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Labrie EXPERT 2000 Maintenance Manual

Cool-hand
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EXPERT 2000
Cool-Hand
Maintenance Manual
www.labriegroup.com

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Summary of Contents for Labrie EXPERT 2000

  • Page 1 EXPERT 2000 Cool-Hand Maintenance Manual www.labriegroup.com...
  • Page 2 Thank you for your purchase of a new Labrie , Leach or Wittke product. To ensure maximum reliability, insist on genuine replacement parts. LabriePlus replacement parts are designed and manufactured to exacting standards. The use of counterfeit, will-fit or substitute parts may effect the operation and performance of the unit.
  • Page 3 CAPSCREW MARKING AND TORQUE VALUES Usage Much Used Used at Times Used at Times Capscrew Diameter - 120,000 - 140,000 150,000 & Minimum Tensile To 1 - 115,000 - 133,000 Strength PSI Quality of Material Min. Commercial Med. Commercial Best Commercial SAE Grade Number 6 or 7 CAPSCREW HEAD MARKINGS...
  • Page 4 13-3 COOL HAND AUTOMATED ARM EXPERT 2000 Table of contents 13.0 COOL HAND AUTOMATED ARM MAINTENANCE ........13 - 7 13.1 HYDRAULIC SYSTEM ................... 13 - 7 13.1.1 GENERAL DESCRIPTION ..................13 - 7 13.1.2 TANDEM PUMP ...................... 13 - 8 13.1.3 VANE PUMP ......................
  • Page 5 13-5 COOL HAND AUTOMATED ARM EXPERT 2000 Table of contents 13.4 TROUBLESHOOTING GUIDE ................13 - 36 13.4.1 COOL HAND TROUBLESHOOTING ..............13 - 36 13.4.2 PROXIMITY SWITCH SIGNAL CHECKING PROCEDURE ......13 - 38 13.5 HYDRAULIC SCHEMATICS (Arm section) ............13 - 39 13.6...
  • Page 6 13-6 EXPERT 2000...
  • Page 7 This section will show how to adjust the hydraulic pressure of the arm and to calibrate cushioning system. At the end of the section, you will find a troubleshooting section, which if combined to the Expert 2000 Troubleshooting section, will help resolve most of the commonly seen problems on that type of unit.
  • Page 8 13-8 13.1.2 TANDEM PUMP The automated version of the Expert 2000 is equipped with a tandem pump (figure 13.3). The tandem pump is made of two separate sections: The vane pump and the piston pump with variable flow. The vane pump section powers all the body functions such as the tailgate, the body hoist, the packer and the crusher panel.
  • Page 9 13-9 13.1.3 VANE PUMP Dump valve Since the pump is connected directly to the engine, it is constantly turning and pumping hydraulic oil. In order to control the hydraulic flow, a dump valve mounted on the pump (figure 13.4) is either used to send the fluid to the body hydraulic system or sent back to the tank.
  • Page 10 PURPOSES ONLY. the proportional valve, the pump switch must be turned “ON” and the joystick moved out from its center position. Arm control valve Outer boom coil (Proportional) Grabber (On/Off) Manual control levers Inner boom coil (Proportional) FIGURE 13.7 EXPERT 2000...
  • Page 11 13-11 13.1.5 PRESSURIZED TANK To ensure proper fluid supply to the pump and to prevent cavitation in the hydraulic system, air pressure of 3 to 3.5 PSI is applied to the hydraulic tank. The cavitation is defined as the formation of air pockets in a moving fluid. The presence of air in the hydraulic oil produces cavitation inside the pump, generating 5 PSI RELIEF...
  • Page 12 For any other problem with the pump, FOUND. IF THE UNIT HAS TO BE refer to section 3.3 “Troubleshooting DRIVEN AWAY FOR REPAIRS ON guide. THE HYDRAULIC SYSTEM, REMOVE THE DRIVE SHAFT BETWEEN THE ENGINE AND THE PUMP BEFORE RESTARTING THE ENGINE. EXPERT 2000...
  • Page 13 13-13 13.1.7 PUMP EMERGENCY SHUTDOWN If a major problem occurs with the arm or the hydraulic system, or in the case of hydraulic hose failure, apply the following procedure: PUMP EMERGENCY SHUTDOWN PROCEDURE Press on the nearest Emergency Stop Button (figure 13.13). EMERGENCY STOP BUTTON Turn the pump switch “OFF”...
  • Page 14 12. Before putting the vehicle back in service, recalibrate the system pressure according to section 13.2 “Hydraulic pressure adjustment”. EXPERT 2000...
