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Labrie Optimizer Maintenance Manual

Manual is about: Labrie Optimizer Front Loading Refuse Truck

Summary of Optimizer

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    Maintenance manual release: february 2007 part number: 90313.

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    Foreword here is the new labrie parts and maintenance manual for the optimizer tm front loading unit. We sincerely hope that you will find it easy to use. We have designed it in a way that will allow you to easily make it available to drivers, mechanics, and to parts department personnel. Any time t...

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    Optimizer tm 4.

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    5 maintenance optimizer tm maintenance manual table of contents 1.0 maintenance manual .................................................................................... 9 2.0 lubrication .................................................................................................... 33 3.0 tr...

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    Optimizer tm 6 optimizer tm chapter 1.0 table of contents 1.0 maintenance manual .................................................................................... 9 1.1 general safety precautions ..................................................................... 9 1.1.1 general precaution .......

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    7 maintenance optimizer tm chapter 1.0 table of contents 1.4 hydraulic system maintenance .............................................................. 26 1.4.1 hydraulic system general inspection ................................................ 26 1.4.2 main relief valve pressure adjustment .........

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    9 maintenance warning personnel in charge of maintenance shall not perform any maintenance on the equipment without knowing the proper operations of the equipment as well as all safety precautions of such operations. Refer to the operation manual prior to perform any type of work on the unit. For ma...

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    Optimizer tm 10 1.1.3 fire protection if for any reason the maintenance personnel has to work on an equipment that has not been unloaded, for any type of work, a fire extinguisher should be made readily available close to this vehicle. Anytime a loaded vehicle is inside a garage there should be a fi...

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    11 maintenance shut down procedure • park on a hard level surface. • apply parking brake. • make sure that all moving parts are in the storage position (tailgate, arms and forks, packer, etc). • turn hydraulics, electricals and engine off. • turn the master switch off (if equipped). • empty air tank...

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    Optimizer tm 12 warning to protect the new components, the return filter must be changed after the first 50 hours of use. See hydraulic filter replacement procedure in section 1.4.8. Before starting the engine, make sure that the suction valve on the reservoir is completely open (figure #1.1). If th...

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    13 maintenance hopper cleaning procedure (cont’d) • press and hold the yellow button on the console to retract the packer to its home position. • close the tailgate, turn off the engine, and put the safety pins back into place. • close the hopper roof gate. Danger never close the hopper door behind ...

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    Optimizer tm 14 danger never go under the body when the safety props are not installed. Failure to do so will result in serious injuries or even death. Put the body safety props in place safety props locking pin use the pump lever to lift the body d c e clamps located under the body, near the center.

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    15 maintenance danger figure #1.2 figure #1.3 1.1.10 propping procedures never work under, or close to equipment or any part that is not safely propped or secured. Always usethe provided step ladders (or any other safe ladder to work towards the front) to get on the roof or to work on higher parts o...

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    Optimizer tm 16 1.2 packing system maintenance 1.2.1 packing system general maintenance the optimizer tm packing system has an heavy duty guiding system using special hardened steel wear plates. However, because of the frequent use of the ram, we recommend that daily visual inspections be performed ...

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    17 maintenance adjusting the proximity switches • move the packer blade about 1 inch back from the fully extended position. • adjust the proximity switch #1 so it is “active” (the amber light on the proximity switch should be on) when the packer blade reaches this position. • apply the same procedur...

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    Optimizer tm 18 1.2.3 packer blade wear plates replacement if the packer blade has a vertical movement greater than 3/16 or a side movement greater than 1/8; verify the wear plates and the body guide. We use two different types of steel for wear plates: the “ar 425” and the “ar 500”. Packer blade we...

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    19 maintenance 1.2.4 body guide wear plates replacement body guide wear plates replacement procedure • remove the packer blade (refer to packer blade removal procedure, sec. 1.2.5 ). • retract the packing cylinders and move them out of the way. • remove body wear plates by grinding or cutting the st...

