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Labrie Optimizer Maintenance Manual

Front loading refuse truck
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MAINTENANCE
MANUAL
RELEASE: February 2007
Part Number: 90313

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Summary of Contents for Labrie Optimizer

  • Page 1: Maintenance Manual

    MAINTENANCE MANUAL RELEASE: February 2007 Part Number: 90313...
  • Page 3 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 that you have a problem with a Labrie unit, you should contact your vendor first. He should be able to provide you with the proper help required (parts or technical advice).
  • Page 4 OPTIMIZER...
  • Page 5 Table of contents MAINTENANCE MANUAL ..................9 LUBRICATION ....................33 TROUBLESHOOTING SECTION ..............39 OPTIMIZER BODY PARTS ................49 HYDRAULIC SYSTEMS, PARTS AND DIAGRAMS ........... 65 BODY AIR SYSTEMS, PARTS AND DIAGRAMS ..........93 ELECTRICAL SYSTEMS DIAGRAMS AND PARTS .......... 99...

  • Page 6: Table Of Contents

    OPTIMIZER CHAPTER 1.0 Table of contents MAINTENANCE MANUAL ..................9 GENERAL SAFETY PRECAUTIONS ..............9 1.1.1 GENERAL PRECAUTION ..................9 1.1.2 SURFACE FINISHING AND PAINT ..............10 1.1.3 FIRE PROTECTION ..................10 1.1.4 LOCKOUT / TAGOUT PROCEDURE ..............10 1.1.5 SHUTDOWN PROCEDURE ................
  • Page 7 OPTIMIZER CHAPTER 1.0 Table of contents HYDRAULIC SYSTEM MAINTENANCE .............. 26 1.4.1 HYDRAULIC SYSTEM GENERAL INSPECTION ..........26 1.4.2 MAIN RELIEF VALVE PRESSURE ADJUSTMENT ..........26 1.4.3 HYDRAULIC DIRECTIONAL CONTROL VALVE ..........27 1.4.4 PRESSURE ADJUSTMENT PROCEDURE ............28 1.4.5 PUMP MAINTENANCE ..................

  • Page 9: Maintenance Manual

    QUALIFIED PERSONNEL WHO equipment, particular attention should be paid to ARE FAMILIAR WITH THIS the deterioration of structural components due to EQUIPMENT. LABRIE corrosion. Touch-ups or complete paint jobs ENVIRONMENTAL GROUP IS NOT should be done when necessary. RESPONSIBLE FAILURES RESULING OF REPAIRS PERFORM BY THE USER.

  • Page 10: Surface Finishing And Paint

    LOCKOUT / TAGOUT PROCEDURE - Battery It is the employer’s responsibility to follow and apply the “lockout / tagout procedure” for any inspection, repairs or maintenance being done on the vehicle, whether it is on the road or in the employer’s garage. OPTIMIZER...

  • Page 11: Shutdown Procedure

    1.1.5 SHUTDOWN PROCEDURE HYDRAULIC TANK Oil Gage When you park the vehicle for an extended Safety Valve (Temp/Level) period of time, follow the truck manufacturer Filler Cap requirements as well as your maintenance requirements and ensure of the following: SHUT DOWN PROCEDURE •...

  • Page 12: Hydraulic Filter First Replacement

    The packer will not work properly if hopper door. the waste accumulates in this area, it could even • Back in the cab, turn on the engine cause severe damage to the packer and other and the hydraulic system. adjacent systems. OPTIMIZER...

  • Page 13: Body Hoisting

    HOPPER CLEANING PROCEDURE DANGER (cont’d) ALWAYS USE THE SAFETY • Press and hold the yellow button on PROPS WHEN RAISING THE the console to retract the packer to BODY. FAILURE TO DO SO WILL its home position. RESULT IN SERIOUS INJURIES OR EVEN DEATH.
  • Page 14 NEVER GO UNDER THE BODY WHEN THE SAFETY PROPS ARE NOT INSTALLED. FAILURE TO DO SO WILL RESULT IN SERIOUS INJURIES OR EVEN DEATH. USE THE PUT THE BODY PUMP LEVER SAFETY TO LIFT THE PROPS IN BODY PLACE SAFETY PROPS LOCKING PIN OPTIMIZER...

