopper). : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel.
Page 93 General Maintenance 83 Figure 3-92 Flashing light removed Remove all packer roller assemblies from the follower panels (See Rollers on page 190). Fold the follower panels over the packer. Weld the follower panels to the packer. Attach the packer to a lifting device (fork lift, etc.) and lift it out of the hopper. Warning! Use an appropriate lifting device to lift the packer out of the hopper.
Page 94 84 General Maintenance : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel. Remove the lower part of both side rails (one on each side of the hopper) by using a 5/16-inch Allen wrench and a 3/4-inch wrench (see Figure 3-194).
Page 95 General Maintenance 85 Figure 3-95 Marking down arm stopper location Remove both side panels (one on each side of the hopper). Figure 3-96 Side panel : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel.
Page 96 86 General Maintenance Figure 3-97 Flashing light removed Remove all packer roller assemblies from the follower panels (See Rollers on page 190). Fold the follower panels over the packer. Weld the follower panels to the packer. Attach the packer to a lifting device (fork lift, etc.) and lift it out of the hopper. Warning! Use an appropriate lifting device to lift the packer out of the hopper.
Page 97 General Maintenance 87 : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel. Remove the lower part of both side rails (one on each side of the hopper) by using a 5/16-inch Allen wrench and a 3/4-inch wrench (see Figure 3-194).
Page 98 88 General Maintenance Figure 3-100 Marking down arm stopper location Remove both side panels (one on each side of the hopper). : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel.
Page 99: Installing New Packer
General Maintenance 89 Figure 3-102 Flashing light removed Remove all packer roller assemblies from the follower panels (See Rollers on page 190). Fold the follower panels over the packer. Weld the follower panels to the packer. Attach the packer to a lifting device (fork lift, etc.) and lift it out of the hopper. Warning! Use an appropriate lifting device to lift the packer out of the hopper.
Page 100 90 General Maintenance Figure 3-103 Plastic wiper blade Reinstall all parts that have been removed by applying the following procedures in reverse order: A. Removing Packer Panel - Standard Units W/ Loading Arm on page 81, A. Disconnecting Packer - Standard Units W/ Loading Arm on page 73 and A.
Page 101 General Maintenance 91 Figure 3-104 Plastic wiper blade Reinstall all parts that have been removed by applying the following procedures in reverse order: B. Removing Packer Panel - Standard Units W/O Loading Arm on page 83, B. Disconnecting Packer - Standard Units W/O Loading Arm on page 74 and B. Accessing Packer - Standard Units W/O Loading Arm on page 52.
Page 102 92 General Maintenance Figure 3-105 Plastic wiper blade Reinstall all parts that have been removed by applying the following procedures in reverse order: C. Removing Packer Panel - Co-Mingle Units W/ Loading Arm on page 84, C. Disconnecting Packer - Co-Mingle Units W/ Loading Arm on page 76 and C.
Page 103 General Maintenance 93 Figure 3-106 Plastic wiper blade Reinstall all parts that have been removed by applying the following procedures in reverse order: D. Removing Packer Panel - Co-Mingle Units W/O Loading Arm on page 86, D. Disconnecting Packer - Co-Mingle Units W/O Loading Arm on page 78 and D. Accessing Packer - Co-Mingle Units W/O Loading Arm on page 62.
Page 104: Chute (Co-Mingle Vehicles Only)
94 General Maintenance Figure 3-107 Plastic wiper blade Reinstall all parts that have been removed by applying the following procedures in reverse order: E. Removing Packer Panel - Dual H ™ U on page 87, E. Disconnecting Packer - ELPING NITS Dual H ™...
Page 105 General Maintenance 95 Figure 3-108 Chute inside hopper Turn OFF both the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Enter the hopper on the right side. Inspect the chute, pivot and fittings.
Page 106 96 General Maintenance Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). 12 d. Enter the hopper on the left side. 12 e. Check for leaks. Inspect the rubber bumper (see Figure 3-112). Replace if necessary. Lubricate the front grease fitting of the chute pivot (on units with an automated arm) [see Figure 3-110].
Page 107: Inspecting Chute Cylinder
General Maintenance 97 Figure 3-112 Rubber bumper Inspecting Chute Cylinder To inspect the chute cylinder, proceed as follows: Start the truck and engage the hydraulic pump. Danger! Never enter the hopper while the hydraulic system is engaged. Fully retract the packer and position the chute on the hopper streetside (see Figure 3-113). Lower the crusher panel completely, if equipped, using the C switch on RUSHER...
Page 108 98 General Maintenance Figure 3-114 Crusher panel in lowered position Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Remove the right-hand side protective panel that is fixed to the rear hopper wall (see Figure 3-115).
Page 109 General Maintenance 99 Once the protective cover is removed, you will be able to access the area where the chute cylinder Check for leaks on cylinder head, jacket and rod. Figure 3-117 Chute cylinder Cylinder head Cylinder rod Cylinder jacket By using a straight edge, check the cylinder rod to make sure it is straight.
Page 110: Adjusting Chute Cylinder
100 General Maintenance Adjusting Chute Cylinder When performing inspection inside the hopper, check if the chute rests on all rubber bumpers. The cylinder that controls the chute can be adjusted so that the chute rests properly on the bumpers. To adjust the chute cylinder: Start the truck and engage the hydraulic pump.
Page 111 General Maintenance 101 Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Remove the right-hand side protective panel that is fixed to the rear hopper wall (see Figure 3-121). Figure 3-121 RHS protective panel : On some trucks, especially those with a single split crusher panel, the crusher panel deflector also needs to be removed (see Figure 3-122).
Page 112: Adjusting Chute Angle
102 General Maintenance Secure the pin with the cotter pin. Test the chute. When testing, the chute must not slam on the rubber bumpers. Figure 3-123 Rod head Rod head Locknut Adjusting Chute Angle The angle of the chute against the arm assembly or the floating panels should be 21° on both sides. If the angle of your chute differs from this value, you should apply the following procedure.
Page 113 General Maintenance 103 Figure 3-124 Chute tilted towards streetside Figure 3-125 Crusher panel in lowered position Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Remove the right-hand side protective panel that is fixed to the rear hopper wall (see Figure 3-126).
Page 114 104 General Maintenance : On some trucks, especially those with a single split crusher panel, the crusher panel deflector also needs to be removed (see Figure 3-127). Figure 3-127 Hopper rear side Crusher panel deflector Protective cover Crusher panel Once the protective cover is removed, you will be able to access the area where the chute cylinder Remove the cotter pin (see Figure 3-132) that holds the cylinder pin in.
Page 115: Dual Chute (Co-Mingle Units Only)
General Maintenance 105 Manually adjust the chute cylinder. Adjustment can be done by turning either the cylinder rod or the rod head clockwise or counter- clockwise. Caution! Be careful not to damage the cylinder rod. Do not use tools that may damage the rod. Once done, retighten the locknut.
Page 116 106 General Maintenance To remove a dual (or split) chute, use the following procedure: Start the engine and engage the hydraulic pump. If the truck is equipped with a right-hand side crusher panel, position both chutes on the left- hand side of the hopper by using the chute control levers (see Figure 3-129). Lower the crusher panel, if installed.
Page 117 General Maintenance 107 Lower the crusher panel, if installed. Danger! Never enter the hopper while the hydraulic system is engaged. Turn OFF the hydraulic pump and the engine. : Most of the time, mechanics are able to access both chute cylinders without having to remove all two protective panels.
Page 118 108 General Maintenance Figure 3-132 Chute cylinder and related parts Plate Plate Grease holding bolt fitting holding bolt Hydraulic hoses Pillow block Plate Chute cylinder Chute lever Cotter pin Chute shaft : The above illustration is used only to show where the parts are located and how they are attached to each other.
Page 119 General Maintenance 109 Start the engine and engage the hydraulic pump. 21 a. Danger! Never enter the hopper while the hydraulic system is engaged. Retract both cylinders using the outside chute-operating levers (see Figure 3-129). 21 b. Turn OFF the hydraulic pump and stop the engine. 21 c.
Page 120 110 General Maintenance Figure 3-135 Floating panels Left side Right side floating panel floating panel To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-61). To remove the left-hand side floating panel: a) open the panel, b) slide it to the left and c) lift it Figure 3-136 Removing RHS floating panel...
Page 121: Fixed Chute (Co-Mingle Units W/ Sso Tipper)
General Maintenance 111 Figure 3-137 Flange bearing and holding bolts To reinstall the chutes, reverse this procedure. Fixed Chute (Co-Mingle Units W/ SSO Tipper) ™ units that are equipped with an SSO tipper have a fixed chute in their hopper (see Figure XPERT 3-138).
Page 122: Removing Fixed Chute
112 General Maintenance Removing Fixed Chute To remove the fixed chute apply the following procedure: : While it is possible to remove the fixed chute altogether, as a single part, we recommend removing it by taking out its main components one at a time. The fixed chute is comprised of five main components: the chute itself, the deflector, the chute cap, the upper reinforcement and the chute support (see Figure 3-138).
Page 123: Hopper Divider Wear Pads And Sliding Shoe
General Maintenance 113 4 bolts are to be taken out to remove that part. Remove the chute support (see Figure 3-138). 3 carriage bolts have to be removed to remove the chute support; 2 of them secure the chute support to the hopper rear side wall and one to the divider guard. Remove the divider guard (see Figure 3-140) by removing its 5 retaining bolts.
Page 124 114 General Maintenance Fully retract the packer. Open both tailgates and install their safety props. Lower the tailgates until they rest on their respective safety prop. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Enter the body and remove the nut that is at the rear end of the hopper divider (see Figure 3-141).
Page 125 General Maintenance 115 Figure 3-143 Exterior guide Remove all 6 wear pads (3 each in both upper and lower sections of the rail) and the sliding shoe (see Figure 3-144). Figure 3-144 Wear pads and sliding shoe Wear pads Sliding shoe...
Page 126 116 General Maintenance Figure 3-145 Wear pads, sliding shoe and exterior guide (schematic view) Wear pads Sliding shoe Exterior guide : If you only need to replace the sliding shoe (see Figure 3-146), all you have to do is remove the exterior guide and 2 wear pads (one from each rail section).
Page 127 General Maintenance 117 Figure 3-147 Installing wear pads Install the sliding shoe (see Figure 3-148). 11 c. Figure 3-148 Installing sliding shoe Place the 2 remaining wear pads (one in each section of the rail). 11 d. This will keep the sliding shoe in place. Figure 3-149 Wear pads Install the exterior guide and tighten all 14 bolts.
Page 128: Packer Cylinders
118 General Maintenance Figure 3-150 Exterior guide Position the sliding shoe at the start of the rail near the hopper and fix it to the hopper 11 f. divider by inserting the sliding shoe stud into the divider bushing (see Figure 3-151). Use the nut to secure the stud.
Page 129 General Maintenance 119 If the truck is equipped with an automated arm: use the joystick to extend the automated arm in order to get better access to the hopper area. Danger! Secure the area around the path of the arm when performing maintenance or repair. If the truck is equipped with an SSO tipper, fully lower the tipper.
Page 130 120 General Maintenance Figure 3-153 Access cover Bolts to be removed Unscrew both grease fittings. Figure 3-154 Grease fittings Take 2 5/8-18 NF, 9-inch long fine-threaded bolts and screw them in the pin head holes. Figure 3-155 5/8-18 NF fine-threaded bolts Tighten the bolts until the cylinder pin is completely removed.
Page 131: Removing Faulty Packer Cylinder
General Maintenance 121 Figure 3-156 Cylinder pin removed Exit the hopper. Start the truck and engage the hydraulic pump. Danger! Do not enter the hopper while the pump is engaged. Fully retract both packer cylinders. Disengage the pump and stop the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 132 122 General Maintenance Figure 3-157 Hydraulic tank Breather cap Disconnect both hydraulic hoses from the faulty cylinder. Figure 3-158 Removing hydraulic hose Caution! Make sure to place a bucket under the hydraulic hoses or use absorbent material to avoid oil spills. Cap each hose and cylinder fitting as soon as they are disconnected (see Figure 3-159).