  • Page 15 13-15 13.2 HYDRAULIC PRESSURE ADJUSTMENT VANE PUMP RELIEF VALVE 13.2.1 VANE PUMP RELIEF VALVE ADJUSTMENT The tandem pump has its own relief valve (figure 13.16). The pressure chart below gives the proper adjustment pressure of both 22 and 29/34 cubic yard bodies. Use this chart to adjust the relief of the pump and the body function valve.
  • Page 16 Adjust the relief valve of the vane pump (figure 13.20) according to the pressure chart. VANE PUMP When the vane pump is adjusted to RELIEF VALVE the proper pressure, calibrate the relief of the body function valve according to the pressure chart. FIGURE 13.20 EXPERT 2000...
  • Page 17 13-17 13.2.2 PISTON PUMP ADJUSTMENT As described in section 13.1.3, the piston pump delivers its flow only on demand (when the joystick is moved). The compensator, located on the pump (figure 13.22), controls both the pressure output and the load sensing system of the piston pump.
  • Page 18 Note: If the arm is moving erratically or 11. Verify that the arm is working properly intermittently, the presence of air in the system with the manual levers on the valve. may be the cause. EXPERT 2000...
  • Page 19 13-19 13.2.4 PISTON PUMP PRESSURE COMPENSATOR ADJUSTMENT Apply the following procedure to calibrate the piston pump pressure. COMPENSATOR ADJUSTMENT PROCEDURE Apply the lockout / tagout procedure. COMPENSATOR ADJUSTMENT SCREW Secure the area around the path of the arm. FIGURE 13.25 Remove all residual hydraulic pressure by moving the levers back and forth.
  • Page 20 * The calibration of the main relief valve requires a flow meter. It is not recommended to adjust it since the calibration was done by the manufacturer of the valve. ** Add 1/4 of turn to the adjustment screw EXPERT 2000...
  • Page 21 13-21 13.2.6 GRABBER PRESSURE 13.2.7 CYLINDER CUSHION ADJUSTMENT ADJUSTMENT The inner and outer boom cylinders are both GRABBER RELIEF VALVE cushioned on their extension and retraction ADJUSTMENT PROCEDURE strokes. The cushioning system slows down the speed of the cylinder at the end of the Fully extend the arm.
  • Page 22 DO NOT STAND DIRECTLY IN THE PATH WHILE CARRYING THESE ADJUSTMENTS. The word “extension” and “retraction” refer only to the cylinder movement and not the movement of the arm itself. FIGURE 13.29 OUTER BOOM EXTEND* ........(Dx3) OUTER BOOM RETRACT* ........ (Dx4) EXPERT 2000...
  • Page 23 13-23 Inner boom retract Inner boom extend (Proximity switch #1) (Proximity switch #2) Dx2=18” 3/4 Dx1 = 4” 1/8 Inner boom cylinder inner boom cylinder FIGURE 13.30 FIGURE 13.31 Outer boom retract Outer boom extend (Proximity switch #4) (Proximity switch #3) Outer boom Outer boom cylinder...
  • Page 24 Increasing the amount of cushion will result in reducing the speed of the arm in the cushion range. Decreasing the amount of cushion will result in faster arm speed in the cushion range. EXPERT 2000...
  • Page 25 13-25 OUTER BOOM INNER BOOM EXTENSION RETRACTION INCREASE CUSHION (PROX. #4) (PROX #2) DECREASE CUSHION DECREASE CUSHION INCREASE CUSHION RETRACTION EXTENSION (PROX #3) (PROX #1) ADJUSTMENT SCREW CUSHIONING MODULE SIDE VIEW FRONT VIEW Part #ELC12000 FIGURE 13.34 REST POSITION IN HOPPER SECTION INNER BOOM DOWN (Joystick @ 12 O’clock) OUTER BOOM...
  • Page 26 APPLY THE “LOCKOUT/TAGOUT” the amount of oil (flow) going through them. PROCEDURE AT ALL TIMES. Controlling the flow of oil means controlling the speed of the arm. DANGER DO NOT STAND DIRECTLY IN THE PATH WHILE CARRYING THESE ADJUSTMENTS. EXPERT 2000...
  • Page 27 13-27 13.2.9 OUTER BOOM RESTRICTOR RESTRICTOR ADJUSTMENT ADJUSTMENT PROCEDURE The outer boom cylinder is equipped with an adjustable restrictor on the rod side (extension). Secure the area around the path of the arm. The restrictor (figure 13.37) prevents the weight of the arm to pull the cylinder faster Engine at idle speed: 750-800 RPM.
