Labrie ALLEY -GATOR RIGHT-HAND Maintenance Manual
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Labrie ALLEY -GATOR RIGHT-HAND Maintenance Manual

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Summary of Contents for Labrie ALLEY -GATOR RIGHT-HAND

  • Page 1 LLEY ATOR IGHT AINTENANCE ANUAL...
  • Page 3 LLEY ATOR IGHT AINTENANCE MANUAL...
  • Page 4 Liability In no event shall Labrie Enviroquip Group assume liability for any incidental, consequential or special risks or damages arising from the use or misuse of the information provided herein, breach of warranty, breach of contract, negligence, strict tort liability or any other legal theory and/or hypothesis.

  • Page 7: Table Of Contents

    IGHT MDM Control Module ................................2 Danger and Caution Lamps on the Control Console ....................3 Pre-operating Instructions ................................4 To Contact Labrie Plus ..................................5 In the U.S....................................... 5 In Canada ...................................... 5 Safety ................... 7 Safety Precautions for the Owner ............................... 7 Safety Precautions for the Employee ............................
  • Page 8 vi Table of Contents Maintenance ................29 Cautionary Notes for Maintenance Personnel ........................29 For Welding Purposes .................................. 29 Hydraulic Oil ....................................30 Oil Identification ..................................30 Oil Recommendations ................................30 Common Hydraulic Components ............................31 Hydraulic Oil Tank ................................... 31 Hydraulic Oil Cooler ................................
  • Page 9 Table of Contents vii Alley-Gator Right-Hand Hydraulic System ....................... 66 Pressure and Cycle Time Chart - Packer Circuit ......................67 Pressure and Cycle Time Chart - Body Circuit ......................67 Pressure and Cycle Time Chart - Right-Hand Arm Circuit ..................68 Hydraulic Hose ..................................
  • Page 10 viii Table of Contents...

  • Page 11: Introduction

    Introduction About this Manual This manual is designed to help qualified maintenance personnel repair, service and maintain the A LLEY . It outlines maintenance ATOR IGHT procedures for body and packer components. It is imperative that you carefully review this manual prior to performing any maintenance to your new Automated Side LLEY...

  • Page 12: About The Illustrations In This Manual

    : A number of system schematics are included in this manual. 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 13: Danger And Caution Lamps On The Control Console

    Introduction 3 Figure 1-1 MDM control module (standard version, left; built-in version, right) Danger and Caution Lamps on the Control Console Danger Lamp This lamp will illuminate whenever the following occurs:  The tailgate is ajar  The body is raised ...

  • Page 14: Pre-Operating Instructions

    4 Introduction Caution Lamp This lamp will illuminate whenever the following occurs:  The hopper cover (top door) is not open (if installed)  The arm is not parked Figure 1-3 Caution lamp Pre-operating Instructions Upon receipt of your new A , perform a complete lubrication as per the LLEY ATOR...

  • Page 15: To Contact Labrie Plus

    E-mail: sales@labriegroup.com For technical support and parts ordering, the serial number of your vehicle is required. Therefore, MPORTANT Labrie Enviroquip Group recommends to keep record of the information found on the VIN plate, which is located in the cab.
  • Page 16 6 Introduction...

  • Page 17: Safety

    Safety Safety comes first and Labrie Enviroquip Group is committed to your safety. Ultimately, safety is everyone’s responsibility when operating or maintaining your A LLEY ATOR IGHT Automated Side Loader. Make it your first priority! Be aware and apply the safety practices and features detailed in this manual.

  • Page 18: Safety Precautions For The Employee

    8 Safety  Ensure that a vehicle and safety equipment inspection is performed daily. Document the inspections, including all maintenance, repair and malfunction items. Keep inspection documents complete and current. Under no circumstances should your A be operated if damaged or MPORTANT LLEY ATOR...

  • Page 19: Safety Decals

    Safety 9  Back up the truck while unloading refuse.  Hoist the body while on uneven ground.  Prop a loaded body with the hoist safety prop.  Enter the hopper or main body unless the engine is shut off, the key is removed and there is an out-of-service tag on the steering wheel.

  • Page 20: Counterbalance Valves

    10 Safety Figure 2-1 Grease manifold Counterbalance Valves Counterbalance valves prevent the discharge of oil out of a cylinder in the event of hose failure (see Figure 2-2). Figure 2-2 Counterbalance valve Environmental Spill Kit (optional) This kit is used to contain hydraulic oil or diesel spill due to component failure. Consult with your maintenance and safety personnel for availability and location (see Figure 2-3).