  • Page 15: Propping Procedures

    1.1.10 PROPPING PROCEDURES CLEANING BEHIND THE PACKER BLADE DANGER 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 WORK TOWARDS THE FRONT) TO GET ON THE ROOF OR TO WORK ON HIGHER PARTS...

  • Page 16: Packing System Maintenance

    MAINTENANCE INSTALLATION PROCEDURE 1.2.1 PACKING SYSTEM GENERAL • Start engine. MAINTENANCE • Remove tailgate safety pins. The OPTIMIZER packing system has an heavy duty guiding system using special • Ensure nobody is behind the hardened steel wear plates. However, vehicle.
  • Page 17 1.2.2 PROXIMITY LIMIT SWITCHES ADJUSTMENT (continued) ADJUSTING THE PROXIMITY SWITCHES DANGER • Move the packer blade about 1 inch back from the fully extended position. APPROPRIATE LOCKOUT/TAGOUT PROCEDURE • Adjust the proximity switch #1 so it AT ALL TIMES (SECTION 1.1.4). is “active”...

  • Page 18: Packer Blade Wear Plates Replacement

    (Figure #1.6). • Verify corresponding wear plates under guiding tracks (Figure #1.7). • Install new packer blade wear plates on packer blade FIGURE #1.6 • Reinstall packer blade on unit (refer to packer blade removal procedure, Sec. 1.2.5). OPTIMIZER...

  • Page 19: Body Guide Wear Plates Replacement

    1.2.4 BODY GUIDE WEAR PLATES BODY GUIDE WEAR PLATES REPLACEMENT DANGER APPROPRIATE LOCKOUT/TAGOUT PROCEDURE AT ALL TIMES (SECTION 1.1.4). 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.

  • Page 20: Packer Blade Removal Procedure

    #1.8). • Retract cylinders. • Pull packer out of the body with lifting device (Figure #1.9). REAR PINS DANGER FIGURE #1.8 APPROPRIATE LOCKOUT/TAGOUT PROCEDURE AT ALL TIMES (SECTION 1.1.4). PACKER AT THE REAR END OF THE BODY FIGURE #1.9 OPTIMIZER...

  • Page 21: Packer Cylinders Replacement

    1.2.6 PACKER CYLINDERS REPLACEMENT 1.2.7 LUBRICATION OF PACKING SYSTEM CAUTION CAUTION SUPPORT THE CYLINDER TO BE BECAUSE OF IT’S FREQUENT REMOVED WITH PROPER USE, THE PACKER IT'S LIFTING DEVICE. ACCESSORIES MUST LUBRICATED EVERY WORKING DAY. PACKER CYLINDER REPLACEMENT PROCEDURE Refer to the chapter 5 on lubrication for: •...

  • Page 22: Tailgate System And Body Hinges Maintenance

    TAILGATE LOCKING MECHANISM DANGER FREQUENTLY VERIFY THAT THE RETAINING RINGS (FIGURE #1.12) ARE IN PLACE TO AVOID ACCIDENTAL DROPPING OF THE TAILGATE. Tailgate locking mechanism Locking Tailgate lock pins mechanism Retaining ring Safety lock pin FIGURE #1.11 FIGURE #1.12 OPTIMIZER...

  • Page 23: Tailgate Seal And Hinges Inspection

    1.3.2 TAILGATE SEAL AND HINGES 1.3.4 PROXIMITY SWITCHES ON TAILGATE INSPECTION The unit has a proximity switch that activates The hinge pins must not have any signs of the back-up alarm and a warning buzzer excessive wear or metal fatigue. The retaining (inside the cab) to tell the operator that the bolts must be kept tight (Figure #1.15).

  • Page 24: Hopper Door Sensor

    (on right-hand side). If the forks are not fold when the arms are raising and reaching a certain point, the Forks Overhead warning light comes ON on the dashboard. OPTIMIZER...

