Labrie Top Select User manual

Maintenance Manual
Maintenance Manual
Top Select TM

Part # 90406 i
Contents
CHAPTER 1 Top Select Maintenance Guide ..............................1-1
Liability....................................................................................................1-2
Important Safety Notions ........................................................................1-3
General Precautions...............................................................................1-5
General Responsibilities of the Employer .......................................................1-7
General Responsibilities of the Employee ......................................................1-8
Summary of Daily Maintenance......................................................................1-9
Fire Hazard .....................................................................................................1-9
Lockout/Tagout Procedure..............................................................................1-10
Body Safety Prop............................................................................................1-12
Loading Bucket Safety Pin..............................................................................1-14
Tailgate Safety Prop........................................................................................1-16
Shutdown Procedure.......................................................................................1-17
Prior to Start Up...............................................................................................1-18
General Cleanliness................................................................................1-21
Body Daily Cleaning........................................................................................1-22
Loading Bucket Daily Cleaning .......................................................................1-24
Chassis Daily Cleaning ...................................................................................1-25

Contents
ii Part # 90406
Monthly Visual Inspection.......................................................................1-26
Visual Inspection on the Loading Bucket.........................................................1-27
Visual Inspection on the Roof..........................................................................1-29
Visual Inspection on the Tailgate.....................................................................1-30
Visual Inspection on the Body.........................................................................1-31
Visual Inspection on the Chassis.....................................................................1-33
Loading Container Maintenance ............................................................1-35
General Maintenance on the Loading Container.............................................1-35
Bucket Swing Out Procedure..........................................................................1-36
Container Rollers Replacement or Cleaning...................................................1-37
Sliding Shoe Replacement Procedure ............................................................1-39
Replacing the Bucket Rod Ends......................................................................1-40
Ajusting the Length of the Bucket Rods..........................................................1-42
Bucket Limit Switches Adjustment ..................................................................1-44
Limit Switch Arm Adjustment...........................................................................1-45
Optional Automatic Cart Latches Adjustment..................................................1-46
Replacing the Rod Ends of the Mobile Roof ...................................................1-47
Adjusting the Length of the Mobile Roof Rods................................................1-49
Replacing Loading Bucket Hydraulic Cylinders...............................................1-49
Removing the Roof Mechanism Pivot.............................................................1-51
Adjusting the Loading Bucket Cylinder Cushion .............................................1-52
Loading Bucket Partition Adjustment ..............................................................1-58
Tailgate and Body Maintenance.............................................................1-60
Tailgate Locking Mechanism (single tailgate)..................................................1-60
Tailgate and Hinges Inspection .......................................................................1-61
Replacing the Tailgate Hydraulic Cylinder.......................................................1-61
Tailgate Limit Switch Adjustment.....................................................................1-63
Body Chassis Hinges Inspection.....................................................................1-64
Body Raised Limit Switch................................................................................1-64
Body Partitions Adjustment .............................................................................1-65
Hydraulic System Maintenance..............................................................1-69
General Maintenance......................................................................................1-69
Hydraulic Cylinder Inspection..........................................................................1-69
Main Hydraulic Valve.......................................................................................1-70
Cycle Time For All Hydraulic Functions...........................................................1-70
Hydraulic Tank Inspection Procedure..............................................................1-71
Hydraulic Fluid Replacement Procedure.........................................................1-73
Strainer Cleaning Procedure...........................................................................1-75
Filter Element Replacement Procedure ..........................................................1-77
Hydraulic Gear Pump Systems ..............................................................1-79

Part # 90406 iii
Contents
Gear Pump Inspection Procedure...................................................................1-80
Main Relief Valve Pressure Adjustment..........................................................1-80
Pressure and RPM Chart (since January 2000) .............................................1-82
Body Hoist Replacement Procedure.......................................................1-83
Air System Maintenance.........................................................................1-87
Surface Finishing and Painting...............................................................1-89
Preventive Maintenance .........................................................................1-90
CHAPTER 2 Maximizer Maintenance..........................................2-1
General Cleanliness................................................................................2-2
Maximizer Daily Cleaning................................................................................2-3
Maximizer General Maintenance............................................................2-5
Maximizer Monthly Visual Inspection......................................................2-6
Pressure Adjustment...............................................................................2-9
Replacing the Maximizer Cylinder ..........................................................2-11
Removing the Cylinder Guard.........................................................................2-11
Removing the Cylinder....................................................................................2-12
Installing a New Cylinder.................................................................................2-13
Replacing the Maximizer.........................................................................2-15
Replacing the Maximizer Extensible Air Hose ................................................2-17
CHAPTER 3 Lubrication..............................................................3-1
Recommended Lubricant........................................................................3-2
Location of Grease Fittings on Chassis..................................................3-3
Location of Grease Fittings on Body.......................................................3-4
Lubrication Chart.....................................................................................3-6
CHAPTER 4 Troubleshooting......................................................4-1
Troubleshooting Table.............................................................................4-2
Internal Leak Detection for Cylinders......................................................4-3

