Labrie expert 2000 User manual

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Expert (t) 2000 TM
Maintenance Manual

MAINTENANCE MANUAL
1/4/2008 Part # : 55379-04

iiiExpert(t) 2000TM
Maintenance Manual
TABLE OF CONTENTS
Introduction
About this Manual ................................................................ 1
What You Will Find in this Manual ..............................................1
Elements that are not covered in this Manual .............................1
Introducing the Expert(t) 2000TM ........................................... 2
Expert(t) 2000TM for Manual and Automated Collection ...............2
Service and Maintenance on the Expert(t) 2000TM ............... 3
Contacting Labrie Environmental Group ........................... 4
LabriePlus ...................................................................................4
Plant information .........................................................................4
Chapter 1 Safety
Safety Conventions .............................................................. 5
Responsibilities of the Employer .................................................5
Responsibilities of the Employee ................................................6
Lockout/Tagout Procedure .................................................. 7
Protection Against Fire ........................................................ 9
Safety Props .......................................................................... 9
Body Safety Prop ......................................................................10
Setting the Body Safety Prop ........................................................10
Putting the Body Safety Prop in its Home Position .......................10
Tailgate Safety Prop .................................................................10
Setting the Tailgate Safety Prop ...................................................11
Putting the Tailgate Safety Prop Back in Place ............................12
Other General Safety Precautions .................................... 14

iv
Table of Contents
Chapter 2 Maintenance
Prior to start up ....................................................................18
Shutdown procedure ...........................................................20
Air Tank Draining Procedure ....................................................20
General Cleanliness ............................................................22
Cleaning the Hopper Area ........................................................22
On units equipped with an Helping HandTM ....................................22
On manual-collection units and on units equipped with a cart tipper
or a Cool HandTM ............................................................................24
Packer Maintenance ............................................................28
Changing Packer Multi-cycle Settings ......................................29
Adjusting the Limit Switches .....................................................31
Sliding Shoes and Wear Pads ..................................................32
Replacing Sliding Shoes and Wear Plates ...................................33
To Replace Wear Pads Located Between Packer and Side Rails 38
Replacing Packer Teflon Wear Pads ............................................39
Replacing Side Rails Wear Pads ..................................................40
Replacing the follower panel rollers ..........................................40
Replacing a roller ..........................................................................41
How to Separate the Follower Panels from the Packer ............42
Packer Cylinder Inspection Procedure ....................................42
Packer Cylinder Replacement ..................................................44
How to Remove the Packer ......................................................51
How to Reinstall the Packer ......................................................56
Packer Cylinders Reinstallation ................................................58
Packer Scraper Adjustment ......................................................61
Floor Guide Replacement Procedure .......................................62
Teflon Scraper Replacement ....................................................64
Tailgate and Body Hinges Maintenance ............................68
Tailgate Locking Mechanism (Single Tailgate) .........................68
Tailgate Seal and Hinges Inspection ........................................69

vExpert(t) 2000TM
Maintenance Manual
Body/Chassis Hinges Inspection ..............................................69
Body Raised Limit Switch .........................................................69
Tailgate Limit Switch Adjustment ..............................................69
Tailgate Fully Open Proximity Switch .......................................71
Glass Compartment Limit Switch ..............................................71
Hydraulic System Maintenance ......................................... 72
Hydraulic Cylinder Inspection Procedures ................................72
Packer Cylinders Internal Leak Detection .....................................73
Main Hydraulic Valve ................................................................74
Cycle Time for All Hydraulic Functions .....................................76
Hydraulic Tank Inspection Procedure .......................................76
Hydraulic Oil Replacement Procedure ..........................................77
Filter Element Replacement Procedure ........................................78
Strainer Cleaning Procedure ........................................................79
Pressurizing the Tank System ......................................................81
Hydraulic Vane Pump Systems (single pump) ................ 83
Main Relief Valve Pressure Adjustment (Vane Pump Systems) ..
84
Crusher panel ...............................................................................84
Tailgate .........................................................................................84
Packer ...........................................................................................84
Hoist ..............................................................................................84
Priming a New Pump .......................................................... 87
Body Hoist Replacement Procedure ................................. 88
Speed-up System Maintenance ................................................89
Air System Maintenance .................................................... 90
Surface Finishing and Painting ......................................... 92

vi
Table of Contents
Chapter 3 Lubrication
Recommended lubricants ...................................................97
Grease ......................................................................................97
Hopper Lubrication .............................................................97
Glass Compartment Lubrication ........................................97
Engine Oil .............................................................................98
Hydraulic Oil ........................................................................98
Minimum Requirements for Hydraulic Oil .................................98
Hydraulic Oil Test .....................................................................99
Crusher Panel Lubrication ................................................102
Lubrication Charts .............................................................104
Crusher Panel and Floating Panel ...................................107
Body-Chassis Hinges ........................................................108
Hopper, Packer and Body Hoist Cylinder .......................109
Tailgate ...............................................................................110
Chapter 4 Troubleshooting
Troubleshooting Guide .....................................................111

