TROUBLESHOOTING - Superior Truck Equipment Inc.
Contents
1. HOLOINNOI Hosin30 019NNO2 aly AGOA NO TROUBLESHOOTING FIGURE 3 6 3 18 3 5 PUMP CAVITATION The cavitation is defined as the formation of air pockets in a moving fluid The presence of airin the hydraulic oil produces cavitation inside the pump generating excessive noise Cavitation is forming most of the time after replacing hydraulic components or after flushing the hydraulic system Make sure to prime the pump properly after its replacement Refer to General Maintenance section 1 17 Priming a new pump in the General Maintenance Manual When the pump is properly primed the cavitation will disappear after a short time because air is returning to the hydraulic tank If the pump still generates unusual noise after the priming procedure has been apply the following procedure to remove residual air from the system Loosen ring 4 Ma ve mr 4 A i al FIGURE 3 7 EXPERT 20007 HYDRAULIC SYSTEM BLEEDING PROCEDURE Apply all safety measures to ensure safety around the vehicle at all times Connect a 0 4000PSI gauge to the main valve to ensure that no pressure build up is present in the system Apply the parking brake Start the engine Engage the hydraulic pump PTO switch ON Loosen slowly the press2. TK WIRE 131 NC WIRE 156 FIGURE 3 54 TROUBLESHOOTING PROCEDURE CONTINUES 10 Using a multimeter or a VOM check the continuity between the wire 131 on the pressure switch and wire 531 on the auto neutral relay 1 Check for continuity between wire 156 on the pressure switch and the wire 556 on the auto neutral relay 1 amp 2 If one or both tests failed replace the harness part 23560 for conventional cab or part 27731 for cab over 3 53 3 16 ELECTRIC SCHEMATICS SYMBOLS on pneumatic line 1 PNI00605 6 11116 10 fuses ATO fuse block ELR00460 Typical 1 te 21 12 volt single pole N O N C relay and base 3 577 ELR00810 and base ELR00860 ELL02765 _ 12 volt alternating flasher relay crudi J d ELR 00700 12 volt amber flashing light ELL02855 Me 55 PSI pressure switch N O installed on pneumatic S 12 volt work light ELL01300 tine 1 PNI00600 M 0 60 PSI adjustable pressure switch N O installed 12 volt backup alarm on chassis ELA00700 p Sa 2 solenoid valve PNV01957 Packer module CL ELM01005 CF ELM01025 12 volt dual solenoid val
3. 5 Restriction in the system SOLUTION S Perform hydraulic pressure adjustment procedure Refer to section 1 15 Hydraulic Vane Pump Systems or section 1 16 Gear Pump Systems for pressure adjtment procedure Refer to section 3 19 Internal leak detection Replace the pump SOLUTION S Add oil to the required level Refer to section 1 14 5 Hydraulic tank inspection procedure Perform the hydraulic pressure adjustment procedure Refer to section 1 15 Hydraulic Vane Pump Systems or section 1 16 Gear Pump Systems for pressure adjtment procedure See section 2 1 Recommended Lubricants for proper type oil to use Refer also to section 1 14 6 Hydraulic oil replacement procedure 4 Clean the strainer inside the tank and change the return filter element Fill with clean oil Refer to section 1 14 6 1 14 7 amp 1 14 8 5 Check all hydraulic components that may have debris causing restriction in the system Have the pump inspected by a specialist 3 9 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM POSSIBLE CAUSE S SOLUTION S Oil is foaming 1 Low oil level 1 Add oil to the required level Refer to section 1 14 5 Hydraulic tank inspection procedure 2 Air getting into the system 2 Tighten the connections of all hoses and pipes between the pump and the hydraulic tank 3 Not the proper grade of oil Empty oil and refill with an