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    Optimizer tm 20 1.2.5 packer blade removal procedure packer blade removal procedure • start engine and hydraulic system. Bring the packer to the rear end of the body to easily access the pins (figure #1.8). • remove rear cylinder pins (figure #1.8). • retract cylinders. • pull packer out of the body...

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    21 maintenance caution because of it’s frequent use, the packer and it's accessories must be lubricated every working day. 1.2.7 lubrication of packing system refer to the chapter 5 on lubrication for: • cylinder pins (figure #1.10) • door hinges. 1.2.6 packer cylinders replacement packer cylinder r...

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    Optimizer tm 22 caution 1.3.1 tailgate locking mechanism 1.3 tailgate system and body hinges maintenance it is important to lubricate the hinges and the slides for the rear door locks with multi-purpose grease. Also, inspect the welds and the proper working order of the following components (figure ...

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    23 maintenance 1.3.2 tailgate seal and hinges inspection the hinge pins must not have any signs of excessive wear or metal fatigue. The retaining bolts must be kept tight (figure #1.15). Perform a visual inspection of the rubber seal along the rim of the tailgate. Replace any broken components neces...

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    Optimizer tm 24 1.3.5 hopper door sensor the hopper door is equipped with a limit switch that detects if the side door is open. On some units, this task is performed by a proximity switch instead (optional). When the hopper door is open, the pump can not be engaged. That way, it is impossible to use...

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    25 maintenance 1.3.8 arms partly raised proximity switch some units are equipped with a proximity switch that allows the operator to raised the arms when the packer is retracting. If the packer is not completely retracted when the arms pass in front of the proximity switch, the arms stop to avoid de...

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    Optimizer tm 26 1.4 hydraulic system maintenance 1.4.1 hydraulic system general inspection hydraulic system general inspection procedure • for new equipment, change the return element filter after 50 hours of use, and every 500 hours thereafter. See hydraulic filter replacement procedure section 1.4...

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    27 maintenance 1.4.3 hydraulic directional control valve the optimizer is equipped with a parker directional control valve, model vg-35. The hydraulic valve controlling all the functions of the front loader refuse body is assembled as follows: (from bottom to top as positioned on the truck). Sliding...

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    Optimizer tm 28 pressure adjustment procedure • install a 3000psi pressure gauge on the quick coupling found on the main valve (figure #1.17). • start the engine and engage the hydraulic system. Maintain the engine speed at 1500 rpm. • open the tailgate until the mechanism reaches the end of its str...

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    29 maintenance 1.4.6 hydraulic cylinders inspection procedures to maintain proper working order and prolonged cylinder performance, it is essential to inspect them at least once a week as recommended. Verify that all the connections of the flexible hoses and pipes are tight, and that there are no ex...

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    Optimizer tm 30 caution caution 1.4.8 hydraulic fluid replacement procedure it is not recommended to mix different types of oil in the same reservoir. Highly contaminated hydraulic fluid must be changed to avoid any damage on the system . Verify that the ball valve on the suction is completely open ...

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    31 maintenance 10. Clean inside the hydraulic tank with a clean and dry cloth in order to remove any metal particles or debris accumulated at the bottom. • to clean the interior of the an aluminum tank (cylindrical), insert the hand in the hole where the strainer was fixed. This allows to clean one ...

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    Optimizer tm 32 hydraulic filter replacement procedure • shut off the hydraulic system and truck engine; • shut off the ball valve on the suction line (figure #1.1). • remove the filter head’s four retaining bolts (shroeder type) or front cap (pall type) (figure #1.16). • replace the filter element ...

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    33 maintenance caution 1.4.11 tailgate hydraulic system maintenance the optimizer tm units are equipped with a special hydraulic system that controls the locking mechanism of the tailgate. If the continuous re-locking system is not working properly: tailgate unlocks by itself or if the tailgate is d...

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    Optimizer tm 34 1.4.12 body hoistingsystem maintenance(cont’d) body hoisting system pump adjustment (cont’d) • the pressure reading shall be at 2000 psi. Adjust the relief if necessary. • turn the adjustment clockwise to increase the pressure and counter- clockwise to reduce the pressure (see figure...