1Expert(t) 2000TM
Maintenance Manual
INTRODUCTION
ABOUT THIS MANUAL
The current manual is designed to help qualified
maintenance personnel through repairing,
servicing and maintaining the Expert(t) 2000TM.
What You Will Find in this
Manual
This manual outlines maintenance procedures of
the body and packer components.
Elements that are not
covered in this Manual
•For maintenance of the chassis, refer to the
chassis manufacturer service manual;
•For details on options such as cameras and
backing-accidents prevention systems, refer
to the optional material manufacturer service
manual;
•For details on operation of the Expert(t)
2000TM, refer to the Expert(t) 2000TMOperator
Manual;
•For details and schematics concerning body
parts, refer to the Expert(t) 2000TM Parts
Catalog;
•For body systems schematics, refer to the
schematics provided with your Expert(t)
2000TM.
• For electrical system schematics, refer to the
schematics provided with your Expert(t)
2000TM.
• For pneumatic and hydraulic system
schematics, refer to the schematics provided
with your Expert(t) 2000TM.

2
Introduction
INTRODUCING THE EXPERT(T)
2000TM
The Expert(t) 2000TM is a side-loading refuse
collection vehicle. It is designed and built to aid in
the manual collection of different types of refuse
by only one operator.
• Expert(t) 2000TM units equipped with a lifting
arm are primarily designed to be operated by
only one person.
If, however, the end user elects to operate the
unit with more than one worker, the following
safety items shall be installed to protect the
co-worker from hazardous situations.
For example, an additional set of sustained
manual pressure controls for each additional
worker shall be provided. The actuation of the
controls shall take place concurrently in order
to operate the automated arm (if equipped).
The sustained manual pressure control shall
be located so that the co-worker pressing it, is
not in the path of the arm and has a clear and
full view of the point of operation.
• In such a case, Labrie Environmental Group
must be informed of every and all units
equipped with a lifting arm operated by more
than one worker. Labrie Environmental Group
will then determine and supply, at the
customer’s expense, the required safety
items.
• Please contact LabriePlus at 1-800-231-2771
for additional information.
The Expert(t) 2000TM is a unit that, depending on
the type of collection it will be used for, appears
in three main categories: manual, semi
automated, and automated. The Expert(t) 2000TM
always allows for manual collection, that is, in
whatever configuration the product is built,
manual collection is available.
Also, the Expert(t) 2000TM exists in what is called a
“co-mingle” version where the body is split in half
to create two separate compartments for the
collection of two different types of load.
Expert(t) 2000TM for Manual
and Automated Collection
ALL Expert(t) 2000TM vehicles are designed with a
lowered hopper to allow easier manual collection.
That is, instead of placing the body on top of a
straight frame chassis, we have placed it on a
chassis frame that has been modified and
lowered at the hopper area. Therefore, the
hopper is at a more friendly height for the manual
collection of waste bags and other refuse.
Figure 1. Expert(t) 2000TM for manual and
automated collection
SOME Expert(t) 2000TM vehicles are equipped
with an automated arm called Helping HandTM or
Cool HandTM for collecting waste from roller carts.
DANGER
FAILURE TO CONTACT LABRIE
ENVIRONMENTAL GROUP TO REPORT THE
UNIT IS SUBJECT TO BE USED BY MORE
THAN ONE OPERATOR AT ATIME MAY
RESULT IN UNIT AND / OR PROPERTY
DAMAGES, PERSONAL INJURY OR EVEN
DEATH.
Helping HandTM
shown

3Expert(t) 2000TM
Maintenance Manual
SERVICE AND MAINTENANCE
ON THE EXPERT(T) 2000TM
Maintenance on the Expert(t) 2000TM is of utmost
importance to ensure a longer durability of all its
parts and optimal performance in the field.
Maintenance has to be done on almost every
system involved in the operation of the Expert(t)
2000TM such as the hydraulic, electrical, and
mechanical systems. There are parts submitted
to more repetitive and intensive activity than
others, therefore, a more often and dedicated
maintenance is required on them.
In this manual, you’ll find the most common
maintenance and inspection procedures needed
on the Expert(t) 2000TM.