  • Page 25: Arms Partly Raised Proximity Switch

    1.3.8 ARMS PARTLY RAISED PROXIMITY CAUTION SWITCH Some units are equipped with a proximity MAKE SURE THAT ALL THE switch that allows the operator to raised the PROXIMITY SWITCHES ARE arms when the packer is retracting. If the WELL ADJUSTED AND THAT packer is not completely retracted when the THEY ARE WORKING arms pass in front of the proximity switch, the...

  • Page 26: Hydraulic System Maintenance

    CAUTION • The suction valve on the reservoir must be fully open (Figure #1.1) ADJUSTING THE MAIN RELIEF before starting the engine; VALVE AT HIGHER PRESSURE THAN 2500 PSI WILL CREATE EXTENSIVE DAMAGE AND VOID MANUFACTURER’S WARRANTY. OPTIMIZER...

  • Page 27: Hydraulic Directional Control Valve

    HYDRAULIC DIRECTIONAL CONTROL Arm: 4 ways, 3 positions, operated with an air VALVE actuator. The OPTIMIZER is equipped with a Parker Packer: 4 ways, 3 positions, operated with directional control valve, model VG-35. The an air actuator. hydraulic valve controlling all the functions of...

  • Page 28: Pressure Adjustment Procedure

    1.4.4 PRESSURE ADJUSTMENT 1.4.5 PUMP MAINTENANCE PROCEDURE The hydraulic pump on the OPTIMIZER PRESSURE ADJUSTMENT a gear pump type equipped with a Muncie PROCEDURE live pack pump (Figure #1.18). • Install a 3000PSI pressure gauge on the quick coupling found on the If the pump is properly maintained, it will main valve (Figure #1.17).

  • Page 29: Hydraulic Cylinders Inspection Procedures

    1.4.6 HYDRAULIC CYLINDERS INSPECTION 1.4.7 HYDRAULIC RESERVOIR INSPECTION PROCEDURES PROCEDURE To maintain proper working order and prolonged Verify that the oil in the reservoir is clean and cylinder performance, it is essential to inspect always at the proper level. them at least once a week as recommended. HYDRAULIC RESERVOIR Verify that all the connections of the flexible MAINTENANCE PROCEDURE...

  • Page 30: Hydraulic Fluid Replacement Procedure

    1. Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes (refer to the section 1.1.4 “Lockout/Tagout FIGURE # 1.19 procedure”). 2. Start the engine, engage the hydraulic pump and disable the speed-up system. OPTIMIZER...
  • Page 31 HYDRAULIC OIL 13. The oil must be clean and free of REPLACEMENT PROCEDURE (Cont’d) any dirt, metallic particles or sand etc.) The use of a filtering screen is strongly recommended while filling 10. Clean inside the hydraulic tank the tank with new oil. with a clean and dry cloth in order to remove any metal particles or debris 14.

  • Page 32: Hydraulic Filter Replacement Procedure

    2 gallons of oil • Refer to hydraulic fluid replacement approximately. An in-tank return procedure for filling the tank back filter system has a self-closing valve preventing the whole tank to empty itself through the return filter core. OPTIMIZER...

  • Page 33: Tailgate Hydraulic System Maintenance

    1.4.11 TAILGATE HYDRAULIC SYSTEM 1.4.12 BODY HOISTING SYSTEM MAINTENANCE MAINTENANCE The OPTIMIZER is equipped with a hoisting The OPTIMIZER units are equipped with a system used to raised the body. This system special hydraulic system that controls the is fed by its own hydraulic pump (see Figure locking mechanism of the tailgate.
  • Page 34 (see Figure #1.24). ADJUSTMENT SCREW LOCKING PIN FIGURE #1.21 PUMP MANUAL LEVER FIGURE #1.23 DANGER ALWAYS USE THE SAFETY PROPS WHEN WORKING UNDER FIGURE #1.22 THE BODY. FAILURE TO DO SO MAY CAUSE SERIOUS INJURIES OR EVEN DEATH. OPTIMIZER...
  • Page 35 1.4.12 BODY HOISTING SYSTEM MAINTENANCE(cont’d) BOTTOM GREASING POINT SAFETY PROPS SAFETY PROP SUPPORT FIGURE #1.24 FIGURE #1.24 To lubricate the body safety props, apply the recommended grease through the greasing TOP GREASING POINT points, which are located near the safety props shaft, inside the rails (see Figure #1.25).

