Labrie Automizer Versa Hand, General Maintenance

Page 1: ...e March 2007 Part 90337 GENERAL MAINTENANCE AUTOMIZER VERSA HANDTM LabriePlusTM Parts Service and Warranty duringbusinesshours TechnicalSupportService 24 hours 1 800 231 2771 3630 Stearns Drive Oshkos...

Page 2: ...AUTOMIZER VERSA HANDTM 1 2...

Page 3: ...rts Department personnel Any time that you have a problem with a Labrie unit you should contact your local distributor first He should be able to provide you with the proper help required parts or tec...

Page 4: ...AUTOMIZER VERSA HANDTM 1 4...

Page 5: ...24 1 12 1 GENERAL MAINTENANCE 1 24 1 12 2 LIMIT SWITCH ADJUSTMENT 1 26 1 12 3 REPLACING SLIDING SHOES AND WEAR PAD 1 30 1 12 4 SLIDING SHOE REPLACEMENT 1 30 1 12 5 WEAR PAD REPLACEMENT 1 34 1 12 6 PAC...

Page 6: ...NG THE TANK SYSTEM 1 71 1 14 11 PUMP INSPECTION 1 72 1 15 HYDRAULIC PRESSURE ADJUSTMENT 1 73 1 15 1 BODY FUNCTION MAIN RELIEF VALVE ADJUSTMENT 1 73 1 15 2 ARM VANE PUMP RELIEF VALVE ADJUSTMENT cont d...

Page 7: ...SYSTEM MAINTENANCE 1 100 1 19 SURFACE FINISHING AND PAINTING 1 101 1 20 ALLISON TRANSMISSION PROGRAMMING PARAMETERS 1 102 1 21 AUTOMIZER PREVENTIVE MAINTENANCE CHART 1 103 GENERAL MAINTENANCE AUTOMIZE...

Page 8: ...AUTOMIZER VERSA HANDTM 1 8...

Page 9: ...vehicle that is as safe as possible the operator s safety certainly depends on the precautionary measures taken while operating or servicing the vehicle If in doubt ask your supervisor or contact the...

Page 10: ...y 1 1 GENERAL PRECAUTIONS It is the employer s responsibility to be assured that their employees are qualified and capable of operating this equipment THE FOLLOWING IS GENERAL SAFETY AND OPERATIONAL P...

Page 11: ...r the operator 6 Verify that the mirrors brakes accelerator pedal steering wheel and turn signals are in good working order 7 Do not operate this equipment if there are any signs of damage or incomple...

Page 12: ...ning the employee to such equipment 2 The employer must keep the vehicle maintained and properly adjusted to meet the manufacturer s standards and recommendations If in doubt contact the manufacturer...

Page 13: ...AR WITH THE EQUIPMENT LABRIE EQUIPMENT DECLINES ANY RESPONSIBILITY FOR FAILURES RESULTING UNPROPER REPAIRS PERFORMED BY THE END USER 1 3 GENERAL RESPONSIBILITIES OF THE EMPLOYEE 1 The employee must en...

Page 14: ...ide a garage there shall be a fire extinguisher very close nearby The employer must inform and train all personnel about the measures to be taken in case of a truck and or a loaded body catching on fi...

Page 15: ...1 Release any residual pressure in the hydraulic and pneumatic system 12 Block wheels on both sides to prevent movement of vehicle 13 Disconnect the following items if any type of welding is required...

Page 16: ...e Figure 1 5 to release the safety prop then pull down the safety prop 4 Slowly lower the body so it rests properly on the prop Figure 1 6 5 Once finished with repairs or inspection slightly raise the...

Page 17: ...safety prop FIGURE 1 7 1 7 TAILGATE SAFETY PROP The tailgate safety prop is used to support andkeepthetailgateopenduringinspection or when maintenance is carried out on the vehicle It is mandatory to...

Page 18: ...build up to at least 70 PSI Do not operate or move the vehicle until the air pressure has reached 70 PSI FIGURE 1 9 1 8 SHUTDOWN PROCEDURE If the vehicle has to be stored for an extended period follo...

Page 19: ...URE 1 10 MAIN HYDRAULIC TANK 2 DIFFERENT TYPES BALL VALVE OPEN NOTE The hydraulic tank model can vary according to the options installed on the truck SUCTION LINE MOUNTED VALVE STEEL TANK FIGURE 1 11...

Page 20: ...HE RIGHT AND LEFT HAND SIDE CAB FLOOR DRY AND CLEAN TO PREVENT ANY RISK OF SLIPPING AND ACCIDENT 1 10 GENERAL CLEANLINESS Cleanliness is part of the safety Ensure the equipment will work properly by r...