4
Introduction
CONTACTING LABRIE
ENVIRONMENTAL GROUP
LabriePlus
Address 3630 Stearns Drive
Oshkosh, WI 54904
Toll free: 1-800-231-2771
Telephone: [phone]
Parts, Service and Warranty
(during business hours, 7:00AM to 7:00PM
Central Standard Time)
Technical Support Service
(24 hours)
Web Site:www.labriegroup.com
E-mail: [email protected]
Plant information
Address 175 du Pont
St-Nicolas (Quebec)
CANADA G7A 2T3
Phone: [phone]
[phone]
Fax: Sales Dept.:
[phone]
Service & Warranty:
[phone]
Parts:
[phone]
IMPORTANT
FOR TECHNICAL SUPPORT AND PARTS
ORDERING, THE SERIAL NUMBER OF YOUR
VEHICLE IS REQUIRED, THEREFORE, LABRIE
ENVIRONMENTAL GROUP RECOMMENDS TO
KEEP RECORD OF THE INFORMATION
FOUND ON THE VIN PLATE WHICH IS
LOCATED IN THE CAB.

5Expert(t) 2000TM
Maintenance Manual
SAFETY
Being a heavy duty vehicle, the Expert(t) 2000TM
implies a number of safety issues. Such issues,
along with all necessary safety instructions and
conventions, are presented in this section of the
Maintenance Manual.
SAFETY CONVENTIONS
Responsibilities of the
Employer
In accordance with ANSI Z245.1 1999
Standards, it is the responsibility of the
employer:
• To ensure the operation of the Expert(t)
2000TM is in accordance with all safety
requirements and codes, including all
applicable regulations, the Occupational
Safety and Health Act (OSHA) and the
American National Standards Institute
(ANSI).
• To ensure the employees are qualified for the
operation of the equipment and take all safety
measures before working with this
equipment.
• To properly maintain all mobile equipment to
meet all provincial/state and federal safety
standards.
• To supply adequate instructions and training
for the safe use of the vehicle before
assigning the employee to such equipment.
• To keep the vehicle maintained and properly
adjusted to meet the manufacturer’s
standards and recommendations. For help or
more information, contact the manufacturer
or any authorized representative.
• To keep record of any breakdowns or
malfunctions of the vehicle as well as any
inspection and maintenance.
• To ensure the repair of any failures or
malfunctions that may affect the safe use of
the vehicle, always before it is used again.
• To meet the appropriate lighting requirements
for night shift work (if permitted).
• To regularly accompany the operator of the
vehicle and take measures to ensure the
smooth and safe operation of the vehicle.
• To make sure that the backup alarm works
properly while the vehicle is in reverse.
• To take the necessary measures that follow a
damage or malfunction report from any
employee.
• To establish and ensure the application of a
“Lockout/Tagout Procedure” at thetime of any
inspection, repair or maintenance to the
DANGER
INDICATES AN IMMINENTLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, WILL
RESULT IN DEATH OR SERIOUS INJURY.
WARNING
INDICATES APOTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN DEATH OR SERIOUS INJURY.
CAUTION
INDICATES APOTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, MAY
RESULT IN MINOR OR MODERATE INJURY.