Contents
iv Part # 90406
CHAPTER 5 Hydraulic and Pneumatic Schematics....................5-1
Pneumatics Top Select 1000 and Options .............................................5-2
Pneumatics Top Select 2000 and Options .............................................5-3
Pneumatics Brake System ..................................................................... 5-4
Pneumatics Brake System (Inter cab)....................................................5-5
Hydraulics Top Select 1000 With Maximizer ..........................................5-6
Hydraulics Top Select 2000 With Maximizer ..........................................5-7
Hydraulics Top Select 1000....................................................................5-8
Hydraulics Top Select 2000....................................................................5-9

Top Select Maintenance Manual 1-1
CHAPTER 1 Top Select
Maintenance Guide
Only body and Maximizer components maintenance guidelines
are outlined in this manual. For maintenance on the chassis,
refer to the chassis manufacturer’s service manual.

Top Select Maintenance Guide
1-2 Top Select Maintenance Manual
1.1 Liability
Labrie Environmental Group assumes no liability for any incidental, consequential or
other liability from the use of this information. All risks and damages, incidental or
otherwise, arising from use or misuse of the information contained herein are entirely the
responsibility of the user. Although careful precaution has been taken in the preparation
of this material, we assume no responsibility for errors or omissions.

Top Select Maintenance Manual 1-3
Important Safety Notions
1.2 Important Safety Notions
DANGER, WARNING, CAUTION notations appear throughout this manual and on labels
on and inside of the vehicle.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
SERIOUS INJURY OR DEATH.
DANGER
INDICATES APOTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN
SERIOUS INJURY OR DEATH.
WARNING
INDICATES APOTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY.
CAUTION
INDICATES APOTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
PROPERTY DAMAGE.
CAUTION

Top Select Maintenance Guide
1-4 Top Select Maintenance Manual
The word NOTE also appears in this manual and precedes information, which is vital to
the proper operation and maintenance of the vehicle equipment.
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 Labrie Plus
for any technical support you may require.
Establish and apply a periodic inspection program to keep moving parts in good working
order, properly adjusted and safe. It is recommended that a brief inspection be done by
the operator EVERYDAY and any detected malfunctions must be reported for correction
BEFORE using the equipment.
Once a month, inspect the chassis and the body for breaks, cracks or any potential
problems. Any defects found must be repaired without delay. To ensure the good working
order of the equipment, a particular attention should be paid to structural components in
order to prevent deterioration due to corrosion; touchups and/or complete paint jobs
should be done when necessary.

Top Select Maintenance Manual 1-5
General Precautions
1.3 General Precautions
It is the employer’s responsibility to make sure that the employees are qualified and
capable of operating this equipment.
THE FOLLOWING ARE GENERAL SAFETY RULES AND OPERATIONAL PRECAUTIONS WHICH
SHOULD BE OBSERVED BY OPERATORS AND/OR MAINTENANCE PERSONNEL AT ALL TIMES
1. Do not operate or service this vehicle before having read and completely understood
this manual and the safety labels on the vehicle. Maintenance personnel must also
read and understand the Operator Manual for this vehicle.
2. THE TOP SELECT MUST BE OPERATED BY ONLY ONE PERSON AT ATIME.
3. The operator must be in full and clear view of the operation of the moving hydraulic
systems at all times. The operator must be able to stop the motion of the hydraylic
systems at any time, in order to prevent injury to surrounding people or damage to
property.
4. The operator of the Top Select unit shall make sure that any people or obstructions
are far away from the loading bucket before moving it.
5. At the beginning of every working day, inspect the body, the Maximizer and any
system that might endanger the safety of the public and/or 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 incomplete repairs.
8. Report any doubts and any equipment safety service requirements to your supervisor.
9. Maximum speed, if permitted, while right-hand side driving is 20 MPH or 32 km/h.
FAILURE TO DO SO MAY RESULT IN UNIT AND/OR PROPERTY DAMAGES OR PERSONAL INJURIES.
WARNING