  • Page 21: Access Ladder Proximity Switch (Optional)

    Safety 11 Figure 2-3 Optional environmental spill kit Access Ladder Proximity Switch (optional) Installed on the access ladder, this proximity switch disables/locks out all hydraulic functions when the ladder is deployed. : Only on units equipped with an access ladder. Figure 2-4 Extension ladder proximity switch with ladder deployed (left) and in stored position (right) IQAN MDM Master Control Module...

  • Page 22: Fire Extinguisher

    12 Safety The IQAN MDM is the main unit of the central control system. It contains the system’s application software. In addition, the MDM contains a visual interface screen that displays text, parameters and other settings. All communication with the control system takes place from the MDM via the CAN- bus network.

  • Page 23: First Aid Kit (Optional)

    Safety 13 Figure 2-6 5-lb fire extinguisher First Aid Kit (optional) Your vehicle should be equipped with a first aid kit. It should be placed inside the cab for quick access. Figure 2-7 First aid kit Triangle Kit A triangle kit is provided with the truck. Figure 2-8 Triangle kit...

  • Page 24: Global Motion Sensors (Optional)

    Hopper Camera/Side Door Camera (optional) The hopper and side door cameras send information to the monitor inside the cab when the monitor is selected to the proper camera. Please consult your Labrie distributor/dealer for more information. Figure 2-10 Hopper Camera (optional) left/Side door camera (optional) right/Camera monitor (inside cab) center...

  • Page 25: Tailgate Safety Pins

    Safety 15 Figure 2-11 Hoist safety prop Always unload the unit before setting the hoist safety prop. MPORTANT Tailgate Safety Pins The tailgate pins are located on both sides of the rear of the body. The tailgate pins prevent the tailgate from opening accidentally.

  • Page 26: Safety Lockout Tests

    16 Safety Figure 2-13 Tailgate safety prop Safety Lockout Tests Your daily inspection includes completing the safety lockout tests. Successful completion of these tests ensure that your vehicle is safe to operate. If any of these tests fail, do not operate your vehicle until the appropriate adjustment or service has been completed.

  • Page 27: Arm Limit Switches (2)

    Safety 17 IF ANY hydraulic function is OPERATIONAL when the ladder is deployed, NOTIFY your maintenance supervisor immediately. Location: This proximity switch is located at the base of the access ladder. Figure 2-14 Access ladder proximity switch Figure 2-15 IQAN MDM display screen Arm Limit Switches (2) Performing this test ensures the Arm not parked message will appear on the IQAN MDM screen (see Figure 2-15) when the slide is extended from the home position.
  • Page 28 18 Safety You should have sufficient room to drive approximately 100 yards (91.44 m) forward. EXTEND the slide. CHECK that the caution lamp on the control console illuminates (see Figure 1-3) and the Arm not parked message appears on the MDM screen (see Figure 2-15). DRIVE the vehicle forward and increase engine speed to over 1,000 rpm.

  • Page 29: Hopper Cover Proximity Switch (If Equipped)

    Safety 19 Hopper Cover Proximity Switch (if equipped) : The following test is for units that are equipped with a hopper cover. Performing this test ensures that you cannot accidentally dump refuse on top of the hopper cover. To perform this test: CLOSE the hopper cover.

  • Page 30: Lockout Reference Chart

    20 Safety Figure 2-18 proximity switch AISED Lockout Reference Chart Extension ladder deployed - if equipped All hydraulic functions inoperative Vehicle engine over 1000 rpm Slide out, gripper CLOSE and lift up inoperative Arm slide not extended beyond hopper Dump inoperative Lift raised above vertical Gripper OPEN inoperative Hopper cover closed (or not fully open) - if...

  • Page 31: Utilizing Tailgate Pins

    Safety 21 It is recommended that you keep the keys on your person. MOVE any one of the hydraulic controls to RELIEVE any residual pressure in the system. PLACE an Out-of-Service tag on the steering wheel using a non-reusable fastener and place an Out-of-Service sign in the front window.

