Labrie Optimizer User manual

MAINTENANCE
MANUAL
RELEASE: February 2007 Part Number: 90313

FOREWORD
HereisthenewLabriepartsandmaintenancemanualforthe
OPTIMIZERTM front loading unit. We sincerely hope that you
will find it easy to use.
Wehavedesigneditinawaythatwillallowyoutoeasilymakeit
availabletodrivers,mechanics,andtopartsdepartmentpersonnel.
AnytimethatyouhaveaproblemwithaLabrieunit,youshould
contactyourvendorfirst.Heshouldbeabletoprovideyouwiththe
properhelprequired(partsortechnicaladvice).
FIRST THINGS FIRST:
DO NOT FORGET TO COMPLETE THE OWNER
REGISTRATION FORM AND TO SEND IT TO LABRIE
EQUIPMENT,MAKING SURE TO INDICATE “INSERVICE
DATE”. THIS DATE WILL BE USED TO START THE
WARRANTY PERIOD. OTHERWISE, THE DATE OF
DELIVERY FROM THE FACTORY WILL BE USED.

OPTIMIZERTM
4

5
MAINTENANCE
OPTIMIZERTM
MAINTENANCEMANUAL
Table of contents
1.0 MAINTENANCEMANUAL ....................................................................................9
2.0 LUBRICATION.................................................................................................... 33
3.0 TROUBLESHOOTING SECTION ...................................................................... 39
4.0 OPTIMIZER BODYPARTS ................................................................................ 49
5.0 HYDRAULIC SYSTEMS, PARTSAND DIAGRAMS ........................................... 65
6.0 BODYAIR SYSTEMS, PARTSAND DIAGRAMS............................................... 93
7.0 ELECTRICALSYSTEMS DIAGRAMSAND PARTS .......................................... 99

OPTIMIZERTM
6
OPTIMIZERTM
CHAPTER 1.0
Table of contents
1.0 MAINTENANCEMANUAL .................................................................................... 9
1.1 GENERALSAFETY PRECAUTIONS .....................................................................9
1.1.1 GENERALPRECAUTION ..................................................................................... 9
1.1.2 SURFACEFINISHINGAND PAINT..................................................................... 10
1.1.3 FIRE PROTECTION .......................................................................................... 10
1.1.4 LOCKOUT/TAGOUTPROCEDURE................................................................... 10
1.1.5 SHUTDOWNPROCEDURE ................................................................................11
1.1.6 PRIORTOSTARTUP..........................................................................................11
1.1.7 HYDRAULICFILTERFIRSTREPLACEMENT .................................................... 12
1.1.8 GENERALCLEANLINESS ................................................................................. 12
1.1.9 CLEANINGTHEHOPPERAREA........................................................................ 12
1.1.9A BODYHOISTING ............................................................................................... 13
1.1.10 PROPPINGPROCEDURES ............................................................................... 15
1.2 PACKING SYSTEM MAINTENANCE .................................................................16
1.2.1 PACKING SYSTEMGENERALMAINTENANCE ................................................. 16
1.2.2 PROXIMITYSWITCHESADJUSTMENT ............................................................ 16
1.2.3 PACKERBLADEWEARPLATES REPLACEMENT ........................................... 18
1.2.4 BODYGUIDE WEAR PLATESREPLACEMENT ................................................ 19
1.2.5 PACKER BLADEREMOVALPROCEDURE ....................................................... 20
1.2.6 PACKER CYLINDERSREPLACEMENT............................................................. 21
1.2.7 LUBRICATIONOFPACKING SYSTEM .............................................................. 21
1.3 TAILGATESYSTEMANDBODYHINGESMAINTENANCE ................................22
1.3.1 TAILGATELOCKINGMECHANISM .................................................................... 22
1.3.2 TAILGATESEALANDHINGESINSPECTION .................................................... 23
1.3.3 REARBODYHINGEINSPECTION .................................................................... 23
1.3.4 PROXIMITYSWITCHES ONTAILGATE ............................................................. 23
1.3.5 HOPPERDOORSENSOR.................................................................................. 24
1.3.6 ROOFPROXIMITYSWITCH .............................................................................. 24
1.3.7 FORKSANDARMS PROXIMITYSWITCHES .................................................... 24
1.3.8 ARMSPARTLYRAISEDPROXIMITYSWITCH.................................................. 25
1.3.9 PROXIMITYSWITCHADJUSTMENT ................................................................. 25

7
MAINTENANCE
OPTIMIZERTM
CHAPTER 1.0
Table of contents
1.4 HYDRAULICSYSTEMMAINTENANCE ..............................................................26
1.4.1 HYDRAULICSYSTEMGENERALINSPECTION ................................................ 26
1.4.2 MAINRELIEFVALVE PRESSUREADJUSTMENT ............................................. 26
1.4.3 HYDRAULICDIRECTIONALCONTROLVALVE ................................................. 27
1.4.4 PRESSUREADJUSTMENTPROCEDURE ......................................................... 28
1.4.5 PUMPMAINTENANCE ....................................................................................... 28
1.4.6 HYDRAULICCYLINDERSINSPECTION PROCEDURES .................................. 29
1.4.7 HYDRAULICRESERVOIRINSPECTIONPROCEDURE .................................... 29
1.4.8 HYDRAULICFLUIDREPLACEMENT PROCEDURE.......................................... 30
1.4.9 HYDRAULICFILTERREPLACEMENTPROCEDURE ........................................ 32
1.4.10 HYDRAULICSTRAINERCLEANING PROCEDURE ........................................... 32
1.4.11 TAILGATEHYDRAULICSYSTEMMAINTENANCE ............................................ 33
1.4.12 CYCLETIMETABLE FORALLHYDRAULICFUNCTIONS ................................. 33
1.4.12 BODYHOISTINGSYSTEMMAINTENANCE ...................................................... 33
1.4.13 ARMS UPDECELERATION VALVE .................................................................. 36
1.4.14 ARMS DOWNDECELERATIONVALVE............................................................ 38
1.5 AIRSYSTEMMAINTENANCE .............................................................................39
1.5.1 AIRSYSTEMMAINTENANCEPROCEDURE..................................................... 39