Top Select Maintenance Guide
1-6 Top Select Maintenance Manual
10.Keep both hands on the steering wheel at all times for better control.
11.Do not leave the driving position until the vehicle is completely stopped and the
parking brake applied.
12.When the vehicle is parked, the parking brake must be applied.
13.For any work, cleaning or inspecting being done between the body and the chassis,
the body safety prop MUST be used. The vehicle must also be on level ground.
14.Watch for and be absolutely sure that there are no people at the rear of the vehicle
when opening and closing the tailgate and/or when raising the body.
15. Observe the following:
16.Observe the following:
For any additional information, please contact Labrie Plus.
1-800-231-2771 (24 hours)
DONOT GET INTO THE BODY OR TRY TO REPAIR ANYTHING BEHIND THE MAXIMIZER WHEN IT IS
WORKING OR WHEN THE HYDRAULIC PUMP OR ENGINE IS STILL RUNNING. PERSONNEL
AUTHORIZED TO GET INTO THE BODY MUST FIRST COMPLETE THE LOCKOUT/TAGOUT
PROCEDURES REQUIRED BY THE EMPLOYER.
DANGER
WHILE COLLECTING RECYCLE MATERIAL, WATCH FOR EXPLOSIVE OBJECTS, SUCH AS
TELEVISION TUBES, FLUORESCENT TUBES, CANS UNDER PRESSURE, ETC. THE OPERATOR
MUST WEAR SAFETY EQUIPMENT, SUCH AS SAFETY GLASSES, GLOVES AND PROTECTIVE
FOOTWEAR AT ALL TIMES
WARNING

Top Select Maintenance Manual 1-7
General Precautions
1.3.1 General Responsibilities of the Employer
(REF. ANSI Z 245.1 THAT WAS IN EFFECT AT TIME OF PRODUCTION)
It is the employer’s responsibility to be familiar with and ensure that operation is in
accordance with safety requirements and codes including all applicable regulations,
including the Occupational Safety and Health Act (OSHA) and the American National
Standards Institute (ANSI).
It is also the employer’s responsibility to properly maintain all mobile equipment to meet
provincial/state and federal safety standards. The employer also has the following
responsibilities:
1. Supply adequate instructions and training for the safe use of the vehicle before
assigning 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 or any authorized representative.
3. The employer must keep a record of any breakdowns, malfunctions of the vehicle,
records of inspection and maintenance.
4. Any breaks or malfunctions that can affect the safe usage of the vehicle must be
repaired before the vehicle is to be used again.
5. Meet the appropriate lighting requirements for working at night (if permitted).
6. On a regular basis, accompany the operator of the vehicle and take measures to
insure the smooth and safe operation of the vehicle. Respect all safety measures.
7. Make sure the backup alarm works properly while vehicle is in reverse, the tailgate is
opening or the bucket is rising
8. At the end of this chapter, the owner will find a preventive maintenance chart. It is
strongly recommended that he follow it and keep a record of all work done on each
unit.

Top Select Maintenance Guide
1-8 Top Select Maintenance Manual
1.3.2 General Responsibilities of the Employee
1. The employee must enforce all of the safety requirements for mobile equipment
supplied by the employer and by the present manual.
2. Equipment is to be operated only after having received instructions and training in
accordance to the Operator Manual.
3. The employee has the responsibility to report any damages or malfunctions of the
vehicle to his employer or his supervisor without any delay. The employer will then
take the necessary measures prior to the re-operation of the vehicle to insure its safe
operation.
4. The employee must make sure that there is nobody near the vehicle before activating
any of the controls and must be prepared to stop anything in case of danger.
BEFORE DOING ANY MAINTENANCE ON THE VEHICLE, ALL SAFETY REGULATIONS MENTIONED IN
THE OPERATOR MANUAL, SECTION 2.0, MUST BE RESPECTED, ESPECIALLY THE “LOCKOUT/
TAGOUT” PROCEDURE.
WARNING
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 UNPROPER REPAIRS
PERFORMED BY THE END USER.
CAUTION

Top Select Maintenance Manual 1-9
General Precautions
1.3.3 Summary of Daily Maintenance
For the Top Select maintenance, there are basic steps to be performed daily. Any other
necessary maintenance operations are clearly presented further on in this guide. You
must first be familiar with all the precautions in this manual before going any further.
When the Top Select is brought in for daily maintenance, you must:
1. Apply lockout/tagout procedure as described in section 1.3.5 on page 10.
2. Perform daily cleaning following the instructions of section section 1.4 on page 21.
3. Perform the daily inspection as instructed in the Operator Manual. If anything wrong
comes up, perform a visual inspection, see section 1.5 on page 26.
4. Perform all the necessary maintenance following the visual inspection.
5. Review the preventive maintenance chart and perform any due care.
6. If any issue has been reported as wrong, go through the troubleshooting chart to fix
the problem.
1.3.4 Fire Hazard
If for any reason the maintenance personnel has to work on a truck that has not been
unloaded or for any type of work, a fire extinguisher should be readily available and close
to the vehicle. Anytime a loaded vehicle is inside a garage, there should be a fire
extinguisher at reach.
MAINTENANCE PERSONNEL SHALL NOT DO 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 WORK ON THE UNIT.
CAUTION