  • Page 32: Positioning The Tailgate Safety Prop

    22 Safety Before operating the A Automated Side Loader, place both tailgate pins in lock MPORTANT LLEY ATOR IGHT position. Before opening the tailgate, disengage both tailgate pins from their lock position and place them in MPORTANT their stored position. Figure 2-21 Tailgate pin Positioning the Tailgate Safety Prop...
  • Page 33 Safety 23 Figure 2-22 Pulling safety prop upward (left) and setting it down (right) LOWER the tailgate onto the safety prop. COMPLETE the Lockout/Tagout Procedure. Refer to “Lockout/Tagout Procedure” on page 20. Figure 2-23 Tailgate safety prop...

  • Page 34: Stabilizing A Hoisted Body

    24 Safety Figure 2-24 Danger decal Never walk or work under the tailgate when it is open unless the tailgate safety prop is in place. MPORTANT Stabilizing a Hoisted Body The A Automated Side Loader is equipped with a hoist safety prop LLEY ATOR IGHT...
  • Page 35 Safety 25 Figure 2-25 Spring storage latch RAISE the body until the safety prop hangs free. Do not raise the body higher than is required for the prop. If the unlatched prop does not swing into MPORTANT place with the body raised, the prop has been damaged and must be repaired prior to use. LOWER the body until the safety prop feet fit into the prop retainer cut-outs and seat securely onto the chassis frame.

  • Page 36: Raising The Front-End Body

    26 Safety Figure 2-27 Warning decal Raising the Front-End Body It may be required to raise the front-end body to complete repairs. For this, you will require two suitable chains, one shackle, two grab hooks and a lifting device such as an overhead crane. Caution! Do not lift the front-end body if the hinges at the rear end of the body are not securely fixed to the frame rails.
  • Page 37 Safety 27 Figure 2-28 Example of a lifting installation Lifting device Shackle Grab hooks Lifting lugs...
  • Page 38 28 Safety...

  • Page 39: Maintenance

    Maintenance Cautionary Notes for Maintenance Personnel Keeping your safety in mind, please note that it is imperative that ONLY QUALIFIED PERSONNEL (who are knowledgable with the operations of the vehicle) perform service to the hydraulic, electrical and pneumatic systems. Please read carefully the SAFETY INFORMATION (chapter 2, in this manual), VEHICLE CONTROLS (chapter 3, in the Operator’s Manual), and VEHICLE OPERATION (chapter 4, in the Operator’s Manual),...

  • Page 40: Hydraulic Oil

    Labrie Parts Department. Figure 3-1 Oil Identification Tag Oil Recommendations Labrie Enviroquip Group recommends that you refer to the guidelines on the next page and that you consult the oil manufacturer to ensure that your oil needs are fulfilled.

  • Page 41: Common Hydraulic Components

    Maintenance 31 Please consider cold weather operation requires special oil consideration. Viscosity should not exceed 7500 SUS / 1620 cSt at lowest start-up temperature. Continuous operation should range between 60 - 1000 SUS (10.5 - 216 cSt) for all temperature ranges. Viscosity 40°C = 32.3 cSt...

  • Page 42: Hydraulic Oil Cooler

    Filter Replacement Labrie Enviroquip Group recommends the filter elements be replaced as per pop up indicator (on the filter) or every 2500 hours of regular operational use. Examination of routine contamination is also recommended. Regular filter replacement done by qualified maintenance personnel helps to remove...

  • Page 43: Hydraulic Return Line Filter

    : The element must also be changed following a major hydraulic component failure. Please consider the following recommendations by Labrie Enviroquip Group when replacing your filters. In-Line Pressure Filter (2)

  • Page 44: Return Line Filter Element

    Pop-up indicator Return Line Filter Element : While every effort is made at the Labrie factory to ensure clean hydraulic systems, it should be noted that most hydraulic system manufacturers recommend the filter be replaced after a break-in period. Labrie’s recommendation is to replace this filter element after a break-in period of 50 hours of operational use.

  • Page 45: In-Line Pressure Filter

    In-Line Pressure Filter : Hydraulic system manufacturers recommend the first filter replacement be made after a break- in period. Labrie’s recommendation is to replace the filter elements after a break-in period of 50 hours of operational use. In-Line Pressure Filter Replacement Procedure Follow this procedure to replace in-line pressure filters (see Figure 3-6): SWITCH OFF the hydraulic system.