Page 21: ...igure 1 12 and push on the red button Figure 1 13 to stop the packer in this position The hopper door MUST be closed in order to move the packer 5 Turn off the hydraulic pump and the engine DANGER 1 1...

Page 22: ...er to gain access to the rear area of the packer Figure 1 17 PREVENT HANDS OR FINGERS FROM BEING CAUGHT AT THE PINCH POINT OF THE FLOATING PANEL INSTALL THE SAFETY PIN FIGURE 1 15 FIGURE 1 16 CLEAN OU...

Page 23: ...g components checking for proper working order and or alignment Rollers Cylinders pins Hoses pipes and connections Proper tightness of bolts Check for excessive wear of the floor and sidewalls of the...

Page 24: ...s PACKER INSPECTION PROCEDURE 1 Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes refer to the section 1 5 Lockout Tagout procedure 2 Start the engine eng...

Page 25: ...nocking noise when the packer reaches the end of the cylinder s stroke A knocking noise will indicate that both limit switches require adjustment Refer to section 1 12 2 Limit switch adjustment 12 In...

Page 26: ...vent the cylinders from completely extending and retracting to the end of their strokes There are two limit switches that control the packer s extension and the retraction limits Both limit switches a...

Page 27: ...3 Press the green button on the packer control station in order to extend the packer about 1 inch back from the fully extended position Figure 1 25 4 Push the red button when the packer reaches the p...

Page 28: ...the limit switch lever so it is active when the packer cylinder finger is in the position shown on figure 1 27 Limit switch is clicked The lever may require to be bent or twisted to properly activate...

Page 29: ...own on figure 1 29 Limit switch is clicked The lever may require to be bent or twisted to properly activate the limit switch at this exact position 11 Test the packer for a full cycle Make sure that t...

Page 30: ...ion for replacement part numbers To keep the packer in good working order and to prevent breakdowns replace the sliding shoes and wear pads before extensive wear or damage appears on the hopper floor...

Page 31: ...llow button on the packer control station to retract it 6 Turn the hydraulic pump and the engine off 7 Behind the packer remove the welds from both wear shoes Figure 1 31 using a grinder or cutting to...

Page 32: ...retract the packer by pressing the yellow button and the red button 13 The sliding shoes will come out from under the packer as it is retracting Figure 1 35 14 Remove the old sliding shoe and tubing...

Page 33: ...d refer to section 1 12 5 Wear Pad Replacement FIGURE 1 36 FIGURE 1 37 View from behind the packer packer fully retracted WELD HERE SLIDING SHOE REPLACEMENT PROCEDURE 18 Retract the packer 19 Weld bot...

Page 34: ...ve the hopper side panel Figure 1 39 7 Remove both side rail shields 8 Remove the lower bolts 4 of left side wall to be able to remove the left side rail Figure 1 42 43 1 12 5 WEAR PAD REPLACEMENT Rep...

Page 35: ...elds to release the side rails 10 Remove both side rails FIGURE 1 39 1 12 5 WEAR PAD REPLACEMENT cont d FIGURE 1 42 FIGURE 1 43 HOPPER WALL BOLTS 4 Continued next page Note The model of the side panel...

Page 36: ...LD Stitch welds that hold the rail into position should be cut out in order to release the side rail FCAW 1 4 1 6 1 12 5 WEAR PAD REPLACEMENT cont d FIGURE 1 46 Left hand side spacers Always re instal...

Page 37: ...packer Pull the red button and repeat the process until the packer reaches the desired position WEAR PAD REPLACEMENT PROCEDURE 14 Remove and replace both wear pads Figure 1 45 and retract the packer 1...

Page 38: ...he hopper area 4 If the packer is not fully retracted press the yellow button on the packer control station to retract it 5 Turn the hydraulic and the engine off 6 Remove the hopper side panel Figure...

Page 39: ...ER REMOVAL Cont d FIGURE 1 52 FIGURE 1 53 HOPPER WALL BOLTS 4 Continued next page PACKER REMOVAL PROCEDURE cont d 9 Remove stitch welds to release the side rails 10 Remove both side rails 11 When both...

Page 40: ...16 Remove both cylinder pins Figure 1 56 Note that the greasing hoses must be disconnected from the cylinder pins The cylinder pins top plate are provided with two 2 threaded holes to be used as a pul...

Page 41: ...ls 24 Once the packer is installed in the hopper install roller assemblies and reverse the procedure to reconnect the hydraulic cylinders and re install both side rails 25 Stitch weld the rails along...