Page 133 General Maintenance 123 Figure 3-159 Capped hoses and fittings Capped fittings Capped hoses Clearly identify the disconnected hoses and fittings to avoid mix up during reconnection. Use of color-coded tie wraps (see illustration below) is appropriate for such purposes. Figure 3-160 Color-based identification Push the hoses away to facilitate cylinder removal.
Page 134 124 General Maintenance Figure 3-162 Front-end pin Once all bolts have been removed, locate the 2 holes that are threaded. Install puller screws (2 ½-13 NC bolts) into the threaded holes. Screw these bolts in until the cylinder pin comes out. : Make sure the cylinder stays in horizontal position to make the removal process easier.
Page 135: Installing Replacement Packer Cylinder
General Maintenance 125 Figure 3-164 Removing cylinder Remove the proximity switch target (see Figure 3-165) from the faulty cylinder and save it for the replacement cylinder (see note below). This only applies to a right-hand side cylinder being removed. Replace the faulty cylinder (see Installing Replacement Packer Cylinder on page 125). : Replacement cylinder may be new, rebuilt or refurbished.
Page 136 126 General Maintenance Slide the cylinder into position behind the packer through the clean-out trap. Caution! This task must be performed by 2 people. Align the cylinder with the front pin hole. Figure 3-166 Cylinder aligned with front pin hole Front pin hole Reinstall the front cylinder pin and its 4 bolts (see Figure 3-162).
Page 137: Sliding Shoes
General Maintenance 127 Put back the breather cap on the hydraulic tank. Start the truck and engage the hydraulic pump. Using the green push-button on the packer control station, extend both cylinders to reach the rear pin hole. Press the red push-button when both cylinders have reached this position. You may need to use all 3 push-buttons (green, red and yellow) alternatively to position both cylinders correctly.
Page 138: Testing For Excessive Wear
128 General Maintenance Figure 3-168 Sliding shoe Testing for Excessive Wear To test for excessive wear: Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). With a pry bar, try to move the packer vertically (up and down motion) and horizontally (side to side motion).
Page 139 General Maintenance 129 Go behind the packer and, with a grinder or cutting tools, remove the welds on both sliding shoes (see Figure 3-169). Access to the area behind the packer is possible via the clean-out traps. Figure 3-169 Welds to be removed From the cab, start the engine, engage the hydraulic pump and extend the packer to about 18 inches before the end of the stroke.
Page 140 130 General Maintenance Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Remove all 3 bolts retaining each sliding shoe (see Figure 3-171). Figure 3-171 Retaining bolts Tack weld a piece of steel tubing to the floor rail and to the front of both sliding shoes.
Page 141: Replacing Sliding Shoes
General Maintenance 131 Figure 3-173 Packer retracting, exposing sliding shoe Sliding shoe Replacing Sliding Shoes Mechanics must first follow the preceding procedure (Preparing for Sliding Shoe Replacement on page 128) before continuing with the procedure below. To replace the worn-out sliding shoes, proceed this way: : This procedure includes removing and replacing both floor guides.
Page 142 132 General Maintenance Figure 3-174 Stitch welds Place temporary steel tube here Stitch welds Floor guide Clean the hopper floor and wall surfaces. Install temporary steel tubes on the body side end of both floor guides (see Figure 3-174). Position the new guides on the hopper floor using the marks made in Step 4 (do not tack or weld yet).
Page 143 General Maintenance 133 Install the new sliding shoes on the floor guides. Weld a temporary tube on both floor guides. Both tubes must be positioned about six inches from the body end of the floor guides. This is done to facilitate the insertion of the sliding shoes under the packer. Exit the hopper.
Page 144: Finishing Up Replacing Sliding Shoes And Floor Guides
134 General Maintenance Retract the packer completely. Danger! Never enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Align the packer with the hopper walls.
Page 145: Floor Guides
General Maintenance 135 Remove the temporary steel tubes installed in Step 7 on page 132. : Never spray grease on the floor guides. Abrasive material sticks to the grease and can cause premature wear. Figure 3-178 Welds on both sides of floor guide FCAW 3⁄8˝...
Page 146: Preparing For Upper Wear Pad Replacement
136 General Maintenance Figure 3-179 Adjustment screws and upper wear pad Wear pad Adjustment screws Preparing for Upper Wear Pad Replacement A. Standard Units W/ Loading Arm and Dual H ™ Units ELPING : For standard units with no loading arm, go to page 140; for co-mingle units with loading arm, go to page 144;...
Page 147 General Maintenance 137 An R-pin located just behind the anti-spill guard (see Figure 3-181) must be pulled completely to allow for the removal of the guard. Figure 3-180 Anti-spill guards Figure 3-181 R-pin holding anti-spill guard in place Remove the deflector panel. Use a ¾-inch wrench to remove the 4 bolts that hold the panel.
Page 148 138 General Maintenance Figure 3-183 Transversal beam Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-184]. 4 bolts are to be taken out to remove this section of the side rail. Figure 3-184 Side rail Bolts that hold the...
Page 149 General Maintenance 139 Figure 3-185 Marking down arm stopper location Remove both side panels (one on each side of the hopper). : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel.
Page 150 140 General Maintenance Figure 3-187 Flashing light removed NEXT: REPLACING AND ADJUSTING UPPER WEAR PADS: see Replacing and Adjusting Upper Wear Pads on page 163. B. Standard Units W/O Loading Arm Make sure you go through the following steps: Start the engine and engage the hydraulic pump. Fully extend the packer, then push the red emergency button to maintain the packer in its STOP...
Page 151 General Maintenance 141 Figure 3-188 Anti-spill guard Enter the hopper and proceed with the removal of both floating panels (see Figure 3-189). Warning! Beware of the floating panel pinch points. Keep your fingers and hands away from them. Figure 3-189 Floating panels To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-190).
Page 152 142 General Maintenance Figure 3-190 Removing RHS floating panel Remove the transversal beam (see Figure 3-191). Figure 3-191 Floating panel assembly LHS floating panel Carriage bolt Bolts (2) Central cover Carriage bolt RHS floating panel Transversal beam Bolts (2) 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-32).
Page 153 General Maintenance 143 Figure 3-192 Bolts to be taken out to remove upper part of side rail Start the engine and engage the hydraulic pump. Retract the packer to mid-stroke position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 154 144 General Maintenance Remove the lower part of both side rails (one on each side of the hopper) by using a 5/16-inch Allen wrench and a 3/4-inch wrench (see Figure 3-194). There are 6 bolts in total on each side. Figure 3-194 Lower part of side rail : In order to get access to the last of the 6 bolts that hold the lower part of the side rail in place,...
Page 155 General Maintenance 145 Using the joystick, extend the automated arm to get better access to the hopper area. Danger! Secure the area around the path of the automated arm when performing maintenance or repair. Fully retract the packer. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 156 146 General Maintenance Figure 3-197 R-pin holding anti-spill guard in place Remove the hopper divider (see Figure 3-198). There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-200).
Page 157 General Maintenance 147 Figure 3-200 5/8” nut Remove the divider guard. 4 bolts are to be taken out to remove the divider guard (2 on each end). Figure 3-201 Divider guard Remove the chute (see Figure 3-202). To perform this task, apply the following steps: Use a suitable lifting device (e.g.
Page 158 148 General Maintenance Figure 3-202 Chute : The E ™ may be equipped with a dual split crusher panel, or a single split crusher panel XPERT which would be located either on the right-hand side or on the left-hand side of the hopper (see Figure 3-22).
Page 159 General Maintenance 149 Figure 3-204 Hopper rear side Crusher panel deflector Protective cover Crusher panel Remove the cotter pin (see Figure 3-205) that holds the cylinder pin in. 10 g. Figure 3-205 Chute cylinder and related parts Grease fitting Plate Plate holding bolt holding bolt...
Page 160 150 General Maintenance Start the engine and engage the hydraulic pump. Danger! Never enter the hopper while the hydraulic system is engaged. b) Retract the cylinder using the outside chute-operating lever/button. c) Turn OFF the hydraulic pump and stop the engine. d) Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 161 General Maintenance 151 Figure 3-207 Flange bearing Remove these 2 bolts to free the flange bearing Remove the deflector panel on the automated arm assembly (see Figure 3-208). Use a ¾-inch wrench to remove the 4 lower bolts that hold the panel. Also remove the 3 carriage bolts located at the center of the automated arm assembly (see Figure 3-208).
Page 162 152 General Maintenance Figure 3-209 Transversal beam Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-210]. 4 bolts are to be taken out to remove this section of the side rail. Figure 3-210 Side rail Bolts that hold the...
Page 163 General Maintenance 153 Figure 3-211 Marking down arm stopper location Remove both side panels (one on each side of the hopper). Figure 3-212 Side panel : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel.
Page 164 154 General Maintenance Figure 3-213 Flashing light removed NEXT: REPLACING AND ADJUSTING UPPER WEAR PADS: see Replacing and Adjusting Upper Wear Pads on page 163. D. Co-Mingle Units W/O Loading Arm Make sure you go through the following steps: Start the engine and engage the hydraulic pump. Fully retract the packer.
Page 165 General Maintenance 155 Figure 3-215 R-pin holding anti-spill guard in place Remove the hopper divider (see Figure 3-216). There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-218).
Page 166 156 General Maintenance Figure 3-218 5/8” nut Remove the divider guard. 4 bolts are to be taken out to remove the divider guard (2 on each end). Figure 3-219 Divider guard Remove the chute (see Figure 3-220). To perform this task, apply the following steps: Use a suitable lifting device (e.g.
Page 167 General Maintenance 157 Figure 3-220 Chute : The E ™ may be equipped with a dual split crusher panel, or a single split crusher panel XPERT which would be located either on the right-hand side or on the left-hand side of the hopper (see Figure 3-23).
Page 168 158 General Maintenance Figure 3-222 Hopper rear side Crusher panel deflector Protective cover Crusher panel Remove the cotter pin (see Figure 3-223) that holds the cylinder pin in. 9 g. Figure 3-223 Chute cylinder and related parts Grease Plate Plate fitting holding bolt holding bolt...
Page 169 General Maintenance 159 a) Start the engine and engage the hydraulic pump. Danger! Never enter the hopper while the hydraulic system is engaged. b) Retract the cylinder using the outside chute-operating lever/button. c) Turn OFF the hydraulic pump and stop the engine. d) Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 170 160 General Maintenance Figure 3-225 Floating panels Left side Right side floating panel floating panel To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-226). To remove the left-hand side floating panel: a) open the panel, b) slide it to the left and c) lift it Figure 3-226 Removing RHS floating panel...
Page 171 General Maintenance 161 Figure 3-227 Flange bearing and holding bolts Start the engine and engage the hydraulic pump. Fully extend the packer, then push the red emergency button to maintain the packer in its STOP fully extended position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 172 162 General Maintenance 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-228). Remove the upper part of both side rails (one on each side of the hopper). 6 bolts are to be taken out to remove this section of the side rail (see Figure 3-229).
Page 173: Replacing And Adjusting Upper Wear Pads
General Maintenance 163 : If a tipper is installed on the side panel, you will have first to remove it before removing the side panel. Remove the lower part of both side rails (one on each side of the hopper) by using a 5/16-inch Allen wrench and a 3/4-inch wrench (see Figure 3-194).
Page 174 164 General Maintenance Once the new wear pads have been correctly installed, proceed with the reinstallation of the lower part of both side rails (one on each side of the hopper) by using a 5/16-inch Allen wrench and a 3/4-inch wrench (see Figure 3-194). There are 6 bolts in total on each side to hold the lower part in place.
Page 175: Lower Wear Pad
General Maintenance 165 To help you with this task, repeat the same wear pad replacement procedure but in reverse order: a. For standard units w/ loading arm and dual H ™ units, go to page 136; ELPING b. For standard units w/o loading arm, go to page 140; c.
Page 176: Replacing Lower Wear Pad
166 General Maintenance Figure 3-235 Lower wear pad (in units without an automated arm) Replacing Lower Wear Pad A. Standard Units W/ Loading Arm and Dual H ™ Units ELPING : For standard units with no loading arm, go to page 167; for co-mingle units with loading arm, go to page 170;...