9
MAINTENANCE
WARNING
PERSONNEL IN CHARGE OF
MAINTENANCE SHALL NOT
PERFORM ANY MAINTENANCE
ON THE EQUIPMENT WITHOUT
KNOWING THE PROPER
OPERATIONS OF THE
EQUIPMENT AS WELL AS ALL
SAFETYPRECAUTIONSOFSUCH
OPERATIONS. REFER TO THE
OPERATION MANUAL PRIOR TO
PERFORM ANY TYPE OF WORK
ON THE UNIT.
Formaintenanceofthetruckitself,pleaserefer
tothechassismaintenancemanual.Onlythe
body section and its components will be
addressedinthismanual.
Establishandapplyaperiodicinspectionprogram
tokeepthemovingpartsingoodworkingorder,
properlyadjustedandsafe. Itisrecommended
thatabriefinspectionisdonebytheoperator
EVERYDAY andthatanyproblemsordetected
malfunctionsisreportedforcorrectionbefore
reusingtheequipment.
Onceamonth,inspectthechassisandthebody
foranybreaks,cracksor possiblemalfunctions.
Anydefectsfound mustberepaired without
delay. To assure good working order of the
equipment,particularattentionshouldbepaidto
thedeteriorationofstructuralcomponentsdueto
corrosion.Touch-upsorcompletepaintjobs
shouldbedonewhennecessary.
MAINTENANCE AND REPAIRS
CARRIEDOUTONTHISVEHICLE,
MUST BE ONLY DONE BY
QUALIFIED PERSONNEL WHO
ARE FAMILIAR WITH THIS
EQUIPMENT. LABRIE
ENVIRONMENTALGROUPISNOT
RESPONSIBLE FOR ANY
FAILURESRESULINGOFREPAIRS
PERFORM BY THE USER.
BEFORE DOING ANY
MAINTENANCE WORK ON THE
VEHICLE, ALL SAFETY
REGULATIONS MENTIONED IN
THEOPERATORMANUAL, MUST
BERESPECTED,ESPECIALLYTHE
“LOCKOUT/TAGOUT”
PROCEDURE(ANSIZ245.11984).
CAUTION
CAUTION
1.0 MAINTENANCE MANUAL
1.1 GENERALSAFETY
PRECAUTIONS
1.1.1 GENERALPRECAUTION

OPTIMIZERTM
10
1.1.3 FIRE PROTECTION
Ifforanyreasonthemaintenancepersonnelhas
to work on an equipment that has not been
unloaded,foranytypeofwork,afireextinguisher
shouldbemadereadilyavailableclosetothis
vehicle.Anytimealoadedvehicleisinsidea
garagethereshouldbeafireextinguishervery
closenearby.
Informyourpersonnelofmeasurestobetakenin
caseofatruckfireand/oraloadedbodyfire.In
thecaseofaloadcatchingonfire,informthem
ofanappropriateplacetodroptheloadinthe
vicinityofyourmaintenancefacility(Preferably
awayfromtraffic,surfacedrainsandditches).
1.1.4 LOCKOUT / TAGOUT PROCEDURE
Itistheemployer’sresponsibilitytofollowand
applythe“lockout/tagoutprocedure”forany
inspection,repairsormaintenancebeingdone
onthevehicle, whetheritisontheroadorinthe
employer’sgarage.
PAINTING PROCEDURE
• Surface preparation: Grit blasting.
• Primary coat : Anticorrosive
epoxy primer.
• Finishing coat: Two (2) coats
industrial type Imeron paint (or
equivalent).
Typeofsurfacefinishingrecommended:
1.1.2 SURFACEFINISHINGANDPAINT LOCKOUT / TAGOUT PROCEDURE
• Apply the parking brake.
• Turn the engine off.
• Remove the key from the ignition
switch.
• Put the key in a safe controlled
area.
• Tape ignition switch key hole.
• Turn off the master switch (If
installed).
• Put an “OFF SERVICE” tag on the
driver’s wheel.
• Put an “OFF SERVICE” sign in the
front windows.
• Block any system that could move
bygravity witha proper easy to see
safety prop (opened tailgate, etc.).
• Move back and forth all control
handles to release any residual
pressure in the system.
• Install blocks on both sides of
wheels to prevent movement of the
vehicle.
• Disconnect the following items if
any type of welding is required:
- Electronic transmission (ECU)
- Electronic ABS module
- Electronic engine (2 plugs on
engine)
- Wiper module
- Battery