Page 42: ...maintenance purposes refer to the section 1 5 Lockout Tagout procedure 2 Start the engine and engage the hydraulic system 3 Then using the joystick extend the automated arm to give a better access to...

Page 43: ...1 43 GENERAL MAINTENANCE FIGURE 1 59 STITCH WELDS FLOOR GUIDES 1 12 7 FLOOR GUIDE REPLACEMENT PROCEDURE Cont d...

Page 44: ...1 60 13 Tack weld the floor guides to the hopper floor Figure 1 61 14 Adjust the packer wipers on both sides UHMW plastic 15 Connect the packer cylinders refer to section 1 12 6 Packer Removal Procedu...

Page 45: ...63 WELD HERE ON BOTH SIDES OF THE FLOOR GUIDE FIGURE 1 64 WELD HERE ON BOTH SIDES OF THE FLOOR GUIDE 1 12 8 PACKER ROLLER REPLACEMENT Packer rollers need to be replaced when damaged showing excessive...

Page 46: ...ckout Tagout procedure 2 Start the engine and engage the hydraulic system 3 Then using the joystick extend the automated arm to give a better access to the hopper area 4 Fully extend the packer then p...

Page 47: ...pad and bring back the floating panel in place 10 Check for even contact of wear pad with packer blade and the follower panels FIGURE 1 67 DANGER APPLY THE LOCKOUT TAGOUT PROCEDURE AT ALL TIMES WHEN...

Page 48: ...mated arm to give a better access to the hopper area 4 Fully extend the packer 5 Disengage the pump and stop the engine 6 Remove the floating panel refer to section 1 12 9 7 Open the access cover Figu...

Page 49: ...limit switches installed on both cylinders and keep them for the new cylinder 15 Replace the faulty cylinder with a new one Contact the Labrie s Service Department for replacement under warranty 16 In...

Page 50: ...NEL MAINTENANCE PROCEDURE 1 Grease the cylinder heads of the crusher panel by using the greasing points 2 Grease also the crusher panel bushings NOTE The crusher panel is optional GREASING POINT GREAS...

Page 51: ...KING MECHANISM It is important to lubricate the tailgate hinges and the locking mechanism with multipurpose grease as per the lubricating schedule Refer to section 2 1 Recommended Lubricants Also insp...

Page 52: ...PMENT IF THERE IS ANY SIGN OF DAMAGE OR INCOMPLETE REPAIRS DANGER 1 13 4 BODY RAISED LIMIT SWITCH A limit switch located on the truck chassis Figure 1 76 activates the backup alarm and a warning buzze...

Page 53: ...E THAT NO ONE IS STANDING BEHIND OR NEAR THE TAILGATE WHEN ADJUSTMENT PROCEDURE IS CARRIED OUT Apply the following procedure to adjust the limitswitchlocatednexttohydrauliccylinder tailgate unlocked L...

Page 54: ...essary 7 Inspect the pump for leaks or unusual noise 8 The ball valve on the hydraulic tank must be completely open before engaging the pump or starting the engine See section 1 9 Prior to Start up La...

Page 55: ...htened and there are no oil leaks Check that all cylinder caps are firmly tightened and there are no leaks All leaks must be repaired immediately by replacing damaged or faulty cylinders Lubricate and...

Page 56: ...nal control valve which is assembled as follows from top to bottom Figure 1 79 For further details refer to the hydraulic system Parts and Diagram section or see the simplified diagram for the packing...

Page 57: ...9 Dual Vane Pump Each section of the valve is actuated by an electrical coil located under the valve The proportionalvalvesectionsaredescribedas follow from top to bottom on figure 1 81 VALVE SECTION...

Page 58: ...AUTOMIZER VERSA HANDTM 1 58 FIGURE 1 81 INPUT OUTPUT COVER ELECTRICAL COILS...

Page 59: ...re adjustment of the arm Use any precaution necessary around the vehicle to work safely at all times Securethearm sworkingareausingbarrier tape or barricades DANGER STAY OUT OF THE PATH OF THE ARM WHI...

Page 60: ...AUTOMIZER VERSA HANDTM 1 60 0 4000PSI PRESSURE GAGE Part HYF00910 QUICK COUPLER Part HYF10195 QUICK COUPLER CONTROL LEVER MAIN RELIEF VALVE ADJUSTMENT SCREW...

Page 61: ...0 hours Refer to section section 1 14 7 Filter element replacement procedure 4 Ensure the proper operation of the filler cap Figure 1 83 See that the filler cap has no obstruction 5 The hydraulic oil...