Page 177 General Maintenance 167 Figure 3-236 Deflector panel Unscrew the 4 bolts that hold the transversal beam in place (2 on each side). Figure 3-237 Transversal beam Remove the transversal beam by sliding it out. Remove the worn-out wear pad. : The wear pad is not bolted to the transversal beam. Check the compression rubber inside the beam (under the scraper).
Page 178 168 General Maintenance Fully extend the packer, then push the red emergency button to maintain the packer in its STOP fully extended position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 179 General Maintenance 169 Figure 3-239 Floating panels Handle Locking pin Floating panels Remove both floating panels. Warning! Beware of the floating panel pinch points. Keep your fingers and hands away from them. To remove the right-hand side floating panel: a) open the panel, b) slide it to the right and c) lift it up (see Figure 3-240).
Page 180 170 General Maintenance Figure 3-241 Floating panel assembly LHS floating panel Carriage bolt Bolts (2) Central cover Carriage bolt RHS floating panel Transversal beam Bolts (2) 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-241).
Page 181 General Maintenance 171 Using the joystick, extend the automated arm to get better access to the hopper area. Danger! Secure the area around the path of the automated arm when performing maintenance or repair. Fully retract the packer using the yellow button on the packer control station. Danger! Do not enter the hopper while the packer is moving.
Page 182 172 General Maintenance There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-246).
Page 183 General Maintenance 173 Figure 3-247 Divider guard Remove the chute (see Step 4 on page 57). Start the engine and engage the hydraulic pump. Fully extend the packer, then push the red emergency button to maintain the packer in its STOP fully extended position.
Page 184 174 General Maintenance Unscrew the 4 bolts that hold the transversal beam in place (2 on each side). Figure 3-249 Transversal beam Remove the transversal beam by sliding it out. Remove the worn-out wear pad. : The wear pad is not bolted to the transversal beam. Check the compression rubber inside the beam (under the scraper).
Page 185 General Maintenance 175 D. Co-Mingle Units W/O Loading Arm To replace a worn-out lower wear pad, apply the following procedure: Start the engine and engage the hydraulic pump. Fully retract the packer using the yellow button on the packer control station. Danger! Do not enter the hopper while the packer is moving.
Page 186 176 General Maintenance There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider. A 5/8” nut located at the rear end of the divider must also be taken out (see Figure 3-254).
Page 187 General Maintenance 177 Figure 3-255 Divider guard Remove the chute and both floating panels (see Step 4 on page 64). Start the engine and engage the hydraulic pump. Fully extend the packer. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine.
Page 188: Packer Wiper Blades
178 General Maintenance 6 bolts are to be taken out including 2 carriage bolts to remove the beam and unloose the central cover (see Figure 3-256). Remove the worn-out wear pad. : The wear pad is not bolted to the transversal beam. Check the compression rubber inside the beam (under the scraper).
Page 189: Follower Panels
General Maintenance 179 Use shims as required for proper adjustment. Figure 3-257 Packer wiper blades Follower Panels Replacing Roller Assemblies Packer rollers need to be replaced when damaged or when showing excessive wear or flat spots. The procedure outlined below will show you how to remove both bottom and top rollers and how to replace them.
Page 190 180 General Maintenance Figure 3-258 Anti-spill guards Figure 3-259 R-pin holding anti-spill guard in place Remove the deflector panel. Use a ¾-inch wrench to remove the 4 bolts that hold the panel. Figure 3-260 Deflector panel Remove the transversal beam by taking out the 4 bolts (2 on each side) that retain it.
Page 191 General Maintenance 181 Figure 3-261 Transversal beam Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-262]. 4 bolts are to be taken out to remove this section of the side rail. Figure 3-262 Side rail Bolts that hold the...
Page 192 182 General Maintenance Figure 3-263 Packer and follower panels Packer Bottom follower panel LHS roller retaining bolts RHS roller retaining bolts Top follower panel Remove both rollers (one on each side of the top follower panel). 10 b. Using a 5⁄16-inch Allen wrench and a 3⁄4-inch box, remove all 4 bolts that keep the roller in place (see Figure 3-264).
Page 193 General Maintenance 183 Put back all 4 bolts in their respective holes before tightening them up. Unfold both follower panels. 10 g. All panel rollers must now rest on the lower section of both side rails. Reinstall the upper part of both side rails (one on each side of the hopper). Reinstall the transversal beam and its retaining bolts (2 on each side).
Page 194 184 General Maintenance Remove the right-hand side bottom roller and replace it by repeating Step 9. Exit the hopper. Start the engine and engage the hydraulic pump. Extend the packer until the top rollers are at the same height as were the bottom rollers in the previous steps.
Page 195 General Maintenance 185 Figure 3-265 Anti-spill guard Figure 3-266 R-pin holding anti-spill guard in place Remove the hopper divider (see Figure 3-267). There are 6 bolts that hold the divider to the packer panel. These bolts are to be taken out to remove the hopper divider.
Page 196 186 General Maintenance Figure 3-268 Bolts holding divider (6) Figure 3-269 5/8” nut Remove the divider guard. 4 bolts are to be taken out to remove the divider guard (2 on each end). Figure 3-270 Divider guard Remove the chute (see Step 10 on page 147 for the chute removing procedure). Once the chute has been removed, start the engine and engage the hydraulic pump.
Page 197 General Maintenance 187 Fully extend the packer, then push the red emergency button to maintain the packer in its STOP fully extended position. Danger! Do not enter the hopper while the packer is moving. Turn OFF the hydraulic pump and the engine. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 198 188 General Maintenance Remove the upper part of both side rails (one on each side of the hopper) [see Figure 3-273]. 4 bolts are to be taken out to remove this section of the side rail. Figure 3-273 Side rail Bolts that hold the upper part of the side rail in place...
Page 199 General Maintenance 189 Figure 3-275 Removing bolts Bottom panel panel Packer Roller Install new rollers to replace the ones that have been removed. 16 c. Put back all 4 bolts in their respective holes before tightening them up. Flip the bottom follower panel backward (panel next to packer) [see Figure 3-274]. 16 d.
Page 200: Rollers
190 General Maintenance Once the chute has been reinstalled, put back the divider guard. Reinstall the hopper divider. Reinstall both anti-spill guards. Rollers If the roller itself has to be replaced because of wear, apply the following procedure: Once the roller has been removed from the follower panel (see Follower Panels on page 179), remove the external snap ring.
Page 201: Separating Follower Panels From Packer
General Maintenance 191 Separating Follower Panels from Packer Sometimes there may be situations where you will have to detach the follower panels from the packer. If such a situation arises, the following procedure will help you safely perform this task. To separate the follower panels from the packer proceed this way: Start the engine and engage the hydraulic pump.
Page 202 192 General Maintenance Using a 9/16-inch box and a wrench, remove all 6 bolts that hold the follower panels to the packer (see Figure 3-282). : It is possible to remove the first bolts through the clean-out traps. To remove those that are closer to the center, go between the cab and the hopper.
Page 203 General Maintenance 193 Figure 3-282 Location of all 6 retaining bolts Bolt To reattach the follower panels to the packer, repeat this procedure in reverse order.
Page 204: Body Hoist Cylinder
194 General Maintenance Body Hoist Cylinder Because it is frequently used, the body hoist cylinder needs to be inspected to ensure proper operation at all times. Figure 3-283 Body hoist cylinder Inspecting Body Hoist Cylinder The body hoist cylinder should be visually inspected every week as part of regular maintenance. Check for leaks, cracks and loose parts that could cause failure.
Page 205 General Maintenance 195 If the gap between the gland and the tube is wider than 1⁄8 inch, you must call LabriePlus immediately. Should the gap between the tube and the gland be wider than 1 inch, you must stop using the vehicle immediately and repair the cylinder (see Replacing Body Hoist Cylinder on page 196).
Page 206: Replacing Body Hoist Cylinder
196 General Maintenance Replacing Body Hoist Cylinder Danger! Never prop a loaded body. Unload the body prior to doing any repairs. To replace the body hoist cylinder: Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Disconnect the hydraulic hose and fitting.
Page 207 General Maintenance 197 Figure 3-289 Pillow blocks Using a lifting device, lift the body just enough to be able to tilt the safety prop under the body. The cylinder will remain in place. Ensure that the cylinder remains in vertical position while lifting the body. MPORTANT Install the safety prop.
Page 208 198 General Maintenance Figure 3-290 Securing cylinder to support The pillow blocks that are attached to the cylinder must be correctly positioned to allow insertion of the bolts through the support threaded holes (see Figure 3-290). Put back the 4 bolts and tighten them up to properly secure the cylinder to the support on the body front.
Page 209: Tailgate Seals And Hinges
General Maintenance 199 Tailgate Seals and Hinges Tailgate hinge pins must not show any sign of wear or metal fatigue. The retaining bolts must be kept tight. The tailgate rubber seal must not show any signs of damage. Replace if necessary. Figure 3-292 Tailgate hinge and pin Tailgate pin...
Page 210: Proximity And Limit Switches
200 General Maintenance Proximity and Limit Switches Proximity and limit switches act as remote electrical on/off switches and must be adjusted properly. Warning Proximity and limit switches must function properly. Serious damage to the equipment, injuries or death may occur if you operate the machinery with improperly adjusted switches.
Page 211: Limit Switch Adjustment
General Maintenance 201 Limit Switch Adjustment To adjust the limit switch: Loosen the limit switch nut. Move the lever arm to the approximate position where the switch is to be triggered. Tighten up the nut. To fine tune the adjustment, loosen the nut slightly. With a flathead screwdriver, turn the adjusting screw located at the center of the nut until a click is heard.
Page 212: Adjusting Packer Extend Proximity Switch
202 General Maintenance The proximity switch light should turn on when the target is detected; if not, repeat the adjustment procedure. Adjusting Packer Extend Proximity Switch Danger! Always lock out and tag out the vehicle during inspection and maintenance (see Locking Out and Tagging Out the Vehicle on page 14).
Page 213 General Maintenance 203 If the packer stops before or after reaching the fully extended position, adjust the switch as follows: Important This procedure must be performed by two people. To adjust the packer extend proximity switch: Start the engine and engage the hydraulic pump. Push the green button on the packer control station to extend the packer to about one inch from its fully extended position.
Page 214 204 General Maintenance Loosen both bolts (see Figure 3-298) and adjust the proximity switch so that it gets triggered (its amber light turning on). Triggering occurs when the plate (target) is detected by the switch. Retighten the bolts. Engage the hydraulic pump and check for proper operation. Make sure that the proximity switch detects the plate properly.
Page 215: Adjusting Packer Retract Proximity Switch
General Maintenance 205 Adjusting Packer Retract Proximity Switch Danger! Always lock out and tag out the vehicle during inspection and maintenance (see Locking Out and Tagging Out the Vehicle on page 14). The packer retract proximity switch (see Figure 3-299), which is one of the two proximity switches that control the packer range of motion (the other being the packer extend proximity switch), is located on the front right-hand side corner of the body.
Page 216 206 General Maintenance Push the yellow button to retract the packer up to 1 inch from the fully retracted position (see Figure 3-300). Danger! Do not enter the hopper while the packer is moving. Figure 3-300 Packer retracted to about 1 inch from end-of-stroke When the packer reaches the correct position, push the red emergency S button.
Page 217: Adjusting Body Raised Limit Switch
General Maintenance 207 Figure 3-301 Proximity switch assembly Cover Bracket Bolts Retract proximity switch Nuts Plate Plate Adjusting Body Raised Limit Switch Danger! Always lock out and tag out the vehicle during inspection and maintenance (see Locking Out and Tagging Out the Vehicle on page 14). A limit switch located on the vehicle chassis activates the backup alarm and a warning buzzer, and turns on a warning light inside the cab as soon as the body is raised to a certain height from the chassis.
Page 218: Adjusting Tailgate Unlocked Proximity Switch
208 General Maintenance This safety feature is provided to warn people around that the vehicle is in the process of being unloaded and to remind the operator that the body is still raised. To adjust the body raised limit switch: Loosen the limit switch nut.