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    35 maintenance 1.4.12 body hoisting system maintenance(cont’d) figure #1.24 safety prop support safety props to lubricate the body safety props, apply the recommended grease through the greasing points, which are located near the safety props shaft, inside the rails (see figure #1.25). There are a g...

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    Optimizer tm 36 1.4.13 arms up deceleration valve the arms up deceleration valve automatically decelerates the arms as they are raised to the dump position. A cam bolted to the arm pivot tube rotates as the arms are raised and gradually depresses the valve spool, reducing the flow of oil exiting the...

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    37 maintenance figure #1.29 cam boss body 4” between cam boss and body deceleration valve plunger deceleration valve figure #1.30 figure #1.31 cam boss.

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    Optimizer tm 38 1.4.14 arms down deceleration valve some units are equipped with an arms down deceleration valve. This deceleration valve automatically decelerates the arms as they are lowered. A cam bolted to the arm pivot tube rotates as the arms are lowered and gradually depresses the valve spool...

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    39 maintenance 1.5 air system maintenance 1.5.1 air system maintenance procedure air system is crucial for the brakes to operate with maximum efficiency. All air tanks on the chassis must be drained after each working day. Some units are equipped with an air dryer and/or alcohol evaporator. These de...

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    Optimizer tm 40 2.0 4.0 * replace return filter after the first 50 hours of operation cleaning of hopper area 3 .0 perform a visual inspection of the following components: body and chassis 1.0 hydraulic system component/system optimizer preventive maintenance chart maintenance manual section service...

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    41 maintenance.

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    Optimizer tm 42 1.2.2 1.2.2 proximity switches greasing and lubrication 2.2 safety systems proper adjustment of proximity switches check and clean area around proximity switches packer and its accessories (see lubrication chart on side of the truck apply light grease if required check for proper ope...

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    43 lubrication.

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    Optimizer tm 44 2.0 lubrication .................................................................................................... 46 2.1 recommended lubricant ........................................................................... 46 2.1.1 hydraulic fluids .......................................

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    45 lubrication.

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    Optimizer tm 46 2.0 lubrication 2.1 recommended lubricant 2.1.1 hydraulic fluids minimum requirement for hydraulic oil: viscosity of 320 cst at 104 o f (40 o c) and 6.4 cst at 212 o f (100 o c). Must contain anti-wear, and anti-foam additives, rust and oxidation neutralizers and self protecting agen...

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    47 lubrication.

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    Optimizer tm 48 lubrication chart on side of the truck.

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    49 troubleshooting.

  • Page 50: Labrie Optimizer

    Optimizer tm 50 labrie optimizer chapter 3.0 table of contents 3.0 troubleshooting section ...................................................................... 52 3.1 troubleshooting table ............................................................................. 52 3.2 internal leak detection ...

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    51 troubleshooting.

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    Optimizer tm 52 3.0 troubleshooting section 3.1 troubleshooting table important: at all times when troubleshooting refer to the corresponding sections. Insufficient packing ratio 1. Low oil pressure 1. Check if oil pressure at relief valve is 2500 psi or faulty hydraulic pump (cavitation or wear). 2...

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    53 troubleshooting 3.1 troubleshooting table (continued) problems possible causes remedy 5. Ball valve partly closed 4. Suction hose blocked 3. Dirty strainer 2. Oil too thick 1. Low oil level 1. Refill the reservoir cavitation, excessive noise from the pump 2. Change oil for an appropriate grade of...

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    Optimizer tm 54 1. The packer wear plates have too much wear. 3.1 troubleshooting table (continued) problems possible causes remedy excessive vertical or as sideway of the packer blade. 1. Inspect the wear plates as movement (sec 1.0) and replaced if necessary. 2. The faulty selenoid must be replace...

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    55 troubleshooting internal leak detection for cylinders 1. Apply all safety measures to ensure safety around the vehicle at all times. 2. Ensure that the parking brake is applied. 3. Pull out the emergency stop button (red). 4. Start the engine and engage the hydraulic pump. 5. Fully extend the pac...

