Leach 2R-III Manuale utente

2R-III™

MAINTENANCE MANUAL

2R-III™

MAINTENANCE MANUAL

Liability

Labrie Enviroquip Group assumes no liability for any incidental, consequential, or other liability that

might result from the use of the information contained in this document.

All risks and damages, incidental or otherwise, arising from the 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 document, Labrie Enviroquip

Group assumes no responsibility for errors or omissions.

December 2015

Liability ........................................................................................ ii

Table of Contents ........................................................................ v

Introduction ................................................................................ 1

Introducing the 2R-III™ ................................................................................................................................................................... 1

Terms You Will Need to Know .............................................................................................................................................. 1

Waste Handling Process ................................................................................................................................................................. 3

Loading ......................................................................................................................................................................................... 3

Packing .......................................................................................................................................................................................... 3

Unloading ..................................................................................................................................................................................... 4

Container Handling Systems ........................................................................................................................................................ 5

Terms You Need to Know ....................................................................................................................................................... 6

Container Handling Process ......................................................................................................................................................... 8

Attaching ...................................................................................................................................................................................... 8

Dumping ....................................................................................................................................................................................... 8

Releasing ....................................................................................................................................................................................... 8

To Contact Labrie Plus .................................................................................................................................................................... 9

In the U.S. ...................................................................................................................................................................................... 9

In Canada ...................................................................................................................................................................................... 9

Safety ......................................................................................... 11

Safety Decals ................................................................................................................................................................................... 11

Conventions .................................................................................................................................................................................... 12

Basic Safety Notions ..................................................................................................................................................................... 13

Responsibilities ............................................................................................................................................................................... 13

Employer Responsibilities ................................................................................................................................................... 13

Employee Responsibilities ................................................................................................................................................... 14

Things to Do .................................................................................................................................................................................... 14

Things to Avoid .............................................................................................................................................................................. 14

Safety Precautions ......................................................................................................................................................................... 15

Prior to Start-Up ...................................................................................................................................................................... 15

General Operation .................................................................................................................................................................. 16

Hydraulics .................................................................................................................................................................................. 18

Fire Protection ......................................................................................................................................................................... 18

Housekeeping .......................................................................................................................................................................... 19

Safety Features ............................................................................................................................................................................... 20

Back Up Alarm .......................................................................................................................................................................... 20

Tailgate Safety Props ............................................................................................................................................................. 20

Camera System ........................................................................................................................................................................ 25

Tailgate Open Proximity Switch Test .............................................................................................................................. 26

Locking Out and Tagging Out the Vehicle ........................................................................................................................... 28

Shutting Down the Vehicle ........................................................................................................................................................ 29

Prior to Start-Up ............................................................................................................................................................................. 30

General Repair Practices ........................................................... 33

Preparation for Service ................................................................................................................................................................ 33

Replacement Parts ........................................................................................................................................................................ 34

Technical Service Bulletins ......................................................................................................................................................... 34

Safety Precautions ......................................................................................................................................................................... 34

Prior to Performing any Service or Repair ..................................................................................................................... 34

Table of Contents

vi Table of Contents

During Service or Repair ....................................................................................................................................................... 34

Welding Precautions ..................................................................................................................................................................... 35

Electric Welders ....................................................................................................................................................................... 35

Oxy-Acetylene Torches ......................................................................................................................................................... 35

Removal, Disassembly and Repair ........................................................................................................................................... 36

Reassembly and Installation ...................................................................................................................................................... 36

Electrical Testing ............................................................................................................................................................................ 37

Checking for Voltage ............................................................................................................................................................. 37

Checking Continuity .............................................................................................................................................................. 37

Diode Testing ........................................................................................................................................................................... 37

Welding ............................................................................................................................................................................................. 38

Capacity of Lifting Device Required for Removal ............................................................................................................... 38

Capscrew Marking and Torque Values ................................................................................................................................... 39

Hydraulic Fitting Torque Values ............................................................................................................................................... 40

Specifications ............................................................................ 41

Lubricants ......................................................................................................................................................................................... 41

Hydraulic System ........................................................................................................................................................................... 41