Page 219 General Maintenance 209 When the tailgate is unlocked/open, the tailgate cylinder is partially/fully extended and no triggering of the proximity switch occurs; the cylinder having moved downward away from the switch . This activates the backup alarm and a warning buzzer inside the cab. This also turns on the T AILGATE warning light in the cab and disables packing.
Page 220: Adjusting Tailgate Fully Open Proximity Switch (Optional)
210 General Maintenance To adjust the tailgate unlocked proximity switch: Loosen the nuts on each side of the proximity switch bracket (see Figure 3-305). Figure 3-305 Proximity switch Switch Nuts Adjust the proximity switch so that the switch can be triggered by the cylinder casing as the cylinder head moves upward.
Page 221: Adjusting Top Door Fully Open Limit Switch (Optional)
General Maintenance 211 Figure 3-306 Tailgate fully open proximity switch When installed, this switch is located on the streetside body top near the tailgate hinge. To adjust the optional tailgate fully open proximity switch: Fully open the tailgate. Adjust the switch so that it detects the target. If detection is achieved, the warning light turns on.
Page 222: Adjusting Crusher Panel Up Limit Switch (Optional)
212 General Maintenance Figure 3-307 Top door fully open limit switch If installed, this switch is located on the mid-section of the curbside rubrail next to the top door lock. On dual H ™ units, a second limit switch of this type is installed on the opposite side. ELPING If the automated arm function cannot be activated by the operator despite of the fact that the top door is fully open and locked, an adjustment of the top door fully open limit switch may be required.
Page 223 General Maintenance 213 Figure 3-309 Crusher panel up limit switch This switch is located behind the crusher panel itself. : The crusher panel has to be lowered to access this limit switch. To adjust the crusher panel up limit switch: Lower the crusher panel using the switch on the in-cab control panel.
Page 224: Adjusting Arm Stowed Limit Switch
214 General Maintenance Adjusting Arm Stowed Limit Switch The arm stowed limit switch illuminates the warning lights on the dashboard when the ARM OUT operator extends the arm or closes the gripper. If this limit switch is misaligned, the warning lights on the dashboard may continue to flash even if the gripper is fully open and the arm fully retracted.
Page 225: Adjusting Arm Parked Limit Switch
General Maintenance 215 Retighten the nut. 3 c. Slightly close the gripper or extend the arm out (about 1 inch). The warning lights ARM OUT should start flashing. Repeat the procedure until the limit switch is properly adjusted. Danger! This limit switch MUST be working at all times. Otherwise, the operator may not be aware that the arm is not fully retracted or that the gripper is open or closed.
Page 226 216 General Maintenance The detection lever or actuator must touch the black curved plastic cover when the arm is in the hopper for the switch to be triggered. Warning Injury or death may occur if you attempt to enter the body while the packer or arm is in motion.
Page 227 General Maintenance 217 Figure 3-311 Helping-Hand arm base Top cover plate Figure 3-312 Arm parked limit switch adjustment Curved cover plate Screws Detection lever Figure 3-313 Arm extended warning light...
Page 228: Adjusting Mid-Height Limit Switch
218 General Maintenance Adjusting Mid-Height Limit Switch The mid-height limit switch is located at the base of the Helping-Hand automated arm (Figure 3-314). This limit switch is part of the gripper auto-closing system. Each time the gripper reaches a certain height, it closes automatically in order not to hit the vehicle. Figure 3-314 Mid-height limit switch Backward...
Page 229: Adjusting Chute Limit Switches (Co-Mingle Units)
General Maintenance 219 All limit switches MUST be working at all times. Otherwise, the operator may not be aware that the MPORTANT arm is not fully retracted or that the gripper is open or closed. This may cause an accident, injuries or property damages.
Page 230 220 General Maintenance Move the chute so that it rests on the left rubber bumper. 2 b. Danger! Never enter the hopper while the hydraulic system is engaged. Fully lower the right-hand side crusher panel. 2 c. Turn OFF the hydraulic pump and the engine. 2 d.
Page 231 General Maintenance 221 If there is a gap between the rod and its target, proceed with the adjustment of the former. To do Loosen the adjustment screw on the limit switch (see Figure 3-315). 4 a. Slide the rod sideways to the left or to the right to achieve proper contact with the target. 4 b.
Page 232: Glass Compartment Limit Switch (Optional)
222 General Maintenance Once the adjustment is completed, reinstall all the parts that have been removed, including both protective panels and the crusher panel deflector, if equipped. Glass Compartment Limit Switch (optional) On trucks equipped with a glass compartment, a limit switch is provided which activates an alarm in the cab and outside the truck whenever the glass compartment is raised.
Page 233 General Maintenance 223 Pull the safety prop upward and set it down (see Figure 2-13). Danger! The safety prop shall be set each time the tailgate is opened for inspection and maintenance purposes. Lower the tailgate onto the safety prop. Remove the fork-mounted pin below the threaded rod (see Figure 3-319).
Page 234: Main Control Valve
224 General Maintenance Main Control Valve Main Control Valve Resealing The following work instructions outline the procedure to reseal the main control valve (or directional control valve) on the E ™. XPERT : These repairs should be performed only by trained, experienced technicians. Tools Required ...
Page 235 General Maintenance 225 Thoroughly clean the tie rods, nuts and washers, and lightly lubricate the threads of the tie rods. On the inlet section of the valve assembly, use an o-ring pick to remove and discard the old o- rings. Clean the inside face of the plate, and inspect for cracks, abnormal wear, rust or uneven sealing surfaces.
Page 236 Clean and inspect the dust boot for damage, cracking or swelling. The dust boots are not included with the seal kits. Replace if necessary with Labrie part number HYV02887 dust boot.
Page 237: Arm Control Valve
General Maintenance 227 Add hydraulic fluid as required to the hydraulic tank. Arm Control Valve Arm Control Valve Resealing The following work instructions outline the procedure to reseal the arm control valve (or proportional control valve) on the E ™. XPERT : These repairs should be performed only by trained, experienced technicians.
Page 238 228 General Maintenance Valve Removal Thoroughly clean the valve and coils : The use of brake clean, or similar solvents, may cause damage to the actuator coils. Remove the hydraulic tank fill cap to relieve any air pressure from the reservoir. Remove the hoses and electrical connectors (label them prior to removal to aid in re-assembly).
Page 239 General Maintenance 229 Carefully install the coil to the valve section, taking care to not dislodge the small plungers, and torque the four socket head bolts to 67-75 in/lbs (7.5-8.5 Nm) in a cross-pattern. : If the LabriePlus part number HYV04315 Manual Actuator is leaking from the manual lever pivot, the actuator must be replaced;...
Page 240 230 General Maintenance Lightly lubricate the threads on the tie rods, and install the three washers and nuts on the tie rods. Using a 3-step torque method, torque them to 195-239 in-lbs (22-27 Nm). : The LabriePlus part number 633B1816 valve work port relief adjustment screw seals are not included with the standard seal kit, and should only be resealed if leaking.
Page 241 General Maintenance 231 Figure 3-321 Electric actuator seal configuration Figure 3-322 Manual actuator seal configuration Figure 3-323 Valve section seal configuration...
Page 242: Fuel Filter Replacement
232 General Maintenance Fuel Filter Replacement Fuel filter needs to be replaced periodically according to manufacturer’s specifications. If your ™ unit is a Mack LEU, special procedure must be followed to change the fuel filter. XPERT To change the fuel filter of your E ™...
Page 243 General Maintenance 233 Grit blasting (#50) or sandblasting (#80) for a 1.4 to 2.4-mil deep profile.  PRIMARY COAT: Dupont Black Urethane Primer #373p27678 to get a minimum thickness of 2 mils (dry).  FINISHING COAT: Dupont Emron Elite Paint 2-mil-deep single coat (dry). At the end of the painting process, the product must have a minimum of 4-mil surface thickness.
Page 244 234 General Maintenance...
Page 245: Lubrication
Any lithium-based commercial multipurpose grease may be used. Hydraulic Oil All Labrie hydraulic systems are filled at the factory with a high-quality anti-wear hydraulic fluid meeting an ISO 32 specification. On vehicles that are used in high ambient temperatures or that sustain high duty cycles, it may be desirable to change the fluid to an ISO 46 specification which has a higher viscosity.
Page 246: Engine Oil
236 Lubrication ISO Grade Viscosity @ 100 F, SUS Viscosity @ 210 F, SUS Viscosity Index (Min.) Pour Point -65 F -60 F -54 F Other important points to note:  The oil must contain anti-wear and anti-foam additives, rust and oxidation neutralizers and self- protecting agents.
Page 247: Testing Hydraulic Oil
It is recommended to have hydraulic oil tested and analyzed by a lab to prevent hydraulic system or pump failures. This will also optimize the oil change frequency. Apply the following procedure to take oil samples on Labrie vehicles. : The procedure may differ from other laboratories sample kits.
Page 248: Taking An Oil Sample
238 Lubrication Figure 4-2 Spring ball Taking an Oil Sample Once you have released the residual pressure, you can take the sample. To do so: Remove the sample kit from its bag and, using a screwdriver, remove the vent cap from the bottle cap (see Figure 4-3).
Page 249 Lubrication 239 Figure 4-5 Installing probe on coupler Probe Fill the bottle to the level mark (the pump must be engaged to do this). Remove excess oil through the vent. D O NOT OPEN THE BOTTLE Figure 4-6 Recommended oil level Once the sample is taken, remove the probe from the coupler and pull out the probe to remove it from the bottle (see Figure 4-7).
Page 250: Lubrication Charts
240 Lubrication Figure 4-8 Sealing bottle Sealed sample Fill in the identification form (sticker) and apply it on the sample bottle (see Figure 4-9). Figure 4-9 Identification form (sticker) Lubrication Charts Lubrication charts in this manual may differ from the ones displayed on the vehicles. For lubrication specifications, always refer to the charts on the vehicles.
Page 251 Lubrication 241 Figure 4-11 Glass compartment lubrication chart (optional)
Page 252 242 Lubrication Figure 4-12 ™ lubrication chart XPERT...
Page 253 Lubrication 243 Figure 4-13 ™ arm lubrication chart ELPING Caution! Never grease the side rails and the outside of rollers. Sand and other abrasives stick to grease, which may cause premature component wear. Caution! Because of their intensive use, the packer and its accessories must be lubricated every working day.
Page 254: Specific Components To Be Lubricated
244 Lubrication Specific Components To Be Lubricated Crusher Panel (optional) To properly maintain the crusher panel: Grease the crusher panel cylinder heads by using the grease fittings. Grease the crusher panel bushings. Grease the grease fittings on the lower tube rings (see Figure 4-15). Figure 4-14 Grease areas Cylinder...
Page 255: Body Hinges
Lubrication 245 Body Hinges The body-chassis hinges should be lubricated monthly. Also, check for cracks or corrosion. Any crack must be reported, and repaired by qualified personnel. If necessary, contact LabriePlus for technical support. Danger! Do not operate this equipment if there are any signs of damage or incomplete repairs. Figure 4-16 Body hinge Figure 4-17...
Page 256 246 Lubrication Also, inspect the welds around the hinges. The proper working condition of the following components is also to be checked:  Tailgate hydraulic cylinders  Cylinder pins and circlips  Tailgate hinges and pins  Wear on the locking mechanism ...
Page 257 Lubrication 247 Figure 4-20 Tailgate hinges (standard and co-mingle units) Tailgate hinge Grease fitting Figure 4-21 Tailgate hinges (co-mingle units only) Grease fittings...
Page 258: Tailgate Hooks (Co-Mingle Units)
248 Lubrication Tailgate Hooks (Co-Mingle Units) Figure 4-22 Tailgate hook lubrication points Grease fittings Hopper Door Figure 4-23 Standard hopper door lubrication points Hopper door hinges...
Page 259: Sump Box
Lubrication 249 Figure 4-24 Split hopper door lubrication points Hopper door hinges Sump Box Figure 4-25 Sump box lubrication points...
Page 260: Packer
250 Lubrication Packer Figure 4-26 Packer lubrication points (1) Roller grease fitting Remote grease fittings for rear cylinder pins...