Top Select Maintenance Guide
1-10 Top Select Maintenance Manual
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 1-1. Fire extinguisher
NOTE:FIRE EXTINGUISHER LOCATION MAY VARY ACCORDING TO CHASSIS MODEL.
1.3.5 Lockout/Tagout Procedure
It is the employer’s responsibility to establish and apply a “lockout/tagout procedure” for
any inspection, repairs or maintenance being done on the vehicle, whether it is on the
road or at the shop. Before the “lockout/ tagout” procedure is applied, the body must be
unloaded.
DONOT PERFORM ANY REPAIR OR MAINTENANCE ON AVEHICLE THAT HAS NOT BEEN
UNLOADED.
DANGER

Top Select Maintenance Manual 1-11
General Precautions
FIGURE 1-2. Parking brake
FIGURE 1-3. Master switch
PARKING BRAKE
MASTER SWITCH
BEFORE PERFORMING ANY TYPE OF WELDING, SOAK WITH WATER ALL REMAINING RESIDUES
STUCK BETWEEN THE MAXIMIZER AND THE BODY TO PREVENT FIRE.
DANGER

Top Select Maintenance Guide
1-12 Top Select Maintenance Manual
1.3.6 Body Safety Prop
To install the body safety prop:
1. Lift the body until the safety prop is clear to be tilted under the body.
2. Pull the handle to release the safety prop, then pull down the safety prop.
SUGGESTED LOCKOUT/TAGOUT PROCEDURE
1. Apply the parking brake. Figure 1-2, on page 11.
2. Turn off the pump switch on the console (PTO switch).
3. Turn off 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.
7. If installed, turn off the master switch. Figure 1-3, on page 11.
8. Put an “OFF SERVICE” tag on all steering wheels.
9. Put an “OFF SERVICE” tag on the windshield.
10.Block any system that could move by gravity with a proper and visible safety prop
(open tailgate, raised body, etc.).
11.Release any residual pressure in the hydraulic and pneumatic system.
12.Block wheels on both sides to prevent movement of the vehicle.
13.Disconnect the following items if any type of welding is required.
•Batteries
•ABS module (anti-lock brake system)*
•Electronic transmission (ECU)*
•Electronic engine module (ECM)*
•Intermittent wiper module*
* Refer to the chassis manufacturer service manual to locate electronic components.

Top Select Maintenance Manual 1-13
General Precautions
3. Slowly lower the body until it rests properly on the prop.
FIGURE 1-4. Body safety prop
4. Once finished with repairs or inspection, slightly raise the body to release the safety
prop, bring it back to its vertical position and then lower the body.
DONOT USE PROPS WITH ALOADED BODY. NEVER STAND UNDER ARAISED AND LOADED
BODY.
DANGER

Top Select Maintenance Guide
1-14 Top Select Maintenance Manual
1.3.7 Loading Bucket Safety Pin
The loading bucket can be locked and secured at the end of its tracks (Figure 1-5 and
Figure 1-6) to allow access to the chassis components.
The upper parts of the unit should be accessed by maintenance personnel only and must
be reached only with a guarded platform that meets OSHA regulations about elevated
working stations.
Once engaged, the safety pins mechanically prevent any unwanted downward
movement of the loading bucket.
Installing the loading bucket safety pin:
1. Engage the hydraulic system.
2. Loading bucket has to be empty and in its rest down position. Unload prior to
continuing.
3. Lift the bucket until it is in full dump position.
4. Apply the Lockout/Tagout procedure. See section 1.3.5 on page 10.
5. Use a ladder to climb and get to where the safety pins are in stored position, then
remove them.
ALWAYS INSTALL THE SAFETY PINS IN BOTH FRONT AND REAR LOADING TRACKS.
WARNING

Top Select Maintenance Manual 1-15
General Precautions
FIGURE 1-5. Safety pins location in stored position
6. Install front and rear safety pins in the tracks. Make sure they are firmly held in place.
7. When service is completed, remove the safety pins and slowly lower the bucket to its
down position.
FIGURE 1-6. Safety pin for bucket in full dump position