Capacity (approximately) ..................................................................................................................................................... 41

Total System ............................................................................................................................................................................. 41

Pump .................................................................................................................................................................................................. 42

Leach Hydraulic Fluid Recommendation .............................................................................................................................. 42

Body Dimensions ........................................................................................................................................................................... 43

Hydraulic Fluid ................................................................................................................................................................................ 44

Preventive Maintenance ........................................................... 45

Operating and Maintenance Records ..................................................................................................................................... 45

Lubrication Chart ........................................................................................................................................................................... 46

Recommended Lubricants .................................................................................................................................................. 46

Hydraulic System Service ............................................................................................................................................................ 47

Checking Fluid Level (Daily) ................................................................................................................................................ 47

Checking Tank Breather Cap (Weekly) ............................................................................................................................ 47

Check/Replace Return Line Filter Element .................................................................................................................... 49

Replacement of Filter Element ........................................................................................................................................... 49

Flushing Hydraulic System / Cleaning Hydraulic Strainer (Yearly) ........................................................................ 49

Contamination ................................................................................................................................................................................ 50

Daily Preventive Maintenance .................................................................................................................................................. 50

Inspection .................................................................................................................................................................................. 50

Cleaning ..................................................................................................................................................................................... 50

Lubrication ................................................................................................................................................................................ 51

Container Handling Equipment ........................................................................................................................................ 51

Weekly Preventive Maintenance .............................................................................................................................................. 51

Cleaning ..................................................................................................................................................................................... 51

Inspection .................................................................................................................................................................................. 52

Lubrication ................................................................................................................................................................................ 52

Hydraulic System .................................................................................................................................................................... 52

Container Handling System Hardware ........................................................................................................................... 52

Pivot Points ............................................................................................................................................................................... 52

Carrier Cylinder Pivot Maintenance ................................................................................................................................. 52

Wire Rope (Cable) ................................................................................................................................................................... 53

Maintenance Recommendations ...................................................................................................................................... 54

Monthly Preventive Maintenance ........................................................................................................................................... 54

Lifting Hook ............................................................................................................................................................................... 54

Yearly Preventive Maintenance ................................................................................................................................................ 55

Table of Contents vii

Hydraulic System .................................................................................................................................................................... 55

Check-Out .................................................................................. 57

Checking Hydraulic Tank Fluid Level ..................................................................................................................................... 58

Checking Engine Speed Up Switch ......................................................................................................................................... 58

Checking Engine Speed Up Switches (Body) ...................................................................................................................... 59

Checking Pack Cycle Time .......................................................................................................................................................... 60

Checking Pressures ....................................................................................................................................................................... 61

Checking Main Line Pressure ............................................................................................................................................. 62

Checking Packer and Carrier Panel Shift (Knockout) Pressures ............................................................................. 64

Checking Resistance Cartridge Pressure ........................................................................................................................ 65

Checking Packer High Pressure (Circuit) Relief Cartridge ........................................................................................ 68

Checking Accessory (Circuit) Relief Cartridge .............................................................................................................. 69

Checking Pushout Panel Shoes ................................................................................................................................................ 70

Power Take Off (P.T.O.) ................................................................................................................................................................ 70

Troubleshooting ....................................................................... 71

Compaction ..................................................................................................................................................................................... 71

Dieseling in Hydraulic Systems ................................................................................................................................................. 72

Troubleshooting Tables .............................................................................................................................................................. 73

Hydraulic System ........................................................................................................................................................................... 81

System Component Nomenclature ................................................................................................................................. 81

Transmission in Neutral (with Packer and Carrier Panels in the “Home” Position) ......................................... 82

Packer Panel Sweeps Back Over Load ............................................................................................................................. 83

Carrier & Packer Panels Move Down to “Interrupted Cycle” Position .................................................................. 84

Packer Panel Sweeps Hopper ............................................................................................................................................. 85

Packing Refuse (1) .................................................................................................................................................................. 86

Packing Refuse (2) .................................................................................................................................................................. 87

Raising Tailgate ....................................................................................................................................................................... 88

Ejecting Load ............................................................................................................................................................................ 89