  • Page 36: Arms Up Deceleration Valve

    ADJUSTMENT SCREW at 1500 RPM. WITHOUT CAP NOTE: The arms should slow when they are approximately 18 in. (45.72 cm) away from the arm stops and gently come to rest against the arm stops. FIGURE #1.28 OPTIMIZER...
  • Page 37 4” BETWEEN CAM BOSS AND BODY BODY CAM BOSS DECELERATION VALVE PLUNGER FIGURE #1.29 DECELERATION VALVE CAM BOSS FIGURE #1.30 FIGURE #1.31 MAINTENANCE...

  • Page 38: Arms Down Deceleration Valve

    5. If the arms reach the bottom of their travel with jarring impact of the arms stop before being fully lowered: a. Loosen the retainig bolt. b. Tap the cam in the required direction. c. Tighten the retaining bolt of the cam and repeat step 4. OPTIMIZER...

  • Page 39: Air System Maintenance

    AIR SYSTEM MAINTENANCE AIR SYSTEM MAINTENANCE PROCEDURE 1.5.1 AIR SYSTEM MAINTENANCE PROCEDURE • Ensure that the parking brake is Air system is crucial for the brakes to operate applied and the vehicle is tagged with maximum efficiency. All air tanks on the out for maintenance purposes (refer chassis must be drained after each working to the...
  • Page 40 OPTIMIZER...
  • Page 41 MAINTENANCE...
  • Page 42 OPTIMIZER...
  • Page 43 LUBRICATION...
  • Page 44 LABRIE OPTIMIZER CHAPTER 2.0 Table of contents LUBRICATION ....................46 RECOMMENDED LUBRICANT ................46 2.1.1 HYDRAULIC FLUIDS ..................46 2.1.2 MOTOR OIL FOR VEHICLE ................46 2.1.3 GREASE ......................46 OPTIMIZER...
  • Page 45 LUBRICATION...
  • Page 46 Must meet MIL-H-5606 or SAE IOW “MS” standards. The following oils may be used in the Optimizer. Shell Tellus 32 or T-32 CAUTION DO NOT MIX DIFFERENT BRAND OF OILS IN DOUBT DRAIN AND REFILL WITH NEW OIL.
  • Page 47 LUBRICATION...
  • Page 48 LUBRICATION CHART ON SIDE OF THE TRUCK OPTIMIZER...
  • Page 49 TROUBLESHOOTING...
  • Page 50 LABRIE OPTIMIZER CHAPTER 3.0 Table of contents TROUBLESHOOTING SECTION ..............52 TROUBLESHOOTING TABLE ................52 INTERNAL LEAK DETECTION FOR CYLINDERS ..........55 TAILGATE LOCKING MECHANISM TROUBLESHOOTING ........ 56 MAIN HYDRAULIC SCHEMATIC ................60 OPTIMIZER...
  • Page 51 TROUBLESHOOTING...

  • Page 52: Troubleshooting Section

    1. Air getting into the system 1. Tighten the connections through the hose between the pump and the reservoir 2. Not the proper grade of oil 2. Empty oil and refill with anti- hydraulic oil foam 3. Low oil level 3. Refill the reservoir OPTIMIZER...
  • Page 53 TROUBLESHOOTING TABLE (continued) PROBLEMS POSSIBLE CAUSES REMEDY Cavitation, excessive noise from 1. Low oil level 1. Refill the reservoir the pump 2. Oil too thick 2. Change oil for an appropriate grade of oil according to the ambiant temperature. 3. Dirty strainer 3.
  • Page 54 1. No electrical power reaches 1. Check for power source on the pressing the green button the solenoid valve solenoid valve (located in the console). 2. Check for melted fuses. 2. Solenoid valve is faulty. 2. The faulty selenoid must be replaced. OPTIMIZER...

  • Page 55: Internal Leak Detection For Cylinders

    INTERNAL LEAK DETECTION INTERNAL LEAK DETECTION FOR FOR CYLINDERS CYLINDERS An internal leak is caused by a damaged seal inside the hydraulic cylinder. Because the cylinder is leaking oil inside (bypassing), a certain amount of pressure is lost reducing the cylinder efficiency and its capacity to push or pull.