Page 261 Lubrication 251 Figure 4-27 Packer lubrication points (2) Grease fitting (LH side front cylinder pin)
Page 262: Chute (Co-Mingle Vehicles)
252 Lubrication Chute (Co-Mingle Vehicles) Figure 4-28 Single chute lubrication points Figure 4-29 Dual chute lubrication points...
Page 263: Pump Drive Shaft "U" Joint
Lubrication 253 Pump Drive Shaft “U” Joint Figure 4-30 Pump drive shaft lubrication points Grease fittings...
Page 264 254 Lubrication...
Page 265: Hydraulic System
Hydraulic System As with all hydraulic systems, it may be necessary to periodically check and adjust the pressure relief settings. It may be that a major hydraulic component has been changed, that the vehicle is not performing in terms of payload, or that the vehicle has recently been put into service and the system requires adjustment following a run-in period.
Page 266: Hydraulic Vane Pump System
: The ball valve on the hydraulic tank must be completely open before engaging the pump or starting the engine. Labrie Enviroquip Group requires that the hydraulic fluid and return oil filter be changed and that the strainer be cleaned before changing the hydraulic pump.
Page 267: Single Vane Pump
Hydraulic System 257 In a hot shift system, the pump is declutched when the PTO is disengaged. In that configuration, there is no coil on the dump valve. The dump valve will regulate the hydraulic flow to 45 GPM. The pump (PTO) switch found on the in-cab control panel controls the clutch engagement.
Page 268: Dual Vane Pump
258 Hydraulic System Dual Vane Pump ™ vehicles with automatic loading arm are equipped with a dual vane pump. Both sections of XPERT the dual vane pump are activated by two electric solenoid valves. One is mounted on the pump and the other on the chassis (see Figure 5-3).
Page 269 Hydraulic System 259 Figure 5-4 Directional control valve • Tailgate: 4 ways, 3 positions - air-actuator operated or electrically operated (optional) • Packer: 4 ways, 3 positions - air-actuator operated or electrically operated (optional) • Body hoist: 3 ways, 3 positions - air-actuator operated or electrically operated (optional) •...
Page 270: Proportional Valve
260 Hydraulic System Proportional Valve ™ vehicles with an automated arm are equipped with a proportional valve (see Figure 5-5), as XPERT part of the arm vane pump, that powers all arm functions (gripper [open/close], lifting arm [extend/ retract, up/down], chute [left/right], etc.) and other options. As such, the amount of flow coming out of it will depend on the position of the spool inside a valve section.
Page 271: Inspecting The Pump
Hydraulic System 261 Caution! Very corrosive chemicals used to wash trucks may cause serious damage to the point where the valve coils may crack due to these chemicals. These issues can occur if the potting in the PVE is experiencing prolonged exposure to diesel- or kerosene-type liquids. Be careful when washing your truck especially around the proportional valve.
Page 272: Replacing The Hydraulic Pump
262 Hydraulic System Replacing the Hydraulic Pump Occasionally, circumstances such as a broken pump drive shaft, a leaking or noisy pump or a lack of hydraulic pressure or oil flow may necessitate the replacement of the pump. Before proceeding with the replacement of the pump, determine the type of pump setup that is used on your E ™...
Page 273 Hydraulic System 263 Remove the dump valve. : The dump valve is usually, but not necessarily, located atop the pump. : Always reinstall the dump valve and its components (shims, block assembly) as they were before uninstallation. Make sure you do not invert them. Remove the suction block (see Figure 5-8) and save it for the new pump.
Page 274 264 Hydraulic System Remove all 4 retaining bolts that hold the mounting cap in place. 13 b. : You may leave two retaining bolts partially unscrewed to facilitate rotation with a metallic bar. Rotate the mounting cap accordingly. 13 c.
Page 275 Hydraulic System 265 Rotation can be done by turning the mounting cap clockwise or counter-clockwise with your hands or by using a metallic bar as illustrated in the above picture. : Make sure pump does not come apart. : The cartridge will rotate with the housing. Do not pull on the mounting cap because inside components may move and damage the pump.
Page 276 266 Hydraulic System Remove all 7 retaining bolts that hold the front cap in place. 13 g. : You may leave two retaining bolts partially unscrewed to facilitate rotation with a metallic bar. Rotate the front cap accordingly. 13 h. Rotation can be done by turning the front cap clockwise or counter-clockwise with your hands or by using a metallic bar.
Page 277 Hydraulic System 267 Be sure not to pull on the front cap. Otherwise, the dowel pin may leave its position in the housing MPORTANT causing damage to the pump. : The cartridge will rotate with the housing. Put all 7 bolts back in place. 13 i.
Page 278 Check level of hydraulic oil in tank. Add oil if needed. : Labrie Enviroquip Group strongly recommends you change the filter element and the hydraulic oil as well as clean the hydraulic tank after installation of a new pump (see Replacing Filter Elements on page 282 and Replacing Hydraulic Oil on page 283).
Page 279 Hydraulic System 269 Loosen the breather cap on the hydraulic tank to depressurize the tank. If tank is of the pressurized type. Disconnect the electric coil on the dump valve, if equipped. Place a pan under the pump to catch dripping oil and unscrew all hydraulic hoses (4) that are attached to the pump.
Page 280 270 Hydraulic System If need be, disconnect the drive shaft from the pump and save it for the replacement pump. Install the new pump. Before attempting to install the new pump, it is very important to check the porting configuration of that pump;...
Page 281 Check level of hydraulic oil in tank. Add oil if needed. : Labrie Enviroquip Group strongly recommends you change the filter element and the hydraulic oil as well as clean the hydraulic tank after installation of a new pump (see Replacing Filter Elements on page 282 and Replacing Hydraulic Oil on page 283).
Page 282 272 Hydraulic System Figure 5-12 Suction block Attach the pump to a suitable lifting device and remove all 5/8” bolts that hold the pump to the PTO extension shaft. Remove the pump. Install the new pump using a suitable lifting device. Before attempting to install the new pump, it is very important to check the porting configuration of that pump;...
Page 283 Check level of hydraulic oil in tank. Add oil if needed. : Labrie Enviroquip Group strongly recommends you change the filter element and the hydraulic oil as well as clean the hydraulic tank after installation of a new pump (see Replacing...
Page 284: Installing A Yoke Locking Bolt
274 Hydraulic System Installing a Yoke Locking Bolt : It is important to perform this procedure after a pump replacement or a pump drive shaft replacement. To install a yoke locking bolt, do the following: Locate the hole on the yoke and the hole on the drive shaft (see illustration below). Hole on shaft Hole on yoke Bolt...
Page 285: Priming New Pump
Hydraulic System 275 Figure 5-14 Steel wire on yoke Drive shaft Yoke Bolt Steel wire : Use the following parts: QUB00700 (bolt) and 154503 (steel wire). Priming New Pump To prevent cavitation or air in the hydraulic system after installing a new pump or even when flushing the hydraulic system, make sure to prime the pump before starting the engine.
Page 286: Hydraulic Tank
276 Hydraulic System Crank the engine repeatedly — about five times — without letting it start in order to fill the suction hose and the pump with hydraulic oil and to push the air back into the tank. Start the engine. You can slowly raise the engine RPM only after 5 minutes.
Page 287 Hydraulic System 277 Figure 5-16 Filter housing element For more information on maintenance schedule, see E ™ P XPERT REVENTIVE AINTENANCE on page 28. HART Make sure that the filler cap (see Figure 5-17) is not obstructed and works properly. Make sure that the hydraulic oil is clean (not colored) and at least ¾...
Page 288: Pressurizing Tank System
278 Hydraulic System Figure 5-19 Hydraulic tank components (pressurized tank) Filler/breather cap Baffle Suction line Shut-off valve Strainer Filter element housing Access cover Oil temp/ Oil heater plug Drain plug level gauge Figure 5-20 Hydraulic tank components (non-pressurized tank) Filler/breather cap Return filter housing Filter restriction...
Page 289 Hydraulic System 279 To prevent cavitation, air pressure inside the hydraulic tank must be set between 3 and 3.5 PSI. A gauge and a pressure regulator (see Figure 5-22) are installed to adjust air pressure inside the tank. This gauge is located inside the frame rail on the curbside of the chassis; it can be accessed only when the body is raised.
Page 290: Emptying Hydraulic Tank
280 Hydraulic System : Check the tank breather cap every week to make sure that it is not clogged. If clogged, replace it with a new one. Replacement of the breather cap should be done concomitantly with the replacement of the hydraulic filter. However, the breather cap does not have to be changed after the first 50 hours of truck service as it is the case for the hydraulic filter.
Page 291 Hydraulic System 281 Remove the strainer from the tank port along with the shut-off valve (ball valve) [see Figure 5-24]. Unscrew the strainer. The strainer has to be turned counter-clockwise to be removed. Clean the strainer using solvent, and check for damage; replace if necessary. Apply thread seal compound on the strainer threads and reinstall the strainer.
Page 292: Replacing Filter Elements
282 Hydraulic System Figure 5-25 Return hose and bulkhead fitting Replacing Filter Elements To protect new components of the hydraulic system, the return filter element must be changed after MPORTANT the first 50 hours of truck operation. Change the element twice a year afterwards (see E ™...
Page 293: Replacing Hydraulic Oil
Hydraulic System 283 Figure 5-27 Filter head cover and retaining bolts bolts (4) Filter head cover Replace the filter element with a new one (see Figure 5-28). Figure 5-28 Filter element Reinstall the filter head cover. Replacing Hydraulic Oil Caution! Highly contaminated hydraulic fluid must be changed promptly to avoid damaging the hydraulic system.
Page 294: Hydraulic Cylinders
284 Hydraulic System With a clean dry cloth, remove all metal particles and debris accumulated at the bottom of the hydraulic tank through the 3 openings. Once the cleaning is over, reinstall the access cover. Change and install the return filter element (see Replacing Filter Elements on page 282). Reinstall the strainer (see Cleaning Strainer on page 280).
Page 295: Detecting Cylinder Internal Leaks
Hydraulic System 285 When you do so: Make sure that the shut-off valve on the suction line is completely open before starting the engine. Warning! Failure to open the shut-off valve may damage the hydraulic system. Make sure that connections between all hoses and pipes are tight, and that no oil is leaking. Leaking or otherwise faulty cylinders must be repaired or replaced immediately.
Page 296 286 Hydraulic System Figure 5-29 Detecting cylinder internal leaks If the packer cylinders are bypassing, the seal inside the cylinders may need to be replaced. If an internal leak is suspected, apply the following procedure. To detect internal leaks in packer cylinders: Apply all safety measu res and set the parking brake.
Page 297 Hydraulic System 287 Push the green button and see if oil is leaking from port “A”, then push the emergency S button. If oil leaks out of port “A” when pressure is applied, there might be an internal leak; replace or repair the cylinder.
Page 298: Hydraulic Pressures
288 Hydraulic System Hydraulic Pressures A 0–4000 PSI pressure gauge as well as a set of ball-end hex keys are required to adjust different working pressures of the truck’s hydraulic system (see Figure 5-30). Figure 5-30 Pressure gauge and ball-end hex key Adjusting Vane Pump Relief Valves (if equipped) The body and arm sections of the dual vane pump may have their own relief valve on the dump valve;...
Page 299 Hydraulic System 289 Figure 5-31 Relief valve on pump Adjustment screw Figure 5-32 Relief valve on chassis Adjustment screw To adjust the body vane pump relief valve: Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14). Install the 0–4000 PSI pressure gauge on the quick-connect coupler located on the valve inlet cover.
Page 300: Adjusting Directional Control Valve Pressure
290 Hydraulic System Start the engine and engage the hydraulic pump. Warning! Always make sure the shut-off valve on the suction line is fully open before starting your truck. Failure to open the shut-off valve may damage the hydraulic system. Release the body vane pump relief valve.
Page 301: Adjusting Body Relief Valve (Electro-Hydraulic Valve)
Hydraulic System 291 Adjust the directional control relief valve as needed by loosening the locknut and by turning the adjustment screw (see Figure 5-34). Figure 5-34 Relief valve Locknut Adjustment screw Using a ½” Allen key, turn the adjustment screw clockwise to increase pressure or counter- clockwise to reduce pressure.