  • Page 46: Lubricating

    To ensure proper operation of the system, never let the grease fall below the minimum level as indicated on the grease reservoir. Labrie recommends that the grease reservoir be filled with OEM- recommended grease. You may order this product and system parts from Labrie by contacting our Parts Department toll free at 1 (800) 231-2771 in the U.S.
  • Page 47 Maintenance 37 Figure 3-9 Lube points on body : Figure 3-9 represents the Alley-Gator with the standard arm. For lube points on the optional Right-Hand arm, see Figure 3-10 Figure 3-10 Lube points on optional Right-Hand arm...

  • Page 48: Recommended Maintenance Schedule

    38 Maintenance Recommended Maintenance Schedule Table 1 Lubrication Description Schedule (Performer) Tailgate hinge pins (2) Biweekly (optional) Tailgate cylinder pins (4) Biweekly (optional) Latch pins (2) Biweekly (optional) Rear body hinge pins (2) Biweekly (optional) Inspect hydraulic oil level in Daily (optional) tank Manual greasing system...
  • Page 49 Maintenance 39 Table 2 Cleaning (cont’d) Description Schedule (Performer) Clear debris on lift (if any) At landfill (operator) Wash complete body and Weekly (operator) chassis (more often if required) Other As specified by FMCSR and/or owner Table 3 Mechanical inspection (performed when truck is at rest or stopped) - cont’d Description Schedule (Performer) IMPORTANT: Inspect for distortion, cracks and/or unusual wear.
  • Page 50 40 Maintenance Table 3 Mechanical inspection (performed when truck is at rest or stopped) - cont’d Description Schedule (Performer) Exterior of hopper and main body walls, Pre-trip (operator), monthly (maintenance) floor & roof Hopper cover assembly (optional, if Pre-trip (operator), monthly (maintenance) equipped) Hopper cover cylinder pins, ears, and Pre-trip (operator), monthly (maintenance)
  • Page 51 Maintenance 41 Table 4 Operation (main controls) - cont’d Description Schedule (Performer) Pendulum pack/return/autopack/ Monthly (maintenance) autostop (check stall warning light function) Hopper cover open/close (optional, if Daily (operator) equipped) Tailgate open/close Daily (operator) Body raised up/down Daily (operator) IMPORTANT: Perform safety lockout tests to check limit and proximity switches Access ladder test (access ladder Daily (operator) proximity switch) [optional, if...
  • Page 52 42 Maintenance Table 5 Operation (misc. controls and features) - cont’d Description Schedule (Performer) IMPORTANT: Check external lights and miscellaneous are functioning Stop, signal and tail lights Pre-trip (operator), daily (optional) Marker lights Pre-trip (operator), daily (optional) Hopper light Pre-trip (operator), daily (optional) Lift light Pre-trip (operator), daily (optional) Backup lights...
  • Page 53 Maintenance 43 Table 6 Hydraulic systems (cont’d) Description Schedule (Performer) Clean the breather cap (replace if Monthly (maintenance) necessary) [more often if required] IMPORTANT: To protect the hydraulic components of your new equipment, the return line filter and in-line pressure filter must be changed after the first 50 hours of use. Thereupon, the filters should be changed once every 2500 hours or as per “pop-up”...

  • Page 54: More Notes On Lubrication

    The oil identification tag located on the hydraulic oil tank specifies the manufacturer’s brand of oil that was filled at the Labrie factory. Equivalent oil by other manufacturers may also meet your application requirements. Labrie Enviroquip Group recommends that you refer to the guidelines on page 31 and consult the oil manufacturer to ensure that your needs are fulfilled.

  • Page 55: Electrical System Components

    Maintenance 45 Electrical System Components Auto-Reset Circuit Breakers Power for the Alley-Gator Right-Hand ASL electrical system is protected by various replaceable automotive type fuses located in the inside junction box. The circuit breakers are mounted on the side of the relay box (see Figure 3-12). Figure 3-12 Auto-reset circuit breakers For lights...

  • Page 56: Relay Box

    46 Maintenance Relay Box The relay box is located in the cab of the vehicle (see Figure 3-14). The box interior consists of a series of relays, fuses, and connectors that supply the electrical systems for the Alley-Gator Right- Hand Relays: A relay is a series of switches influenced by a common coil but controlled from a remote location, such as a limit switch or proximity switch.