6CHAPTER 1
Safety
vehicle, whether it takes place on the road or
in the garage.
Responsibilities of the
Employee
In accordance with ANSI Z245.1 1999
Standards, it is the responsibility of the
employee:
• To enforce all safety measures to meet the
requirements established by the employer.
• To operate the Expert(t) 2000TM only after
having received instructions and training in
accordance with the Operator Manual.
• To immediately report to the employer or
supervisor, any damage or malfunction of the
vehicle.
• To make sure that the area is clear around
the vehicle before activating any of the
controls and be prepared to stop everything
upon the existence of possible danger.
WARNING
PRIOR TO PERFORMING ANY MAINTENANCE
ON THE VEHICLE, ALL SAFETY
REGULATIONS MENTIONED IN CHAPTER 1
OF THE OPERATOR MANUAL, MUST BE
RESPECTED, ESPECIALLY THE “LOCKOUT/
TAGOUT” ON PAGE 6.
CAUTION
MAINTENANCE AND REPAIRS CARRIED OUT
ON THIS VEHICLE MUST ONLY BE DONE BY
QUALIFIED PERSONNEL WHO ARE FAMILIAR
WITH THE EQUIPMENT. LABRIE
ENVIRONMENTAL GROUP DECLINES ANY
RESPONSIBILITY FOR FAILURES RESULTING
IMPROPER REPAIRS PERFORMED BY THE
END USER.
WARNING
PRIOR TO PERFORMING ANY MAINTENANCE
ON THE VEHICLE, ALL SAFETY
REGULATIONS MENTIONED IN CHAPTER 1
OF THE OPERATOR MANUAL, MUST BE
RESPECTED, ESPECIALLY THE “LOCKOUT/
TAGOUT” ON PAGE 6.
CAUTION
MAINTENANCE PERSONNEL SHALL NEVER
PERFORM ANY MAINTENANCE ON THE
EQUIPMENT IF THEY ARE NOT WELL
ACQUAINTED WITH THE OPERATIONS OF
THE EQUIPMENT AS WELL AS ALL SAFETY
PRECAUTIONS OF SUCH OPERATIONS.
REFER TO THE OPERATOR MANUAL BEFORE
ATTEMPTING TO PERFORM ANY TYPE OF
WORK ON THE UNIT.
CAUTION
MAINTENANCE AND REPAIRS CARRIED OUT
ON THIS VEHICLE MUST ONLY BE
PERFORMED BY QUALIFIED PERSONNEL
WHO IS FAMILIAR WITH THE EQUIPMENT.
LABRIE ENVIRONMENTAL GROUP DECLINES
ANY RESPONSIBILITY FOR FAILURES
RESULTING IMPROPER REPAIRS
PERFORMED BY THE END USER.

7Expert(t) 2000TM
Maintenance Manual
LOCKOUT/TAGOUT PROCEDURE
The Lockout/Tagout Procedure procedure must
be applied to render the vehicle out of service
and thus ensure its safety and that of those who
will be around it.
To lock out and tag out the Expert(t) 2000TM:
1. Apply the parking brake. See Figure 2.
“Parking brake knob”.
Figure 2. Parking brake knob
2. Turn the pump switch in the console (PTO
switch) to the OFF position.
3. Stop the engine.
4. Remove the key from the ignition switch.
5. Put the key in a safe controlled area.
6. Put adhesive tape over the ignition switch
keyhole.
Note:If the Expert(t) 2000TM is equipped with a
master switch on the battery set, you
must turn it off. See Figure 3. “Master
switch location”.
Figure 3. Master switch location
7. Put an “Off Service” tag on all steering
wheels.
8. Put an “Off Service” sign in the windshield.
9. Block any system that could move by
gravity with a proper and visible safety prop
(open tailgate, raised body, etc.)
DANGER
NEVER PERFORM ANY REPAIR OR
MAINTENANCE ON AVEHICLE THAT HAS NOT
BEEN UNLOADED.
Master Switch

8CHAPTER 1
Safety
10. Release any residual pressure from the
hydraulic and pneumatic system. Refer to
“Air Tank Draining Procedure” on page 20
for details.
11. Move all control levers to release any
residual pressure from the system.
12. Chock wheels on both sides to prevent the
vehicle from moving.
13. Disconnect the following items if any type
of welding is required:
• Battery1
• ABS module (anti-lock braking
system)1
• Electronic transmission (ECU)1
• Electronic engine module (ECM)1
• Intermittent wiper module1
1. Refer to the chassis manufacturer service man-
ual to locate electronic components.

9Expert(t) 2000TM
Maintenance Manual
PROTECTION AGAINST FIRE
It is mandatory to have an ABC-type fire
extinguisher easily accessible from both, outside
and inside the cab.
If, for any reason, the maintenance personnel
has to work on equipment that has not been
unloaded, for any type of work, a fire extinguisher
(see Figure 4. “Fire extinguisher location”) should
be made readily available and close to this
vehicle. Anytime a loaded vehicle is inside 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 fire. The
employer must also inform its employees of an
appropriate place to drop the load near the
maintenance facility (preferably away from traffic,
surface drains and ditches).
Figure 4. Fire extinguisher location
SAFETY PROPS
Safety props are essential safety devices which
are to be used every time maintenance has to be
performed under a raised body or tailgate. Two
types of safety props are installed on every
Expert(t) 2000TM:
• the body safety prop is designed to hold the
empty body in case a hoist-related failure
occurs;
• the tailgate safety prop is designed to hold
the tailgate in case a tailgate-cylinder-related
failure occurs.
CAUTION
ALWAYS MAKE SURE THE HOPPER AND/OR
BODY OF THE EXPERT(T) 2000TM IS EMPTY
BEFORE SERVICING IT, SINCE EXPLOSIVE
AND/OR FLAMMABLE OBJECTS, SUCH AS
TELEVISION TUBES, FLUORESCENT TUBES,
CANS UNDER PRESSURE, ETC. MAY HAVE
BEEN COLLECTED. FAILURE TO EMPTY THE
HOPPER AND/OR BODY OF THE EXPERT(T)
2000TM MAY RESULT IN UNIT AND/ OR
PROPERTY DAMAGES, PERSONAL INJURY.
Fire Extinguisher
DANGER
SAFETY PROPS MUST BE SET PRIOR TO
PERFORMING ANY MAINTENANCE UNDER A
RAISED BODY OR TAILGATE. FAILURE TO DO
SO MAY RESULT IN SEVERE INJURY OR
EVEN DEATH.
DANGER
DONOT USE PROPS WITH ALOADED BODY.
NEVER STAND UNDER ARAISED AND
LOADED BODY.