  • Page 28 450 lbs to the grabber and check if the inner boom goes further down. If the inner boom falls, loosen the adjustment screw until it stops. Once properly adjusted tighten the locknut of the adjustment screw. EXPERT 2000...
  • Page 29 13-29 13.2.11 GRABBER LOCK VALVE DANGER ADJUSTMENT The purpose of this lock valve is to lock the oil APPLY THE “LOCKOUT/TAGOUT” inside the cylinder so no oil can come out on PROCEDURE AT ALL TIMES. either side of it. This situation will remain until enough flow or pressure is sent in again to move the cylinder.
  • Page 30 DO NOT EXCEED A PRESSURE OF 5 PSI WHEN ADJUSTING THE AIR 5 PSI RELIEF REGULATOR. KEEP THE SAFETY VALVE VALVE AND THE FILLER CAP CLEAN AND TAKE EXTREME PRECAUTION WHEN OPENING THE FIGURE 13.43 FILLER CAP. PRESSURE REGULATOR PRESSURE GAGE FIGURE 13.44 EXPERT 2000...
  • Page 31 (figure 13.46). The automated side loader units use the same electrical system for the body and cab controls For every truck configuration, a different as the standard Expert 2000 unit, except the schematic is being used. Therefore, the electrical wiring auto-neutral...
  • Page 32 Allison ECU and verify if the signals are properly reaching the computer and verify the fault code. To tap onto FIGURE 13.47 the ECU, Labrie uses the following wires on the Allison connector: INPUT: OUTPUT:...
  • Page 33 13-33 13.3.4 AUTO-NEUTRAL SYSTEM Pressure switches (figure 13.48) are installed on the footbrake pedals. The one installed on The Auto-neutral switch allows the the right-hand side, is found in the cab behind transmission to shift from “DRIVE” to the pedal (figure 13.49). The one on the left- “NEUTRAL”...
  • Page 34 The pressure switch for (Auto-Neutral) the temporary handbrake (PNI00600) is fixed and it is set to operate at 55PSI. Pressure switch on the engine compartment PRESSURE SWITCH PRESSURE (Temporary handbrake light) SWITCH FIGURE 13.52 FIGURE 13.50 TEMPORARY HANDBRAKE PANEL FIGURE 13.51 EXPERT 2000...
  • Page 35 13-35 AUTO NEUTRAL TROUBLESHOOTING SCHEMATICS FIGURE 13.53 COOL HAND AUTOMATED ARM...
  • Page 36 This guide applies only to the Cool Hand section of the unit. For further information regarding the body or other problems that might occur, refer to the body troubleshooting guide found in section 3 of this manual or contact the Labrie Technical Support service.
  • Page 37 (Without Smart-Hand feature). 2. Power cables are cut off or 2. Check red wires (#158) on each defective. cushioning modules for 12 volts supply (Move joystick to get signals). 3. Faulty joystick. 3. Contact customer’s services at Labrie. COOL HAND AUTOMATED ARM...
  • Page 38 Wire #803 = PROX. #3 BLACK Identify, console, corresponding cushioning module for FIGURE 13.54 each proximity switches. Check each wires (figure 13.54) for proper ground signals. NOTE: For more details on the cushioning modules, refer to section 13.2.7 “Cylinder cushion adjustment”. EXPERT 2000...
  • Page 39 13-39 13.5 HYDRAULIC SCHEMATICS (Arm section) FIGURE 13.55 COOL HAND AUTOMATED ARM...
  • Page 40 CRUSHER PANEL QUICK CONNECT FOR PRESSURE GAUGE SOLENOID VALVE MAIN RELIEF VALVE 3000 PSI VELOCITY FUSE HOLDING VALVE TAILGATE WORK PORT RELIEF 1500 PSI VELOCITY FUSE WORK PORT RELIEF 1700 PSI QUICK CONNECT FOR TEST PORT TANK FIGURE 13.55 EXPERT 2000...
  • Page 41 13-41 PACKING CYLINDER PRESSURE TO DANFOSS VALVE BODY HOIST LOAD SENSING TO DANFOSS VALVE COOL HAND PUMP DOUBLE DENISON PUMP VENT VALVE COOL HAND AUTOMATED ARM...
  • Page 87 S E R V I C E P A R T S OUR OFFICE IN THE U.S. OUR OFFICE IN CANADA 1198 Shattuck Industrial Blvd. 455 1st Avenue LaFayette, GA 30728 Levis, QC G6W 5M6 Toll Free: 1-800-231-2771 Toll Free: 1-877-452-2743 Telephone: 1-706-591-8764 Customer Service: 1-877-452-2743 MAILING ADDRESS...