  • Page 57: Valve Solenoids

    Basic lighting requirements in accordance with FMVSS are fitted as standard equipment to your Alley-Gator Right-Hand ASL. However there are many additional options available that may be added to your vehicle. Consult with the OEM/Labrie Enviroquip Group for more information.

  • Page 58: Joystick

    48 Maintenance Figure 3-18 Rear view camera Joystick The electronic joystick is used to control all slide, arm and grabber functions. The slide and arm functions are variable for speed and control. The grab and release thumbswitches are on-off only switches located on the top of the control lever.

  • Page 59: Proximity And Limit Switches

    Maintenance 49 Proximity and Limit Switches Proximity and limit switches act as remote electrical on/off switches and must be adjusted properly. Figure 3-20 and Figure 3-21 show the location of the proximity/limit switches that are usually installed on the Alley-Gator Right-Hand .

  • Page 60: Limit Switch Adjustment

    50 Maintenance Limit Switch Adjustment The following is the general procedure for adjusting all the limit switches used on the A LLEY ATOR , except for the mid-height limit switch, which calls for a different method of IGHT adjustment. : All limit switches MUST be working at all times. Otherwise, the operator may not be aware that the arm is not fully retracted or that the grabber is open or closed.

  • Page 61: Access Ladder Extension Proximity Switch (Optional)

    Maintenance 51 If adjustment of a shielded proximity switch fails to correct the switch function, the switch shielding may have failed. This cannot be repaired and the switch must be replaced. Refer to pages regarding proper adjustment procedures for each individual switch. : Proximity switches MUST function properly.
  • Page 62 52 Maintenance Figure 3-22 Access ladder proximity switch: ladder in “home” position, left; ladder in deployed position, right How to Adjust To adjust the access ladder proximity switch: RETURN ladder to “home” position. COMPLETE lockout/tagout procedure (see Lockout/Tagout Procedure on page 20). LOOSEN the proximity switch mounting nuts.

  • Page 63: Arm Mid-Height Limit Switches (2)

    Maintenance 53 Arm Mid-Height Limit Switches (2) Both arm mid-height limit switches have two functions: The lower switch allows the gripper to open when the arm is lower than the mid-height sensor and activates the gripper automatic close function when the arm is higher than the sensor. The higher switch is used as a trigger for the camera auto-switching function when there are cameras on the right-hand wall and inside the hopper.
  • Page 64 54 Maintenance Figure 3-24 Arm stowed limit switches These limit switches are located behind each of the gripper fingers (one for each finger). How to Adjust To adjust the arm stowed limit switches: Park the vehicle on safe level ground. Fully open the gripper and retract the arm alongside the body.

  • Page 65: Pendulum Proximity Switches

    Maintenance 55 Repeat the procedure until both limit switches are properly adjusted. Danger! All limit switches 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. This may cause accidents, injuries and/or property damage.
  • Page 66 56 Maintenance  The return proximity switch is triggered by a tab mounted to the pendulum arm pivot. When the pendulum travels to the front of the hopper bowl, the tab ACTIVATES the proximity switch and the contacts close. This SENDS a signal to the control module, which then sends a signal to the pendulum to BEGIN the RETURN sweep.

  • Page 67: Tailgate Unlocked Proximity Switch

    Maintenance 57 Note that the proximity switch indicator light will be ON. ENSURE the proximity switch gap is approximately ¼". TIGHTEN the proximity switch mounting nuts. INITIATE an AUTOPACK cycle and observe the sweep of the pendulum. If no more adjustment is needed put back the protective cover. Figure 3-28 Return proximity switch and tab In the PACK MODE, the pendulum should complete a full sweep and enter the body chamber by...
  • Page 68 58 Maintenance 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 triggers the tailgate unlocked warning message on the MDM display screen (see Figure 2-15) and the warning buzzer inside the cab.
  • Page 69 Maintenance 59 To adjust the tailgate unlocked proximity switch: RELIEVE pressure on the tailgate pins by pressing the lower part of the “Rear Door” button on the MDM module. Do not forget to press the “Doors Enable” button at the same time. REMOVE both tailgate pins (see Figure 3-31).

  • Page 70: Body Raised Proximity Switch

    60 Maintenance Body Raised Proximity Switch The body raised proximity switch is center mounted on the curbside chassis frame rail. Figure 3-33 Body raised proximity switch The body raised proximity switch is not ACTIVATED when the main seal of the body loses contact with the chassis.