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    Optimizer tm 56 3.3 tailgate locking mechanism troubleshooting the tailgate locking mechanism is equipped with hydraulic safety systems that prevent accidental unlocking of the tailgate during operation. One of the systems is the velocity fuse with the “power bleed” and the other is the holding valv...

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    57 troubleshooting main relief gauge port velocity fuse figure #3.3 gauge 1 gauge 2.

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    Optimizer tm 58 tailgate hydraulic troubleshooting 1. Apply all safety measu res to ensure safety around the vehicle at all times. 2. Ensure that the parking brake is applied. 3. Pull out the emergency stop button. 4. Install a pressure gauge on each port of the tailgate section on the valve, as sho...

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    59 troubleshooting tailgate hydraulic troubleshooting 1. Apply all safety measures to ensure safety around the vehicle at all times; 2. Ensure that the parking brake is applied; 3. Remove the velocity fuse (figure #3.3) and verify that it is clean and that the plunger is moving freely. A new velocit...

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    Optimizer tm 60 3.4 main hydraulic schematic.

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    61 troubleshooting intentionally left blank.

  • Page 62: Labrie Optimizer

    Optimizer tm 62 labrie optimizer chapter 4.0 t able of content s 4 .0 hydraulic systems p arts and diagrams ............................................ 6 4 4.1 hydraulic hoses and pipes on chassis ................................................. 6 4 4.1.1 how to order ................................

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    63 hydraulic.

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    Optimizer tm 64 4.0 hydraulic systems p arts and diagrams 4 .1 hydraulic hoses and pipes on chassis 4.1.1 how to order when ordering hydraulic components, always specify the following: a) body serial number: eg. Fl98hha b ) type of body • 40 cubic yards this capacity determines the length of the bod...

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    65 hydraulic 4.1.2 hydraulic piping tank to pump (peterbilt a320 4*2).

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    Optimizer tm 66 4.1.2 hydraulic piping tank to pump (peterbilt a320 4*2) no. Part no. Description qty. 1 5008 rail, tube holder 8” ................................................................................................... 1 2 16949 tank return hose .............................................

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    67 hydraulic 4.2 pumps, valves and hydraulic tank 4.2.1 hydraulic tank.

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    Optimizer tm 68 no. Part no. Description qty. 1 49840 adaptor ......................................................................................................................... 1 2 70737 suction valve assy ..........................................................................................

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    69 hydraulic 12 11 10 9 8 7 6 5 5 4 4 3 2 1 4.2.2 muncie hydraulic pump note: fittings vary according to truck configuration..

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    Optimizer tm 70 no. Part no. Description qty. 1 12635 special fitting ............................................................................................................. 1 2 hyf00095 split flange hardware) .......................................................................................

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    71 hydraulic 4.2.3 main valve 17 16 1 10 15 3 2 11 9 7 5 6 12 4 18 19 8 14 13.

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    Optimizer tm 72 no. Part no. Description qty. 1 68276 adaptor ......................................................................................................................... 1 2 hyf02995 45° adaptor ..............................................................................................

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    73 hydraulic intentionally left blank.

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    74 body air systems labrie optimizer chapter 5.0 t able of content s 5 .0 body air systems, p arts and diagrams ............................................... 7 5 5.1 introduction ................................................................................................. 7 5 5.2 genereal pneu...

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    Body air systems 75 5.0 body air systems, p arts and diagrams 5 .1 introduction this section contains a diagram presenting the pneumatic system of an optimizer tm body..

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    76 body air systems.

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    77 body air systems 5.2 general pneumatic diagram.

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    Optimizer tm 78 intentionally left blank.

  • Page 79: Labrie Optimizer

    Electrical labrie optimizer chapter 6.0 t able of content s 6 .0 electrical systems ................................................................................... 8 0 6.1 electrical schema tics ............................................................................... 8 0 6 .2 delastek mod...

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    80 6.0 electrical systems 6 .1 electrical schematics all the electrical schematics needed to troubleshoot and repair your optimizer tm unit are provided with the truck. They are located inside the cab. For further assistance, call labrie environmental group customer support center at 1-800-231-2771....

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    81 notes.