Labrie expert 2000 User manual

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MAINTENANCE MANUAL
12/14/2006 Part # : 55379

iiiExpert(t) 2000TM
Maintenance Manual
TABLE OF CONTENTS
Introduction
About this Manual .........................................................1
What You Will Find in this Manual ........................................1
What You Will Not Find in this Manual .................................1
Introducing the Expert(t) 2000TM ....................................2
Expert(t) 2000TM for Manual and Automated Collection .........3
Service and Maintenance on the Expert(t) 2000TM .......3
Contacting Labrie Environmental Group ....................4
Plant information ........................................................4
Labrie Customer Support Center ...............................4
Chapter 1 Safety
Safety Conventions .......................................................5
Responsibilities of the Employer ................................5
Responsibilities of the Employee ...............................7
Lockout/Tagout Procedure ..........................................8
Protection Against Fire ...............................................10
Safety Props ................................................................11
Body Safety Prop .....................................................11
Tailgate safety prop .................................................12
Other General Safety Precautions .............................15

iv
Table of Contents
Chapter 2 Controls
Helping HandTM Joystick ..............................................17
Pump Switch ............................................................18
Control Console ..........................................................20
Red Emergency-Stop Button ...................................20
Green Start Cycle Button .........................................21
Yellow Retract Button ..............................................21
Multi-cycle Control Switch .......................................22
Engine RPM Control ................................................22
Speed-up Switch .....................................................23
Speed-up Inhibitor Control .......................................23
Control Station Selector Switch ...............................24
Temporary Handbrake ................................................24
Body Control Station ..................................................26
Strobe Light Switch ....................................................26
Chapter 3 Maintenance
Prior to start up ...........................................................28
Shutdown procedure ..................................................30
Air Tank Draining Procedure ...................................30
General Cleanliness ....................................................33
Cleaning the Hopper Area .......................................33
On Helping HandTM-equipped Units .....................................34
On Manual-collection and Cart-tipper-equipped Units .......36

vExpert(t) 2000TM
Maintenance Manual
Packer Maintenance ....................................................43
Changing Packer Multi-cycle Settings .....................46
Limit Switches Adjustment .......................................48
Sliding Shoes and Wear Pads .................................53
Sliding Shoes Replacement ...............................................54
Wear Pads Replacement ...................................................57
Packer Removal Procedure .....................................61
Floor Guide Replacement Procedure ......................67
Packer Roller Replacement .....................................70
Swivel-style Panel Removal
and Wear Pad Replacement ....................................71
Arm Doghouse Panel Scraper Removal
and Wear Pad Replacement ....................................73
Packer Cylinder Replacement .................................76
Tailgate and Body Hinges Maintenance ...................80
Tailgate Locking Mechanism (Single Tailgate) ........80
Tailgate Seal and Hinges Inspection .......................81
Body/Chassis Hinges Inspection .............................82
Body Raised Limit Switch ........................................83
Tailgate Limit Switch Adjustment .............................84
Optional Limit Switch and Proximity Switch .............85
Hydraulic System Maintenance .................................87
Hydraulic Cylinder Inspection Procedures ...............88
Main Hydraulic Valve ...............................................88

vi
Table of Contents
Cycle Time for All Hydraulic Functions ....................91
Hydraulic Tank Inspection Procedure ......................91
Hydraulic Oil Replacement Procedure ...............................92
Filter Element Replacement Procedure .............................94
Strainer Cleaning Procedure ..............................................96
Hydraulic Vane Pump Systems .................................99
Dump Valve Pressure Adjustment Procedure .......100
Main Relief Valve Pressure Adjustment
(Vane Pump Systems) ...........................................103
Crusher panel ...................................................................103
Tailgate ............................................................................103
Packer ..............................................................................103
Hoist .................................................................................104
Priming a New Pump ................................................107
Body Hoist Replacement Procedure .......................109
Speed-up System Maintenance ............................111
Air System Maintenance ..........................................113
Surface Finishing and Painting ...............................116
Chapter 4 Lubrication
Recommended lubricants ........................................123
Grease ...................................................................123
Hopper Lubrication ................................................123
Engine Oil ..............................................................123
Hydraulic Oil ..........................................................123
Minimum Requirements for Hydraulic Oil .........................124