  • Page 71: Hopper Cover Proximity Switch (Optional)

    Maintenance 61 Hopper Cover Proximity Switch (optional) This is an optional switch and may not be mounted on your vehicle, otherwise the hopper cover proximity switch is mounted on the body roof next to the hopper cover cylinder. Figure 3-34 Hopper cover proximity switch The hopper cover proximity switch disables the lift from proceeding in an upward motion should the hopper cover not be completely open.

  • Page 72: Joystick

    62 Maintenance Figure 3-35 Crusher panel up proximity switch How to Adjust : The crusher panel has to be lowered to access this proximity switch. To adjust the crusher panel up proximity switch: Fully LOWER the crusher panel. COMPLETE the Lockout/Tagout Procedure (refer to “Lockout/Tagout Procedure” on page 20).

  • Page 73: Valve Bank

    Maintenance 63 Figure 3-36 Joystick Release Grab Valve Bank The hydraulic valve bank is controlled by proportional solenoids. The main body valve (see Figure 3-37) is equipped with proportional solenoids. These solenoids are activated through the control module. The packer valve section (see Figure 3-37) is fitted with solenoids that are electrically activated by two proximity switches mounted to the body via the control module.

  • Page 74: Temperature Sending Unit (Optional)

    64 Maintenance Temperature Sending Unit (optional) If a temperature sending unit is installed on the hydraulic oil tank (see Figure 3-38), oil temperature can be monitored by the IQAN. When the temperature reaches 200°F (93.33°C), a corresponding warning message appears on the MDM display screen. Figure 3-38 Temperature sending unit Temperature...

  • Page 75: Hour Meter

    : Tampering with the hour meter WILL VOID WARRANTY. Lighting & Camera Equipment Please note that there are numerous lighting and camera options available for your Alley-Gator Right- Hand . Please consult with the chassis dealer/Labrie for further recommendations, additions and technical data. Figure 3-40 Arm/hopper lights...

  • Page 76: Hydraulic System

    66 Maintenance Use caution as human skin can be easily penetrated by high pressure oil (2000 psi and above). : Exercise stringent equipment support procedures when servicing hydraulic systems. Be cautious to overhead dangers. Danger! Failure to comply with safety precautions and safety procedures may result in serious injury or death.

  • Page 77: Pressure And Cycle Time Chart - Packer Circuit

    Maintenance 67 Pressure and Cycle Time Chart - Packer Circuit Cycle Cycle Engine Time Time Function Pressure Setting (sec.) (sec.) MIN. MAX. Relief on pump manifold 3000 ± 50 PSI Relief on packer valve 2700 ± 50 PSI Complete packer cycle System pressure Packer counterbalance valve See procedure on...

  • Page 78: Pressure And Cycle Time Chart - Right-Hand Arm Circuit

    68 Maintenance Cycle Cycle Engine Time Time Function Pressure Setting (sec.) (sec.) MIN. MAX. Top door close pressure limiter 1400 ± 50 PSI Crusher panel up / top door 3350 ± 50 PSI - non open relief adjustable Crusher panel down / top door 3350 ±...

  • Page 79: Hydraulic Hose

    SAME SAE rating as identified on the original hose. Detailed hydraulic hose information is provided by the LabriePlus Parts Department. Please contact Labrie for further hose descriptions and coupling guidelines when selecting replacement hoses for the Alley-Gator Right-Hand hydraulic system.

  • Page 80: Pto-Driven Or Front-Mounted Pump

    General PTO Safety Information : Labrie Enviroquip Group has given careful consideration to your operational needs and the importance of properly matching the vehicle transmission and auxiliary equipment to the correct PTO. If your Alley-Gator Right-Hand is PTO equipped, it has been fitted with either a Chelsea or Muncie PTO.

  • Page 81: Hydraulic Vane Pump

    Maintenance 71 Carefully refer to your Chelsea or Muncie owner’s manuals, service manuals and/or other instructions provided with your Alley-Gator Right-Hand . Always follow proper installing, operating and repairing procedures. Only use proper components in application for which they are approved.

  • Page 82: Arm And Body Directional Control Valve

    72 Maintenance the signal to the hydraulic pump to supply hydraulic fluid to the hydraulic system. The packer directional control valve also houses a relief valve that is located in the subplate manifold. This relief valve limits the pressure of the packer system. Arm and Body Directional Control Valve The arm and body directional control valve is mounted to the chassis frame in front of the hopper bowl.