Page 62: ...AUTOMIZER VERSA HANDTM 1 62 FIGURE 1 83 HYDRAULIC TANK Front View BREATHER CAP Rear view FILLER FILTER ELEMENT HOUSING SUCTION LINE BALL VALVE OIL TEMP LEVEL GAGE...

Page 63: ...1 63 GENERAL MAINTENANCE ACCESS PANEL FIGURE 1 83A F I L L E R CAP FILTER SUCTION OIL TEMP LEVEL GAGE BREATHER CAP SAFETY VALVE...

Page 64: ...e the drain plug under the tank Use a container with a minimum capacity of 60 US gallons to collect the oil 8 Completely drain the tank 9 Once emptied reinstall the drain plug 10 Remove the strainer b...

Page 65: ...TELLUS T32 or equivalent See the Lubrication section for specifications The whole system will require between 50 and 60 gallons 14 The oil must be clean and free of any dirt metallic particles or san...

Page 66: ...EMENT PROCEDURE 1 Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes refer to the section 1 5 Lockout Tagout procedure 2 Prepare a pan or a bucket to recup...

Page 67: ...rs packer crusher panel tailgate etc 4 Raise the body and install the safety prop STRAINER CLEANING PROCEDURE 5 Disengage the hydraulic pump and turn off the engine 6 Clean around the filler cap and r...

Page 68: ...t Figure 1 89 and 1 89A 11 Once the strainer is removed clean it using solvent and inspect for damage replace if necessary 12 Replace the seal if necessary and re install the strainer 13 Refer to the...

Page 69: ...1 69 GENERAL MAINTENANCE FIGURE 1 89A Strainer Seal...

Page 70: ...ECU monitors the vehicle speed and the engine RPM and then allows or not the vane pump to engage The air pressure MUST be at least of 70 PSI in order to engage the pump If the vehicle is exceeding 15...

Page 71: ...ge and a pressure regulator are installed to adjust the air pressure inside the tank This gage is located inside the frame rail on the curbside of the chassis Figure 1 92 This gage can be accessed onl...

Page 72: ...isually inspected Follow this procedure PUMP INSPECTION PROCEDURE 1 Ensure that the parking brake is applied and the vehicle is tagged out for maintenance purposes refer to section 1 5 lockout tagout...

Page 73: ...o adjust the relief of the pump A 0 4000 pressure gage Figure 1 96 as well as a set of ball end Hex key Figure 1 97 is required to perform the pressure adjustment procedure 0 4000 PSI PRESSURE GAGE HY...

Page 74: ...nctions valve Figure 1 99 4 Start the engine and engage the hydraulic system Pump switch ON 5 Release the vane pump relief if equipped 6 Tighten the main relief valve adjustment screw to be able to ad...

Page 75: ...c valve 5 Back out the main relief and close the tailgate completely Hold the lever in order to make the pressure build up in the system 6 At the same time check the pressure on the gage 7 Adjust the...

Page 76: ...oid 10 Set the Pilot Generation Relief Valve A that is located on the right hand side of the valve bank behind the coil to 420 PSI plus or minus 30 PSI with the engine at IDLE If you re not able to do...

Page 77: ...1 77 GENERAL MAINTENANCE A B C BEHIN D D F MAIN RELIEF B E...

Page 78: ...to adjust the grabber s load sense relief valve The table on the next page presents the operating pressure and the cycle times for each function of the arm Note that speed of the arm is controlled by...

Page 79: ...Up Down Grabber Close Grabber Open 2000 PSI 2000 PSI 1200 PSI load sense 1 2000 PSI turn 5 2 4 2 sec 4 5 3 5 sec Less than 3 sec Less than 2 sec FIGURE 1 103 MOVEMENT RESTRICTORS Table 1 GRABBERLOAD...

Page 80: ...levers back and forth 4 Make sure that all hoses are tight and not leaking 5 Connect a pressure gage 0 4000PSI to the quick connect on proportional valve 6 Put the transmission in Neutral 7 Start the...

Page 81: ...1 81 GENERAL MAINTENANCE Grabber open relief adjustment screw Grabber close relief adjustment screw Main Relief Valve...

Page 82: ...ic system Pump switch ON 5 Clearly identify the stopper screw on the valve that corresponds to the proper function boom extension retraction grabber open close Move the lever to evaluate the speed of...

Page 83: ...body safety prop 4 Apply the lockout tag out procedure 5 Check the cylinder for scratch or leaks 6 At the cylinder base make sure that the pivots are greased and the bolts are tight FIGURE 1 109 APPLY...