Page 302: Adjusting Proportional Valve Pressure
292 Hydraulic System Disconnect the body-up coil (see C on Figure 5-35). With the engine at idle, adjust the pilot generating relief valve (see A on Figure 5-35) to 420 PSI (±20 PSI) while the Body Up function is activated. The valve adjustment screw is located on the right-hand side of the valve section when facing it.
Page 303 Hydraulic System 293 Levers are delivered with the vehicle to make the pressure adjustment. Before making any adjustments to the lifting arm proportional valve, you must first correctly set the MPORTANT pressure in the dump valve (if equipped). For more information on adjusting dump valve pressure, see Adjusting Vane Pump Relief Valves (if equipped) on page 288.
Page 304 294 Hydraulic System To adjust the proportional pressure main relief valve: Secure the arm working area using safety tape or barricades. Warning! Stay out of the path of the arm while manually moving the H ™. ELPING Failure to do so may result in severe injury, or even death. Install the lever on the proportional valve to adjust.
Page 305: Adjusting Chute Pressure (Co-Mingle Vehicles)
Hydraulic System 295 Figure 5-39 Main relief valve adjustment screw Adjusting Chute Pressure (Co-Mingle Vehicles) To calibrate the working pressure of the chute: Secure the arm working area using safety tape or barricades. Warning! Stay out of the path of the arm while manually moving the H ™.
Page 306: Adjusting Gripper Pressure
296 Hydraulic System Figure 5-40 Control levers Chute control lever (also one in the cab) Work port relief (chute right) Work port relief (chute left) Adjusting Gripper Pressure Danger! Do not stand directly in the path of the arm while carrying out these adjustments. See Figure 5-37 to locate the section of the proportional valve that controls the gripper.
Page 307: Adjusting Tipper Valve Pressure
Hydraulic System 297 Put the transmission in Neutral, start the engine and engage the hydraulic pump. Adjust gripper pressure: Install lever on the section of the valve that controls the gripper (see Figure 5-37). 7 a. Close the gripper using the lever you have just installed. 7 b.
Page 308: Adjusting Regeneration Valve Pressure
298 Hydraulic System Figure 5-42 Quick-connect coupler Figure 5-43 Tipper-operating valve Adjustment Lever screw : Some units are equipped with an SSO bucket instead of a standard cart tipper. However, the valve pressure adjustment is the same. Adjusting Regeneration Valve Pressure : This section deals with regeneration valve blocks that carry one of the following part numbers: HYV08200, HYV08200-01, HYV08210 or HYV08210-01.
Page 309 Hydraulic System 299 Stop the engine. Set the relief cartridge on the regeneration valve to maximum adjustment by screwing the adjustment screw clockwise. Disconnect the drain line from the regeneration valve (see Figure 5-44) and put it in a container in order to see the flow that comes from said valve and place a plug (male or female as appropriate) at the end of the disconnected line to prevent oil from flowing when the truck is running.
Page 310: Checking Tailgate Hydraulic System
300 Hydraulic System Lower the relief pressure on the regeneration valve by unscrewing the adjustment screw until the oil flows through the regeneration valve drain (adjust to a drizzle of oil of about 1/8’’ to 3/16’’). Lock the relief adjustment screw on the regeneration valve with a locknut. Stop the engine.
Page 311 Hydraulic System 301 Figure 5-45 Hydraulic cooler fan (optional) Periodic maintenance is recommended for E ™ units equipped with a hydraulic cooler. The XPERT cooler should be cleaned a minimum of every 1,000 hours of operation. Cleaning methods vary depending on the type of contamination (wet or dry). For dry contamination, such as dust, compressed air may be used;...
Page 312: Pressure And Cycle Time Charts - Expert
302 Hydraulic System Pressure and Cycle Time Charts - E ™ XPERT Chart 1...
Page 313: Chart 2
Hydraulic System 303 Chart 2...
Page 314: Chart 3
304 Hydraulic System Chart 3...
Page 315: Hydraulic Schematics
Hydraulic System 305 Hydraulic Schematics Schematic #1 2000 psi single axle 3000 psi dual axle 550 psi 420 psi 1700 psi...
Page 316: Schematic #2
306 Hydraulic System Schematic #2 2000 psi single axle 3000 psi dual axle 550 psi 420 psi 1700 psi...
Page 317: Schematic #3
Hydraulic System 307 Schematic #3 2000 psi single axle 3000 psi dual axle 550 psi 420 psi 1700 psi...
Page 318: Schematic #4
308 Hydraulic System Schematic #4 2000 psi single axle 3000 psi dual axle 550 psi 420 psi 0.030" 0.020" 1700 psi...
Page 319 Hydraulic System 309 : The preceding schematics are for reference only. The hydraulic schematic specific to your truck, based on the body serial number, is found in the truck’s cab.
Page 320 310 Hydraulic System...
Page 321: Electrical System
Electrical System This chapter is divided into two sections. The first section describes how the electrical components work and the second section describes how to adjust and repair the electrical components. How the Electrical System Works The electrical system includes the following components: ...
Page 322 The use of this electronic controller enables mechanics to perform troubleshooting, which facilitates the debugging process. Labrie Enviroquip Group offers training on this technology. To know more about electronic controllers and training schedule, please call LabriePlus.
Page 323: Adjusting And Repairing Electrical Components
Two fuses (30A and 40A), which are located inside the ignition relay box (see Figure 6-3), are used to protect the Labrie electrical system. The 40A circuit is subdivided into 2 secondary circuits (10A and 30A) which are protected by in-line fuses.
Page 324 314 Electrical System Figure 6-3 Fuses inside relay box Plastic cover Fuses Figure 6-4 Fuses outside relay box Circuit breakers The E ™ may have up to 6 manual reset circuit breakers, depending on the options installed. XPERT These breakers are located within the in-cab control box. Mounted on each circuit breaker is a button which, once pushed, resets the breaker (see Figure 6-5).
Page 325: Limit And Proximity Switches
Electrical System 315 : Consult the OEM manual for information on equipment not manufactured by Labrie Enviroquip Group. The following table provides a description of the circuit breakers located in the control box inside the truck cab. Function Ampere Circuit Number...
Page 326: Multiplex System-Related Interventions
IFM Program Update Process Occasionally, the Labrie IFM multiplex control system program may require modification or updating. If a revision to the control system program is required, the following list of action items must be addressed prior to making a program change: ...
Page 327 Figure 6-6 Service kit #01208 Labrie does not archive previous revisions of programs; this will ensure if there is any issue with the new program the original may be installed back into the module. Failing to upload the original program will result in it being lost when the revised program is installed.
Page 328: J1939 Baud Rate
Failure to do so may result in chassis fault codes. To ensure the baud rate setting is correct and the chassis is communicating with the Labrie multiplex system, it may be checked and adjusted using the Labrie multiplex display screen. With the engine running, depress the menu button to access the main menu.
Page 329: Checking Control Module (Node) Supply Voltage
If the engine RPM value on the Labrie system is not changing and synchronized with the chassis tachometer, the baud rate most likely needs to be reset to 500 Kbps. Effective early 2016, The Labrie system has been modified to allow changes to this value. Using the directional pad, select the SETTINGS option in the main menu and press OK.
Page 330 320 Electrical System 1) Turn the ignition switch to the “run” position, activating the IFM display. 2) On the IFM display, select “Menu”, then select “I/O Status”. 3) Using the up/down arrows on the directional pad, scroll down and select “Others”. 4) The real-time supply voltages of the control modules (Nodes) will be displayed: If voltage(s) are below 12 volts, check the supply power to the module;...
Page 331: Pneumatic System
Pneumatic System The air (pneumatic) system is crucial for efficient brake and body operation. : Before searching for parts, identify the type of cab of your unit (cab over or conventional). The mounting of some components for the body depends on the type of cab configuration. On most E ™trucks, the main hydraulic valve, XPERT...
Page 332: Air Actuator Maintenance And Replacement
322 Pneumatic System When the tailgate or body switch on the control panel is activated, the corresponding solenoid valve in the air valve box (see Figure 7-2) sends air to the corresponding air actuator on the main valve. This results in a movement of the hydraulic spool inside the valve. Figure 7-2 Pneumatic valve box Tailgate open...
Page 333: Control System Pneumatic Pressure Switch
Prior to chassis air pressure building to at least 90 PSI, the pump will not be allowed to engage. On multiplex units, a yellow banner on the Labrie IFM display screen showing “Pump: main air pressure” and an audible beep will occur if an attempt is made to engage the pump without sufficient air...
Page 334 If the Labrie-installed air filters are not serviced correctly, this pressure switch may provide intermittent operation due to debris blocking the intake port of the air pressure switch. When...
Page 335: Air Tanks
Pneumatic System 325 Connect a multimeter set to the red and black wires of the air pressure switch and select “Continuity” on the multimeter. Using the 3/32” Allen key, adjust the needle in until the multimeter shows continuity between the red and black wires. Remove the multimeter and air pressure regulator, then connect the air pressure switch wires and re-assemble the pneumatic valve box.
Page 336: Air Filter Assembly
326 Pneumatic System Pay particular attention to the dryer cartridge. On this type of equipment, the compressor works all MPORTANT the time due to the frequent use of the brake system. As a result, a lot of moisture is injected into the air system.
Page 337: Packer Air System
Pneumatic System 327 Packer Air System The hydraulic valve, which controls some of the hydraulic functions, is equipped with air actuators (see Figure 7-1). Each section of the valve has one two-way air actuator. For example, the one that is on the packer section moves the hydraulic spool inside the valve in either direction, resulting in a movement of the packer (extension or retraction).
Page 338: Pneumatic System Schematic
328 Pneumatic System Pneumatic System Schematic...
Page 339: Tools
Troubleshooting This chapter contains information to help you narrow down and/or solve problems that might occur with your E ™. Procedures throughout this chapter XPERT require that the people performing troubleshooting tasks have basic knowledge in electrical, hydraulic and pneumatic systems. The employer shall ensure that maintenance personnel is properly trained prior to starting troubleshooting.
Page 340 332 Troubleshooting : The ammeter must support at least 10 amps. Figure 8-2 Jumper wire with alligator clips Figure 8-3 Two oil pressure gauges (0–4000 PSI) 0–4000 PSI pressure gauge (Part# HYF00910) Female quick coupler (Part# HYF10195) Figure 8-4 Ball-end hex wrench (metric and...
Page 341: Troubleshooting
Troubleshooting 333 Troubleshooting Guide This troubleshooting guide will help identify the most commonly seen problems on the E ™. XPERT The table below will also provide the possible cause of the problem and give solutions to resolve that problem. For further information regarding customized options that might not be found in this troubleshooting guide, contact LabriePlus.
Page 342 334 Troubleshooting Problem Possible causes Solution Not the proper grade of oil Empty oil and refill with anti- foaming oil. See Recommended Lubricants on page 235 and Emptying Hydraulic Tank on page 280. Cavitation, excessive noise Shut-off valve on hydraulic tank Fully open the shut-off valve on the or vibration of the pump.
Page 343 Troubleshooting 335 Problem Possible causes Solution Faulty hydraulic line Perform a circuit analysis using the main hydraulic schematics (see Hydraulic Schematics on page 305). Stuck hydraulic spool inside Make sure that no spool inside the valve directional valve is stuck in a position that could send the hydraulic flow to the tank.
Page 344 336 Troubleshooting Problem Possible causes Solution Emergency S buttons (red) Make sure all emergency stop buttons are pulled out. Hydraulics See Hydraulic Pressures on page 288. Faulty harness between packer Inspect harness for damaged module and control station connectors or broken wires. Defective green/yellow buttons Inspect button assembly.
Page 345: Pump
Troubleshooting 337 Problem Possible causes Solution Arm does not respond to Cut off or defective power Follow wires on the electrical joystick (assuming that the cables schematic for 12-volt supply (move pump switch is ON) joystick to get signal). Faulty joystick Contact LabriePlus.