  • Page 83: Hydraulic Pressure Adjustments

    Maintenance 73 Hydraulic Pressure Adjustments Main Valve Standby Pressure Adjustment Adjustments to the main (arm and body) valve system pressure must be performed by qualified MPORTANT maintenance personnel only. Improper procedure or exceeding correct pressure setting can cause equipment failure/damage, injury or death. : Prior to adjusting the hydraulic arm and body circuit pressures, maintenance personnel must first ensure that the standby pressure is 250 psi.

  • Page 84: Arm & Body Circuit Hydraulic Pressure Adjustments

    74 Maintenance Arm & Body Circuit Hydraulic Pressure Adjustments To adjust the arm and body circuit hydraulic pressure: ENSURE the pressure gauge is in the pressure test port of the directional control valve (see Figure 3-44). While the engine is running and the pump is ON, OPERATE the tailgate circuit to the fully closed position by pushing the tailgate lever.
  • Page 85 Maintenance 75 TURN the tailgate relief valve adjustment screw clockwise until it stops using an Allen key. Figure 3-46 Main relief valve - arm and body directional control valve Figure 3-47 Tailgate section front relief valve Move lever outward REDUCE arm and body pump pressure to minimum using the main relief valve (see Figure 3-48).
  • Page 86 76 Maintenance Figure 3-48 Main relief valve on arm & body pump Once the pressure of the main relief valve on the arm and body pump has been properly set, ADJUST the main relief valve pressure on the main (arm and body) valve (see Figure 3-46). To do so: Using an Allen key TURN the adjustment screw COUNTER-CLOCKWISE until the 10 a.

  • Page 87: Packer Circuit Hydraulic Pressure Adjustment

    Maintenance 77 Figure 3-50 Tailgate section lever Move lever inward Once done, TIGHTEN BACK the locknut. PROCEED with the pressure adjustment on the remaining working sections of the arm and body directional control valve. For each remaining working section, do the following: LOOSEN the locknut of the front relief valve.
  • Page 88 78 Maintenance While the packer is moving, check on the gauge : it should read 2700 psi. Figure 3-51 Test port If adjustment is required, it is performed simultaneously as described: : Two people are needed to make this adjustment correctly. ENSURE the pump is disengaged and the engine is OFF.
  • Page 89 Maintenance 79 Figure 3-53 Main relief valve on packer pump Once the pressure of the packer pump relief valve has been properly set, ADJUST the relief valve pressure on the packer valve (see Figure 3-52). To do so: Using an Allen key TURN the adjustment screw COUNTER-CLOCKWISE until the 9 a.

  • Page 90: Working Sections Of The Arm & Body Directional Control Valve

    80 Maintenance Working Sections of the Arm & Body Directional Control Valve The directional control valve consists of working sections, each individually devoted to two hydraulic functions (Figures 3-56 and 3-57). Each section has outlet ports with secondary relief valves, each one functioning with different working pressures.

  • Page 91: Slide Work Circuit

    Maintenance 81 Pressure adjustments to the system must be performed by qualified maintenance personnel only. MPORTANT Slide Work Circuit The slide work circuit (see Figure 3-54) consists of one double acting cylinder, one valve bank section with proportional solenoid and two secondary port relief valves. Pressure Settings Slide IN 2000 psi...

  • Page 92: Tailgate Work Circuit

    82 Maintenance Tailgate Work Circuit The tailgate work circuit (see Figure 3-55) consists of two double acting hydraulic cylinders, one valve bank section with on/off solenoid, two pilot operated check valves and two secondary port relief valves. Pressure Settings Tailgate UP 2500 psi Tailgate DOWN 2500 psi...

  • Page 93: Bleeding Air Out Of The Lifting Arm Hydraulic Circuit

    Maintenance 83 Bleeding Air Out of the Lifting Arm Hydraulic Circuit When replacing a hydraulic cylinder, a holding valve, or when opening the Right Hand™ hydraulic circuit, air may enter the hoses located between the arm and body directional control valve and the arm cylinder.

  • Page 94: Hydraulic Safety Valves

    84 Maintenance Using the joystick or the lever on the arm and body directional control valve, fully EXTEND the gripper cylinders in order to close the fingers. As soon as a constant and uniform oil flow (without air bubbles) is leaking out, TIGHTEN the fitting.