viiExpert(t) 2000TM
Maintenance Manual
Hydraulic Oil Test .............................................................124
Lubrication Chart ......................................................129
Packer ........................................................................130
Body-Chassis Hinges ...............................................131
Hopper Section (Standard Version) ........................132
Crusher Panel ............................................................133
Full-width Tailgate .....................................................134
Chapter 5 Troubleshooting
Troubleshooting Guide .............................................135
Appendix
About Wiring Schematics .........................................145
Connectors ................................................................146
Commonly-used Electrical Connectors ..................146
Deutsch ............................................................................146
AMP .................................................................................146
LabrieTM Electrical Schematics ..................................147
Commonly-used Symbols ......................................147
Alarms ..............................................................................147
Connectors .......................................................................148
Diodes ..............................................................................148
Fuses ...............................................................................149
Lights ................................................................................150
Relays ..............................................................................152
Solenoids .........................................................................153
Switches ...........................................................................154
Other Symbols .................................................................157

viii
Table of Contents

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
Only maintenance of the body and
packer components are outlined in this
manual.
What You Will Not Find
in this Manual
•For maintenance of the chassis,
refer to the chassis manufacturer’s
service manual;
•For details on options such as
camera, tag axle, and
backing-accidents prevention
systems, refer to the optional
material manufacturer’s service
manual;
•For details on operation of the
Expert(t) 2000TM, refer to the
Expert(t) 2000TM’s Operator Manual;
•For details and schematics
concerning body parts, refer to the
Expert(t) 2000TM’s Parts Catalog.

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
Helping-HandTM lifting arm. The
sustained manual pressure control
shall be located so that the
co-worker pressing it, is not in the
path of thearm 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 the Labrie
Customer Support Center 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 splitted in half to create two
DANGER
FAILURE TO CONTACT LABRIE
ENVIRONMENTAL GROUP TO
REPORT ATWO-OPERATOR USE
OF THE UNIT MAY RESULT IN UNIT
AND / OR PROPERTY DAMAGES,
PERSONAL INJURY OR EVEN
DEATH.

3Expert(t) 2000TM
Maintenance Manual
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 having the body on
top of a straight frame chassis, they
have it on top of 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 for collecting
waste from roller carts.
SERVICE AND MAINTENANCE ON THE EXPERT(T)
2000TM
Maintenance on the Expert(t) 2000TM is
of outmost importance to ensure a
longer durability of all its parts and an
optimal performance in the field.
Maintenance has to be doneon 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 find the most
common maintenance and inspection
procedures needed on the Expert(t)
2000TM.
Helping-HandTM

4
Introduction
CONTACTING LABRIE ENVIRONMENTAL GROUP
Plant information
Address 175 du Pont
St-Nicolas (Quebec)
CANADA G7A 2T3
Phone: [phone]
[phone]
Fax: Sales Dept.:
[phone]
Service & Warranty:
[phone]
Parts:
[phone]
Labrie Customer
Support Center
Address 54 Park Place (Upper)
Appleton, WI 54914
Hot Line Technical Support,
Service & Warranty:
24-Hour Service
1-800-231-2771
Parts:
8 am through 7 pm ET
1-800-231-2771
Web Site: www.labriegroup.com
E-mail: [email protected]
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
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
ON DEATH OR SERIOUS INJURY.
CAUTION
INDICATES APOTENTIALLY
HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY.

6CHAPTER 1
Safety
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 the time of any
inspection, repair or maintenance
to the vehicle, whether it takes
place on the road or in the garage.
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 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
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 about any
damage or malfunction of the
vehicle.
• To make sure that there is nobody
near 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 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’SMANUAL BEFORE
ATTEMPTING TO PERFORM ANY
TYPE OF WORK ON THE UNIT.

8CHAPTER 1
Safety
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
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.
DANGER
NEVER PERFORM ANY REPAIR OR
MAINTENANCE ON AVEHICLE
THAT HAS NOT BEEN UNLOADED.

9Expert(t) 2000TM
Maintenance Manual
2. Turn the pump switch on 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 on 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.)
10. Release any residual pressure
from the hydraulic and
pneumatic system. Refer to “Air
Tank Draining Procedure” on
page 30 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:
•Battery
1
• ABS module (anti-lock
brake system)1
• Electronic transmission
(ECU)1
• Electronic engine module
(ECM)1
• Intermittent wiper module1
Master Switch
1. Refer to the chassis manufacturer
service manual to locate electronic
components.

10 CHAPTER 1
Safety
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
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