Page 346: Pump Cavitation
338 Troubleshooting  Transmission in “Neutral”  Emergency S button(s) pulled out  Pump ( ) switch “ON” : Neither the engine throttle nor the transmission not being in Neutral will affect pump operation once the pump is engaged. Pump Cavitation Cavitation is defined as the formation of air pockets in a moving fluid.
Page 347: Packer Air System
Troubleshooting 339 Cycle the packer to ensure that there are no leaks and the pump is running smoothly. Disconnect the gauge. Packer Air System There may be times when the packer is unable to complete a full cycle. If this is the case, the problem may be related to the packer air system.
Page 348: Tailgate-Locking Mechanism
340 Troubleshooting Figure 8-7 Injecting compressed air Inject compressed air here Hydraulic spool should move back and forth If air is leaking by the opposite port of the pressurized side of the actuator when both tubes are MPORTANT removed, this could indicate that the o-ring on the air actuator piston is leaking. If needed disassemble, clean, and lubricate with grease, or replace the o-ring.
Page 349: Tailgate Unlocking Spontaneously
Troubleshooting 341 Figure 8-8 Velocity fuse Figure 8-9 Holding valve Tailgate Unlocking Spontaneously If the tailgate seems to unlock by itself when using the packer, the “power bleed” inside the valve might not be working on the right side of the hydraulic cylinder.
Page 350: Tailgate Lowering Spontaneously
342 Troubleshooting To fix this problem: Apply all safety measu res to ensure safety around the vehicle at all times. Ensure that the parking brake is applied. Pull out the red emergency S button. Connect a pressure gauge to each quick-connect coupler of the valve tailgate section (see Figure 8-10).
Page 351: Pump: Trans Not Ok
“Pump: Trans not ok” has been identified. The method outlined below can be used in conjunction with the Labrie multiplex diagnostic manual. Only basic tools are needed for this troubleshooting: a quality multimeter (preferably used with back probe leads), assorted screwdrivers, and a set of cutting pliers (for removing zip ties).
Page 352 344 Troubleshooting Utilizing the Labrie multiplex display, perform the following steps: Depress “Menu” then select “I/O Status”. Next, select Module: “10_Cabine”. Once in the Module 10 screen, depress the “Output” button.
Page 353 Troubleshooting 345 After entering the output screen, select the “Force” button. After selecting “Force” a countdown will begin. At the end of the countdown, press the “OK” button to enter force mode. Note the addition of “Force Active” in the center of the screen. This is to alert the technician that force mode has been entered successfully.
Page 354 A) Locate output “OUT 12” and force it “ON”. With this output forced move to the appropriate Labrie/chassis interface connector (see body serial number specific drawings for exact connector number). Measure voltage on the pump trans request wire (104E). If voltage is present proceed to step #4.
Page 355 Troubleshooting 347 Next, place the red lead on pin 1 and the black lead on pin 2. There should not be continuity through the diode.  If the diode passed the above test proceed to step #6.  If the diode did not pass the above test replace the diode and then proceed to step #6. : Connector CM28 &...
Page 356: Troubleshooting Harnesses
348 Troubleshooting Troubleshooting Harnesses To simplify electrical troubleshooting on any E ™ side loader, a kit of different harnesses is XPERT available for use. These harnesses enable digital multimeter readings of both voltage and resistance without poking or damaging wires. Simply connect the compatible harness between two (2) existing connectors and use the additional connector as test points (see pictures below).
Page 357 Troubleshooting 349...
Page 358 350 Troubleshooting...
Page 359: Labrie's Multiplex System
This whole system has been designed to help you operate your unit in an efficient and easy way. Labrie’s multiplexed system is reliable and safe and it requires less wiring harnesses to operate. It can also monitor various function status of the body and display warning and caution messages.
Page 360: Main Page
A flashing red light on the monitor is also a sign of a problem. Call LabriePlus for support. The logo of Labrie Enviroquip Group appears momentarily on the monitor display at the start of the system (see Figure 9-2).
Page 361: Multiplexing 353
Multiplexing 353 Figure 9-3 Main page Press the far right button to reset the counter display to zero. Time and Date Indicator (optional) A time and date indicator may be found on the upper left-hand side corner of the screen. The availability of this indicator is based on the chassis on which the body is mounted.
Page 362 354 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Arm Select:Left Arm Not Stow Place Left Arm in Stowed Position Arm Select:Right Arm Not Stow Place Right Arm in Stowed Position Arm Up:Chute Bad Pos. Place Chute in Correct Position Arm Up:Crusher Not Raised Raise Crusher Panel Arm:Auxiliary Deadman ON...
Page 363 Multiplexing 355 Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Buzzer:TailGate Unlocked Lock Tailgate Chute:Arm Up Lower Arm Chute:Crusher Not Up Raise Crusher Chute:External Control Deactivate External Control Chute:Pump Not Started Engage Pump Crusher: Right Door Closed Open Right Door Crusher:Arm Up Lower Arm Crusher:Chute Not To Left Pos.
Page 364 356 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Packer:Already Extended Refer to Maintenance Personnel or LabriePlus Packer:Already Retracted Refer to Maintenance Personnel or LabriePlus Packer:Extend Too Long Check Extend Prox Packer:Pump Not Started Engage Pump Packer:Retract Too Long Check Retract Prox Packer:Tailgate Not Open Open Tailgate...
Page 365 Multiplexing 357 Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Pump:Aux. OpenGripper Switch ON Release Aux. OpenGripper Switch prior to Engaging Pump Pump:Cab BodyLower Switch ON Release BodyLower Switch prior to Engaging Pump Pump:Cab BodyRaise Switch ON Release BodyRaiseSwitch prior to Engaging Pump Pump:Cab CrusherDown Switch ON Release CrusherDown Switch prior...
Page 366 358 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Pump:J1 OpenGripper Switch ON Release J1 OpenGripper Switch prior to Engaging Pump Pump:J2 AutoDump Switch ON Release J2 AutoDump Switch prior to Engaging Pump Pump:J2 ChuteToLeft Switch ON Release J2 ChuteToLeft Switch prior to Engaging Pump Pump:J2 ChuteToRight Switch ON...
Page 367 Multiplexing 359 Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Pump:PTO Not OK Refer to Maintenance Personnel or LabriePlus Pump:Right ChuteToLeft Switch ON Release Right ChuteToLeft Switch prior to Engaging Pump Pump:Right ChuteToRight Switch ON Release Right ChuteToRight Switch prior to Engaging Pump Pump:Right Crusher Down Switch ON Release Right Crusher Down Switch prior to Engaging Pump...
Page 368 360 Multiplexing Table 1 Warning messages (cont’d) Warning and Caution Messages Solution Tailgate:Packer Not Retracted Retract Packer Tailgate:Pump Not Started Engage Pump Wrong Driver Position Change Driver Position Switch to Correct Position Table 2 Error messages (cont’d) Error Messages Solution Button Pack 12 is disconnected Refer to Maintenance Personnel or LabriePlus Button Pack 13 is disconnected Refer to Maintenance...
Page 369 Multiplexing 361 Table 2 Error messages (cont’d) Error Messages Solution Module 30 not Connected Refer to Maintenance Personnel or LabriePlus Module 50 is disconnected Refer to Maintenance Personnel or LabriePlus Module 50 not Connected Refer to Maintenance Personnel or LabriePlus Module 60 is disconnected Refer to Maintenance Personnel or LabriePlus...
Page 370: Main Menu
“OK” button. Multicycle The monitor used in Labrie’s Multiplexed System is user-friendly. Say you want to change the multicycle settings of the packer. All you have to do is select...
Page 371 Multiplexing 363 : The packer multicycle function has been preset at the factory to carry out 3 cycles after every cart dumped. When the switch on the control panel is on and the packer is activated, the packer will MULTICYCLE move according to the default number of cycles (that is 3) or to the number of cycles you chose.
Page 372 364 Multiplexing To choose a particular module, use the up/down arrows to select it and press “OK”. : Entering “OK” can be done two ways: press either the far right button or the “OK” button. Press “Esc” to return to the preceding page. Figure 9-8 Module I/O Status page 11: Display...
Page 373 Multiplexing 365 : Each rectangle is numbered and relates to a specific function of the truck. However, for a given number, the related function may vary from truck to truck. Table 3 Colored rectangles Rectangles Function Status (inputs) Blue Inactive Green Active Press “Esc”...
Page 374 366 Multiplexing Table 4 Colored rectangles Rectangles Function Status (outputs) Green Active Closed short-circuit Yellow Open circuit Press “Esc” to return to the preceding page. Press the “Force” button to display the Force page. : To go back to the Main Page or Main Menu, press “Esc” as needed until the desired page is displayed.
Page 375 Multiplexing 367 Figure 9-12 Warning message w/ “OK” prompt Press “OK” to go to the Force page or “Esc” to return to the preceding page. After pressing “OK”, the Force page appears on the screen. Figure 9-13 Force page (input) As no input function can be forced to be active or inactive, the operator must press the “Output”...
Page 376 368 Multiplexing This page contains a set of rectangles. Each of these rectangles is numbered and relates to a specific function of the truck. Colors are used to indicate whether the corresponding function is active or not:  a blue rectangle means the corresponding function is inactive ...
Page 377  the CANopen bus, which is used for the body. These 2 communication buses are completely independent of one another, except for some specific data that are transferred from the chassis J1939 bus to Labrie’s Multiplex System in which they will be used. These specific data are the following: ...
Page 378 370 Multiplexing Managing Passwords (optional) With this optional feature, data protection passwords can be added to the IFM Multiplexed System display. This feature can also be used to change or remove already saved passwords. Data that can be protected by passwords relate to the following features: Output Force, Multicycle and J1939 baudrate.
Page 379 Multiplexing 371 If a password already exists, enter it using the arrow keys. Press “Esc” to quit or OK to erase the password. Enter a new password using the arrow keys. Press “Esc” to quit or OK to create a new password. : Entering a new password with only zeros as the number, such as “000000”, will result in deactivating the password function.
Page 380 Looking at Figure 9-17 above you will notice the following digit string 8-8-5-1 between, for example, 10 and R1. As all Labrie electrical schematics begin with ZS00, you simply add those digits to that base number to get the corresponding electrical schematic number.
Page 381: Warning Buzzer
(included in the service kit). For more information on this, contact the LabriePlus Service Department. In advanced troubleshooting process, a modem may be connected to this plug to help Labrie’s technicians to detect and pinpoint the cause of body-related problems.
Page 382: Replacing The Can Bus-Based Multiplex Joystick
90 PSI. It is recommended to raise the engine speed only after the hydraulic system is engaged. Labrie’s multiplex system monitors all safety and operating functions to insure they work at their best. This system transfers data to and from the Allison TCM and the Cummins engine ECU. In order for this to be possible, proper parameters must be put into the TCM and the ECU.
Page 383 Refer to Table 5 to reprogram the new TCM. On chassis supplied by Labrie, the programming package for Allison transmissions is package #142. Some customer chassis may have different programming packages. Refer to your local Allison dealer for original programming packages.
Page 384 Pack enable Input enable Output enable Output neutral indicator – PTO Auto-neutral pack enable (if present) To tap into the TCM, Labrie uses the following wires on the Allison connector: Table 7 Input Wire # Description State Pump pack enable Active when the brakes are used, and when the PTO and auto-neutral switches are ON (ground signal).
Page 385: Allison Transmission Parameters
Multiplexing 377 Table 8 Output Wire # Description State PTO enable output Active when the PTO switch is ON and when all engine and vehicle speed criteria are respected (+12V signal). See Programmed Parameters on page 375. Neutral signal output Active when the transmission is in neutral.
Page 386 378 Multiplexing...
Page 387: Daily Inspection
Lifting Arms To keep the arm in good working order and to reduce the amount of down time and the risk of accidents, a preventive maintenance program must be implemented and followed thoroughly. Maintenance personnel must be familiar with the operation of the arm, the safety around it and the maintenance procedures described in this chapter.
Page 388 380 Lifting Arms Figure 10-1 Mounting bolts Figure 10-2 Wear pads Figure 10-3 Helping-Hand™ gripper...