Retracting Pushout Panel .................................................................................................................................................... 90

Lowering Tailgate ................................................................................................................................................................... 91

Service & Repair ........................................................................ 93

Description of Operating Cylinders (Carrier and Packer Panels) .................................................................................. 93

Test for Leaking Packer Panel Cylinders ................................................................................................................................ 94

Test for Leaking Carrier Panel Cylinders ................................................................................................................................ 97

Removal of Packer Panel Cylinders ....................................................................................................................................... 101

Removal of Carrier Panel Cylinders ....................................................................................................................................... 104

Disassembly of Operating Cylinders .................................................................................................................................... 107

Inspection and Replacement of Operating Cylinders .................................................................................................... 108

Reassembly and Installation of Operating Cylinders ...................................................................................................... 109

Description of the Packer Panel ............................................................................................................................................. 109

Bearing Placement ...................................................................................................................................................................... 110

Roller Replacement ..................................................................................................................................................................... 111

Carrier Roller Adjustment & Maintenance ................................................................................................................... 114

Wear Shoe Replacement ........................................................................................................................................................... 116

Wear Shoe Adjustment ....................................................................................................................................................... 120

Tailgate Lift Cylinders ................................................................................................................................................................. 124

Test for Leaking Tailgate Cylinders ................................................................................................................................ 125

Removal of Tailgate Lift Cylinders .................................................................................................................................. 126

Draining Fluid from Tailgate Lift Cylinder ................................................................................................................... 127

Inspection, Reassembly and Installation of Tailgate Lift Cylinder ...................................................................... 127

Tailgate Assembly ....................................................................................................................................................................... 128

viii Table of Contents

Removal of the Tailgate Assembly ................................................................................................................................ 129

Inspection of Tailgate ......................................................................................................................................................... 130

Reassembly and Installation of Tailgate ...................................................................................................................... 131

Front Control Valve (FCV) ......................................................................................................................................................... 131

Removal of the Front Control Valve .............................................................................................................................. 131

Disassembly and Reassembly of the Front Control Valve ..................................................................................... 132

Reinstallation of the Front Control Valve .................................................................................................................... 133

Main Control Valve (MCV) ........................................................................................................................................................ 133

Removal of the Main Control Valve ............................................................................................................................... 134

Disassembly and Reassembly of the Main Control Valve ...................................................................................... 135

Main Control Valve Resealing .......................................................................................................................................... 136

Telescopic Cylinder .................................................................................................................................................................... 139

Removal of Telescopic Cylinder ...................................................................................................................................... 139

Pushout Panel .............................................................................................................................................................................. 140

Wear Block Replacement .................................................................................................................................................. 141

Removal of Pushout Panel ................................................................................................................................................ 142

Installation of Pushout Panel ........................................................................................................................................... 143

Carrier and Packer Panels ......................................................................................................................................................... 144

Packer Panel .................................................................................................................................................................................. 145

Removal of Packer Panel ................................................................................................................................................... 145

Inspection and Replacement of Packer Panel ........................................................................................................... 148

Replacement of Packer Edge ........................................................................................................................................... 148

Installation of Packer Panel .............................................................................................................................................. 149

Carrier Panel .................................................................................................................................................................................. 149

Removal of Carrier Panel ................................................................................................................................................... 150

Inspection and Replacement of Carrier Panel ........................................................................................................... 151

Installation of Carrier Panel .............................................................................................................................................. 151

Track Bar Replacement ...................................................................................................................................................... 152

Hydraulic Pump ........................................................................................................................................................................... 152

Removal of Hydraulic Pump ............................................................................................................................................ 153

Installation of Hydraulic Pump ........................................................................................................................................ 154

New Pump Preparation ..................................................................................................................................................... 154

Testing a New Pump ........................................................................................................................................................... 155

Electrical System .......................................................................................................................................................................... 156

Testing ..................................................................................................................................................................................... 156

Repair ....................................................................................................................................................................................... 156

Inspection ............................................................................................................................................................................... 156

Schematics ............................................................................................................................................................................. 156

Service Tools ................................................................................................................................................................................. 156