  • Page 56: Tailgate Locking Mechanism Troubleshooting

    The velocity fuse makes the piston side open to tank when the oil is moving under 3 gallons per minute and will shut when a flow signal is sent. NOTE: Refer to the main hydraulic schematic. Holding valve Tailgate Port D2 Port Port D1 Port U1 FIGURE #3.2 OPTIMIZER...
  • Page 57 Gauge port Gauge 2 Main relief Velocity fuse Gauge 1 FIGURE #3.3 TROUBLESHOOTING...
  • Page 58 0 FIGURE #3.5 PSI to 3000 PSI each time the packer NOTE: The figures above show only the reaches the end of a stroke. places where to install the gauges. To install these gauges, use appropriate fittings. OPTIMIZER...
  • Page 59 Problem #2: Tailgate is LOWERING by itself REAR TAILGATE One other problem that may be found on the tailgate hydraulic system is that it would lower by itself. A faulty velocity fuse might be involved. Apply the procedure below in order to verify and /or replace the velocity fuse.

  • Page 60: Main Hydraulic Schematic

    MAIN HYDRAULIC SCHEMATIC OPTIMIZER...
  • Page 61 Intentionally left blank TROUBLESHOOTING...
  • Page 63 HYDRAULIC...
  • Page 65 4.1.2 HYDRAULIC PIPING TANK TO PUMP (PETERBILT A320 4*2) HYDRAULIC...
  • Page 66 SUPPORT ......................... 1 77403 SUPPORT ......................... 1 HYC00120 2.5” CLAMP ........................4 HYF06280 T FITTING .......................... 1 HYS00450 1.25” CLAMP ........................6 HYS00460 0.5” HOSE SUPPORT ....................... 1 HYS00550 2.25” HOSE SUPPORT ..................... 4 HYS00560 2.5” HOSE SUPPORT ....................... 3 OPTIMIZER...
  • Page 67 PUMPS, VALVES AND HYDRAULIC TANK 4.2.1 HYDRAULIC TANK HYDRAULIC...
  • Page 68 HYF06275 T FITTING .......................... 1 HYF07825 90-DEGREE FITTING ......................1 HYF08810 ADAPTOR REDUCED ....................... 1 HYF20015 SCHROEDER RETURN FILTER ..................1 HYF20025 FILTER SEAL ........................1 HYF20162 BREATHER-FILTER ......................1 HYJ00150 OIL GAUGE ........................1 PNF07605 CAP ..........................3 OPTIMIZER...
  • Page 69 4.2.2 MUNCIE HYDRAULIC PUMP NOTE: FITTINGS VARY ACCORDING TO TRUCK CONFIGURATION. HYDRAULIC...
  • Page 70 FITTING ..........................2 HYF25015 ADAPTOR ......................... 1 HYP01175 MUNCIE LIVE PACK PUMP ..................... 1 HYS02500 TYRONE ADAPTOR ......................1 QUB00700 BOLT ..........................1 QUY00200 YOKE WITH FLANGE ....................... 1 QUY00400 YOKE FOR PUMP ......................1 SUD00412 DRIVING SHAFT ....................... 1 OPTIMIZER...
  • Page 71 4.2.3 MAIN VALVE HYDRAULIC...
  • Page 72 90° ADAPTOR ........................2 HYF08110 90° ADAPTOR ........................1 HYF10050 SAFETY CAP ........................1 HYF10200 QUICK CONNECT ......................1 HYF11150 FITTING ..........................1 HYV05110 VG-35 5-SECTION PNEUMATIC VALVE ................1 PNF02850 PNEUMATIC FITTING ....................... 5 PNF04150 90° ADAPTOR ........................5 OPTIMIZER...
  • Page 73 Intentionally Left Blank HYDRAULIC...
  • Page 77 GENERAL PNEUMATIC DIAGRAM BODY AIR SYSTEMS...
  • Page 78 Intentionally Left Blank OPTIMIZER...

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