Page 389: Lifting Arms 381
Lifting Arms 381 Figure 10-4 Hoses and connections Check for loose nuts and bolts. Check the arm stowed limit switch. For more information, see Adjusting Arm Stowed Limit Switch on page 214. Lubricate the arm moving parts as per the arm lubrication chart on page 415. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 14).
Page 390 382 Lifting Arms The hydraulic flow required to feed the valve comes from the dual vane pump. Figure 10-6 Dual vane pump Adjusting Valve Pressure The following pressure adjustment procedure explains how to adjust the pressure of each function of the H ™...
Page 391: Arm Hydraulic System
Lifting Arms 383 Arm Down System Pressure 2.5 - 3.0 Gripper Close 1200 PSI (±50 PSI) 1.0 - 1.5 Gripper Open 1200 PSI (±50 PSI) 1.3 - 1.8 Cycle time is defined as the time required for a function to complete a full back and forth movement. Cycle time may vary depending on weather conditions Warning! Before making any adjustments, secure the arm working area using safety tape or barricades.
Page 392: Adjusting Valve Pressure
384 Lifting Arms Figure 10-8 Gripper relief adjustment screws “Gripper close” relief adjustment screw “Gripper open” relief adjustment screw Main relief valve Warning! Do not stand directly in the path of the arm while carrying out these adjustments. Gripper Closing/Opening Pressure Adjustment Procedure: Secure the arm working area using safety tape or barricades.
Page 393: Arm Functions Adjustment Procedure
Lifting Arms 385 Figure 10-9 Movement restrictors Arm retract speed Arm extend speed restrictor restrictor Arm up speed Arm down speed restrictor restrictor Gripper open Gripper close speed restrictor speed restrictor : The arm movements (extension/retraction, up/down) have been preset in factory to the maximum speed.
Page 394 386 Lifting Arms The speed of the gripper must be fast enough so that the latter does not come in contact with the MPORTANT body during the auto-closing stage when the gripper reaches the mid-height position. : Limiting the stroke of the spools is limiting the amount of oil (flow) going through them. Controlling the oil flow means controlling the arm/gripper speed.
Page 395 Lifting Arms 387 Slowly move the lever on the gripper section of the arm valve (see Figure 10-5) and read the pressure on the pressure gauge at the time the gripper starts closing. The closing movement must begin when the pressure reaches 550 PSI. If the pressure is below or over that value when the gripper starts closing, adjust the holding valve pressure accordingly using the adjustable cartridge (see Figure 10-10).
Page 396: Adjusting Pressure On The Gripper Cylinder Holding Valve
388 Lifting Arms Each of the automated arms has its own arm valve to which a holding valve is attached. Connect a pressure gauge to the quick coupler (see Figure 10-11) of the arm valve that controls the right arm or the left arm. Proceed with one arm at the time.
Page 397: Adjusting Arm In/Out Holding Valve Pressure
Lifting Arms 389 Figure 10-14 Gripper open (left), closed (right) How it works: When the lifting arm is moved up with the gripper open, the limit switch located inside the slide sends an electrical signal to the solenoid mounted on the valve making the gripper close (works the same as pressing the gripper-closing button on the joystick).
Page 398 390 Lifting Arms Cylinder Cushion Adjustment The tipper and extension cylinders are cushioned at the end of their strokes to give a smoother movement. The cushioning speed is adjustable directly on the cylinders using two adjustment screws. If the gripper or the arm hits hard at the end of its strokes, apply the following procedure. Tipper Cylinder Cushioning Adjustment: Secure the arm working area using barrier tape or barricades.
Page 399 Lifting Arms 391 If an adjustment is necessary, stop the hydraulic pump and turn OFF the engine. : To be able to make the necessary adjustment, the temperature of the hydraulic oil must be around 140° F. To adjust the inner rail retraction movement cushioning, open the doghouse door. Tighten the retraction cushioning adjustment screw to obtain a smoother movement at the end of the stroke or loosen it if the movement is too slow (no shock shall occur).
Page 400: Cylinder Cushion Adjustment
392 Lifting Arms To adjust the outer rail retraction movement cushioning, open the doghouse door. Tighten the retraction cushioning adjustment screw (if equipped) to obtain a smoother movement at the end of the stroke or loosen it if the movement is too slow (no shock shall occur). To adjust the outer rail extension movement cushioning, tighten the extension cushioning adjustment screw (if equipped) to obtain a smoother movement at the end of the stroke or loosen it if the movement is too slow (no shock shall occur).
Page 401: Adjusting The Arm Vane Pump Relief Valve
Lifting Arms 393 Adjusting the Arm Vane Pump Relief Valve Usually, there is no arm vane pump relief valve on an E ™. However, if your E ™ vehicle is XPERT XPERT equipped with such a valve, it would be located on the front of the pump. Tighten the relief valve completely on the pump.
Page 402 394 Lifting Arms Figure 10-19 Ball valve Unplug the arm pump dump valve electrical connector and stow the harness safely out of the way. Remove the recirculation hose from the arm dump valve to the body pump and cap off the port at the body pump.
Page 403 Lifting Arms 395 Figure 10-21 Dump valve and orifice block Open the ball valve (or shut-off valve) that was closed in step 3. Start the truck. Note that the second the truck is running there will be hydraulic fluid going to the arm valve assembly.
Page 404 396 Lifting Arms When the converted signal reaches the proportional coil, it has a voltage of between 3V and 9V (6V being called the neutral signal or mid-range signal). An input signal having a range of 6V-3V moves the in/out section spool to one side and an input signal having a range of 6V-9V moves the in/out section spool to the other side.
Page 405: Proportional Coil Signals
Lifting Arms 397 Case of a H ™ arm moving very slowly or not moving ELPING at all in one direction If the H ™ arm of your E ™ unit is moving up/down or in/out very slowly or not ELPING XPERT moving at all in one direction or the other, chances are it may be due to low voltage proportional...
Page 406 398 Lifting Arms Activate the in/out function by moving the joystick in one direction, then the other. 8 b. The further away the joystick is from its neutral position, the faster the arm moves. When you move the joystick to the maximum in one direction, the signal voltage should be either 3V or 9V.
Page 407 Lifting Arms 399 Figure 10-25 Connectors on coils (left) and PWM adapter (right) Gripper Adjustment Rod The gripper adjustment rod performs the same movement as the gripper cylinder and allows the gripper to close and open symmetrically. The gripper cylinder moves the side of the gripper to which it is linked while the adjustment rod moves the other side of the gripper.
Page 408 400 Lifting Arms To adjust the gripper adjustment rod, proceed as follows: Apply all safety measures to ensure safety around the vehicle at all times. Start the engine. Engage the hydraulic pump. Using the arm joystick, extend the arm to gain access to the rear of the gripper. If not already done, partially close the gripper.
Page 409: Gripper Adjustment Rod
Lifting Arms 401 If, during the adjustment of the gripper adjustment rod, the mechanic notices that there is some up- and-down play at the opposite end of that part (the one that is attached to the two-finger section of the gripper [see Figure 10-26]), it may be necessary to replace the bushing/spacer system (see Figure 10-29) that is found inside the circular end of the adjustment rod.
Page 410: Gripper Arm Pivot Bushing Installation
402 Lifting Arms Once done, reinstall the gripper adjustment rod. To do so: Reinstall the end section of the adjustment rod that contains the bushing/spacer system. 7 a. Reinstall the pin with the bolt to secure the rod to the gripper base. 7 b.
Page 411 Lifting Arms 403 Figure 10-31 Vertical bolts Raise or lower the gripper (depending on the current gripper position). Reposition the plate correctly (see Figure 10-32). Figure 10-32 Plate Top of gripper head Position the plate on the top of the gripper head when the gripper is at its lower position or inside the gripper head (see Figure 10-32) when the gripper is at its upper position.
Page 412 404 Lifting Arms Figure 10-34 Bolts in lower row Replacing Green Wear Pads : For units equipped with a long reach H ™ arm only. ELPING When green wear pads are worn out, they have to be replaced. To replace worn-out green wear pads, carry out the following procedure: Fully extend the H ™...
Page 413 Lifting Arms 405 Remove both hydraulic hoses from the inner rail cylinder (see Figure 10-36). Figure 10-36 Inner rail cylinder hydraulic hoses To avoid oil leaks, cap each hose and fitting as soon as the hoses are removed. Clearly identify the disconnected hoses and fittings to avoid any mix up during reinstallation. Remove the outer rail cylinder bolt and pull out the pin (see Figure 10-37).
Page 414: Replacing Green Wear Pads
406 Lifting Arms Once all wear pads have been replaced, use same procedure in reverse order to reinstall the parts that have been removed. Replacing White Wear Pads To replace the white wear pads, proceed with the following procedure: Fully retract the H ™...
Page 415 Lifting Arms 407 Figure 10-41 Wear pad B Remove wear pad C (2 bolts) and replace it by a new one. Figure 10-42 Wear pad C As dust particles and sand stick to grease, never lubricate the H ™ automated arm wear ELPING MPORTANT pads.
Page 416: Replacing White Wear Pads
408 Lifting Arms Figure 10-44 Wear pad E Remove wear pad F (4 bolts) and replace it by a new one. Figure 10-45 Wear pad F Now you may install new wear pads A and B. : There may be shims installed between the pads and the arm structure. These shims are used to fill space between these parts, and usually they should be kept.
Page 417 ELPING The disassembly and assembly procedures differ some depending on the part number you are working with. Refer to the correct procedure and specifications listed in the table below. Labrie P/N Bolt Torque (Qty x Size) Bore Diameter Page Diameter...
Page 418 410 Lifting Arms Be sure to follow all appropriate lockout/tagout procedures (see Locking Out and Tagging Out the MPORTANT Vehicle on page 14) as well as your standard shop/facility procedures before attempting this procedure. Keyless Locking Devices - QUB00495 These locking devices are used on H ™...
Page 419: Keyless Locking Devices
Lifting Arms 411 Typically, the push-off screws appear to be completely tight after just one pass of tightening without any noticeable separation of clamp collars. Although it seems that the screws cannot be tightened further, several more rounds of torqueing in a cross sequence will increase the push-off force in the system and ultimately release the front collar.
Page 420: Keyless Locking Devices - Qub00495
412 Lifting Arms Figure 10-50 Tightening screws in a continuous sequence Keyless Locking Devices - QUB00498 These locking devices are used on H ™ lift arm pivot pin. ELPING Procedure for disassembly Loosen locking screws gradually in a cross sequence, shown in Figure 10-47. Remove all locking screws and ensure there is no damage to push-off threads of the front collar.
Page 421: Slide Wear Pad Lubrication
Lifting Arms 413 Repeat step 4 until the rear collar releases. Procedure for Inspection Inspect pin and bore surfaces for damage or galling. Measure outside diameter of pin and inside diameter of bore and compare measurements to the table on page 409. Replace any worn or damaged parts. If keyless locking device is to be re-used, thoroughly clean all the surfaces and lubricate both screws and treads with a thin film of light-weight oil.
Page 422 414 Lifting Arms Max EP lubricant may be applied to any UHMW wear pad surface during the performance of routine planned maintenance. Max EP dries to leave a protective lubricant film that will not damage or be absorbed by the UHMW material. LabriePlus offers Max EP lubricant in three sizes: ...
Page 423: Lubrication Chart And Hydraulic Schematic
Lifting Arms 415 Lubrication Chart and Hydraulic Schematic The following are examples of lubrication chart and hydraulic schematic for the H ™ ELPING lifting arm. Please note that these documents are for reference purposes only. The lubrication chart is based on a 40-hour-a-week truck operation.
Page 424 416 Lifting Arms 2000 psi single axle 3000 psi dual axle 1700 psi...
Page 425 Our office in the U.S. Our office in Canada 1198 Shattuck Industrial Blvd. 175A Route Marie-Victorin LaFayette, GA 30728 Levis, QC G7A 2T3 Toll Free: 1-800-231-2771 Toll Free: 1-877-831-8250 Telephone: 1-706-591-8764 Telephone: 1-418-831-8250 General Fax: 1-706-639-9275 Service Fax: 1-418-831-1673 Oshkosh General Fax: 1-706-591-8766 Parts Fax: 1-418-831-7561 Mailing Address Mailing Address...

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