Page 84: ...h You must stop using the vehicle immediately and repair the cylinder Refer to section 1 16 2 Body hoist replacement 10 Make sure that the gland safety pins are in place 11 When the inspection is comp...

Page 85: ...ce to lower the safety prop under the body Figure 1 113 5 Install the safety prop and using a lifting device secure the cylinder to prevent the cylinder from tilting on the cab or falling onto the cha...

Page 86: ...hydraulic pump 13 Slowly raise the cylinder until it reaches the top of the cover where the lock nut will be tightened Note that the cover must be aligned with the threaded rod at the top end of the c...

Page 87: ...OF THE ARM WHILE CARRYING OUT THESE ADJUSTMENTS ARM INSPECTION PROCEDURE 1 Make sure to park the vehicle on a safe and level ground 2 Ensure that the parking brake is applied and the vehicle is tagge...

Page 88: ...AUTOMIZER VERSA HANDTM 1 88 FIGURE 1 117 MOUNTING BOLTS on the body CHAINS FIGURE 1 118 ROLLERS AND BEARINGS FIGURE 1 119 FIGURE 1 120 BOLT LOCKS FIGURE 1 121 FIGURE 1 122 HOSES BOLTS...

Page 89: ...ar pad and the guide the total gap is 0 250 or inch In this case the wear pads MUST be replaced To do so perform the following procedure ROLLERWEAR PAD GRABBER TROLLEY WEAR PADS REPLACEMENT PROCEDURE...

Page 90: ...just it in such way that the grabber finger will trigger the limit switch click sound and stop the warning lights One or both levers may require to be bent to stop warning lights 5 Extend the arm or c...

Page 91: ...mit switch apply the following procedure CLIMB CUSHIONING FIGURE 1 124 GRABBER LIMIT SWITCH LIMIT SWITCH END OF STROKE STROKE END LIMIT SWITCH ADJUSTMENT 1 By using the joystick take down the grabber...

Page 92: ...cylinder may leak pressure causing the grabber to open itself by gravity As soon as the hydraulic system is brought online pump switch On the system will close the grabber automaticallybeforetheopera...

Page 93: ...abber Auto Closing system is controlled by a limit switch located on the side of the arm figure 1 128 To adjust the system apply the following procedure DANGER APPLY THE LOCKOUT TAGOUT PROCEDURE AT AL...

Page 94: ...st the roller on the limit switch accordingly click sound Loosen the screws on the roller arm Figure 1 129 8 When the grabber is closing tighten the screws and perform a few up and down cycles of the...

Page 95: ...lete all its cycles until the next time the operator closes the grabber When theoperator closes the grabber the multi cycle function is reset IIf the grabber is closed in the middle of a cycle the pac...

Page 96: ...oller To do so perform the following procedure ARM CHAINS ADJUSTMENT PROCEDURE 1 If the chains are not centered on the bottom roller tighten the suspension adjustment nut until the chains return at th...

Page 97: ...enupachain screw the outer nut and unscrew the inner one Don t tighten up the chains too much It may be also necessary to adjust the grabber chains when the grabber is not centered with the arm INNER...

Page 98: ...by rolling in the slot In consequence it is crucial to verify if the bottom roller bushing are rolling If it is not the case the bushing can wear the slot and when the slot is worn it is necesary to r...

Page 99: ...rt prevents the grabber from closing by itself A the one on the top of the arm prevent the grabber going down by itself B and the one on the right hand side of the arm near the rail prevents the arm t...

Page 100: ...air actuators Figure 1 132 When the tailgate or body lever on the console is moved air pressure passing through the lever will activate the corresponding air actuator on the main valve resulting in a...

Page 101: ...tors found on the main control valve with light oil low temperature See section 3 6 Packer air system troubleshooting To avoid affecting control of packer or other system on the vehicle especially und...

Page 102: ...to program the Allison ECU and verify if the signals are properly reaching the computer and verify the fault code To tap onto the ECU Labrie uses the following wires on the Allison connector INPUT 11...

Page 103: ...ilter Drain flush cleanandrefill strainer 1 9 1 15 1 14 8 1 14 7 Hopper area Clean traps on each side Tiltdownthefloatingpanel and clean dirt under or behind the packer 1 11 1 11 Visual inspection of...

Page 104: ...e truck Check for proper operation Operator control Wiring system Drain Air tanks Check for leaks Air system Safety systems Check for proper operation tailgate alarm and special devices Check for dama...

Page 105: ...1 105 GENERAL MAINTENANCE NOTES...