10 CHAPTER 1
Safety
Body Safety Prop
The body safety prop is used to support and keep
the empty body raised during inspection or when
maintenance is carried out on the vehicle. It is
mandatory to set the safety prop each time the
empty body is raised for such purpose.
Setting the Body Safety Prop
To set the body safety prop, apply the
following procedure:
1. Lift the body until the safety prop is clear to
be tilted under the body.
2. Pull the handle (see Figure 5. “Body safety
prop release handle”) to release the safety
prop, then pull down the safety prop.
Figure 5. Body safety prop release handle
3. Slowly lower the body so it rests properly
on the prop (see Figure 6. “Body safety
prop”).
Figure 6. Body safety prop
Putting the Body Safety Prop in its
Home Position
Once finished with repairs or inspection, you may
want to put the body safety prop in it’s home
position and lower the body.
To safely put the body safety prop in its home
position, apply the following procedure:
1. Slightly raise the body.
2. Bring the safety prop (see Figure 5. “Body
safety prop release handle”) back to its
vertical position. The release handle must
click.
3. Slowly lower the body so it rests properly
on the chassis and the body raised status
light turns off.
Tailgate Safety Prop
The tailgate safety prop is used to support and
keep the tailgate open during inspection or when
maintenance is carried out on the vehicle. It is
mandatory to set the safety prop each time the
tailgate is open for such purpose.
The safety prop can be easily set when the
tailgate is slightly open.
DANGER
ALWAYS USE THE BODY SAFETY PROP
WHEN WORKING UNDER ARAISED BODY.
Handle
Body safety
prop
Handle

11Expert(t) 2000TM
Maintenance Manual
Setting the Tailgate Safety Prop
To set the tailgate safety prop, apply the
following procedure:
1. Make sure there is no garbage inside the
body.
2. Remove the tailgate-locking mechanism
safety pins.
3. Start the engine.
4. Turn the pump switch ON.
5. Open the tailgate and raise it about 3 feet
high (enough to raise the safety prop) by
using the tailgate control lever in the cab
console.
6. Pull the safety prop upward (see Figure 7.
“Pulling the tailgate safety prop out from its
home position”).
DANGER
ALWAYS USE THE TAILGATE SAFETY PROP
WHEN WORKING UNDER ARAISED
TAILGATE. THE SAFETY PROP MUST BE
INSTALLED EVEN IF THE TAILGATE IS IN THE
FULLY RAISED POSITION.
DANGER
MAKE SURE THAT NO ONE IS STANDING
BEHIND THE TRUCK AND THAT THERE IS NO
WASTE MATERIAL IN THE BODY PRIOR TO
RAISING THE TAILGATE.
DANGER
MAKE SURE NO ONE IS STANDING BEHIND
THE TRUCK PRIOR TO RAISING THE
TAILGATE.

12 CHAPTER 1
Safety
Figure 7. Pulling the tailgate safety prop out
from its home position
7. Set the safety prop (see Figure 8. “Putting
the tailgate safety prop in its set position”).
Figure 8. Putting the tailgate safety prop in its
set position
8. Lower the tailgate onto the safety prop.
Putting the Tailgate Safety Prop
Back in Place
To put the tailgate safety prop in its home
position, apply the following procedure:
1. Start the engine.
2. Turn the pump switch ONand raise the
tailgate about 3 feet high.
3. Raise the tailgate safety prop (see Figure
9. “Raising the tailgate safety prop
upward”).
Figure 9. Raising the tailgate safety prop
upward
4. Release your grip on the safety prop to set
in its home position (see Figure 10. “Putting
the tailgate safety prop back in its home
position”).