  • Page 95: Adjusting Gripper Holding Valve Pressure

    Maintenance 85 Type of Movement Arm Type Movement Cushioning Effect Prevented Std & HD In/Out Cylinder Opening In - Adjustable (boom Extension) Out - non adjustable HD only Up Down Cylinder Closing Up/Down - Adjustable (gripper body lowering) Std & HD Gripper Cylinder Opening None...
  • Page 96 86 Maintenance This is the value that should be read when the gripper starts to move. : Pressure reading must be done independently for each side of the gripper (single/dual finger side). To do so, place one of the gripper cylinders in fully extended position and activate the lever on the arm and body directional control valve to initiate the closing movement of the other cylinder.

  • Page 97: Adjusting In/Out Holding Valve Pressure

    Maintenance 87 Adjusting In/Out Holding Valve Pressure : There is a holding valve mounted on the in/out cylinder (standard and HD). To adjust the in/out holding valve pressure: APPLY all safety measures to ensure safety around the vehicle at all times. MAKE SURE that the parking brake is applied.

  • Page 98: Adjusting Up/Down Holding Valve Pressure

    88 Maintenance Figure 3-61 Holding valve adjustment screw (in/out cylinder) Cushioning adjustment screw Holding valve adjustment screw : If the cushioning effect on the retraction stroke needs to be adjusted, simply turn the cushioning adjustment screw accordingly: clockwise to increase cushioning effect; counter- clockwise to reduce it.
  • Page 99 Maintenance 89 Figure 3-62 Pressure test port START the engine and ENGAGE the hydraulic pump. Using a lever on the valve, manually RAISE the Right Hand™ arm gradually. If the gauge does not indicate a pressure of about 700 psi when the automated arm starts going down, ADJUST the up/down holding valve adjustment screw to set the pressure properly.

  • Page 100: Adjusting Arm Speed

    90 Maintenance Adjusting Arm Speed : No arm speed adjustment is required unless replacing the valve or one of its sections. Arm speed is controlled by the amount of hydraulic fluid (flow) that is being sent to the arm cylinder. The arm control valve spools can limit the flow of hydraulic oil, depending on the section of the valve .

  • Page 101: Control Circuit

    Maintenance 91 Control Circuit The control circuit allows maintenance personnel to check and adjust the system pressure at different points along the circuit. The following items can be checked and adjusted:  Standby pressure  Arm pump pressure  Packer pump pressure Adjusting Standby Pressure To adjust the standby pressure, proceed this way: INSERT a 0-3000 psi gauge into the P2 port (see Figure 3-65).

  • Page 102: Adjusting Packer Pump Pressure

    92 Maintenance Figure 3-66 Arm pump pressure adjustment Adjustment capscrew P2 Port Adjusting Packer Pump Pressure To adjust the packer pump pressure: INSERT a 0-3000 psi gauge into the P1 port (see Figure 3-67). With the pump on and the packer function stroked to the full up position, SET pressure to 3000 psi by turning the adjustment capscrew clockwise or counter-clockwise depending on the gauge reading (see Figure 3-67).

  • Page 103: Adjusting Packer Counter Balance Valve

    Maintenance 93 Adjusting Packer Counter Balance Valve To adjust the packer counter balance valve, do the following: ACTIVATE the packer retract let-off switch. SCREW IN the counter balance valve until the packer drifts down. BACK OUT the valve until the packer maintains full up position. Figure 3-68 Packer counter balance valve Adjusting Packer Choke Valve...
  • Page 104 94 Maintenance Figure 3-69 Packer choke valve (w/ cap - w/o cap) Valve Adjustment with cap screw...

  • Page 105: Hydraulic System Schematic

    Maintenance 95 Hydraulic System Schematic...

  • Page 106: Troubleshooting Methodology

    96 Maintenance Troubleshooting Methodology Troubleshooting is an organized study of the problem and a planned method of investigation and correction. Think about the following before proceeding: What were the warning signs prior to failure? Do not rule out previous failed attempts. Ensure components and wiring are installed as per factory specs.
  • Page 108 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: 1-920-233-2770 Telephone: 1-418-831-8250 General Fax: 1-920-232-2496 Service Fax: 1-418-831-1673 Sales Fax: 1-920-232-2498 Parts Fax: 1-418-831-7561 Mailing Address Mailing Address...

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