4. Refer to section 3 8 Packer module troubleshooting SOLUTION S Reprogram the module for higher number of cycles Refer to section 3 9 Packer multi cycle module programming EXPERT 2000 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM Crusher panel does not go down PROBLEM The backup alarm and the warning buzzer inside the cab work all the time POSSIBLE CAUSE S 1 Hydraulic pressure adjustment 2 Electrical POSSIBLE CAUSE S 1 Tailgate limit switch out of adjustment 2 Body raised limit switch out of adjustment 3 Limit switch 4 Faulty harness 3 15 SOLUTION S 1 Make sure the hydraulic system is engaged PTO switch ON and the pressure settings are adjusted Refer to section 1 15 Hydraulic Vane Pump Systems or section 1 16 Gear Pump Systems for pressure adjtment procedure Refer to section 3 7 Crusher panel troubleshooting SOLUTION S Adjust the limit switch arm with the tailgate cylinder Refer to section 1 13 5 Tailgate limit Switch 2 Adjust the limit switch arm with the body floor Refer to section 1 13 4 Body raised limit switch adjustment 3 Check the limit switch with a multimeter or VOM for proper operation ON OFF or click 4 Check for continuity on the electrical harness that is connected to the limit switch Change the electrical harness if necessary TROUBLESHOOTING 3 16 3 4 PUMP TRO
5. 3 31 If the packer does not start at all or moves forward only when holding the start cycle button green apply the following procedure to solve problem NOTE THIS PROCEDURE ALSO APPLIES TO THE RETRACT BUTTON YELLOW PACKER MODULE TROUBLESHOOTING Apply all safety measures to ensure safety around the vehicle at all times Ensure that the parking brake is applied and start the engine Make sure all Emergency Stop Buttons Red are pulled out Remove the access panel on the L H side of the hopper Figure 3 22 This will give access to the packer module Start the engine Select the proper control station for multiple packer control stations Press the start cycle button green or the retract button yellow on the packer control station Left or right and see if the LED OUT 3 OUT 2 for retract button on the module turns ON and stays ON If the LED does not stay REPLACE THE PACKER MODULE If the LED OUT 3 OUT 2 for retract button stays ON and the packer does not move the hydraulic valve controling may be stuck or defective see Section 3 6 TROUBLESHOOTING 3 32 PACKER MODULE TROUBLESHOOTING When either LED IN 7 or IN 8 is check for a 12 volt signal at the valve coming from the packer module on wire 106 packer extend and wire 107 packer retract If you read 12 V refer to Secti
6. Broken wires or loose connection between the console speed up relay s and the engine ECM module or the speed up air cylinder may cause the engine speed up not to work properly A continuity test of this harness is then required Also refer to the Speed up relays to engine ECM harness table Figure 23 41 to find out the type of relay configuration installed on your particular truck This table will indicate the proper wire to test between related pins on the relays and the engine ECM connector NOTE AN ELECTRONIC MULTIMETER OR VOM IS REQUIRED TO PERFORM THIS TEST SEE FIGURE 3 37 ADD AN EXTRA 20 FEET OF CABLE AND TWO INSULATED ALLIGATOR CLIPS TO THE MULTIMETER PROBE TO REACH THE ECM MODULE CONNECTOR UNDER THE HOOD EXCEPT FOR VOLVO WHERE THE MODULE IS LOCATED INSIDE THE CAB EXPERT 2000 HARNESS CONTINUITY TEST PROCEDURE Apply all safety measures to ensure safety around the vehicle at all times Open the console locate and identify the relay s according to figure 3 38 or 3 9 Remove the relay s from the socket s using a small screw driver Refer to the table on figure 3 41 to identify the wires and the related pins on the relay s and the wires on the ECM connector to perform a continuity test Use a multimeter VOM and connect one test probe to the relay socket pin see speed up relay table and the other probe on the ECM module connector There should be continuity between both ends
7. If one of the continuity tests fails between the ECM and any of the relay socket pins check for broken wires or loose connection Replace the harness between the console and the ECM if necessary 3 41 SPEED UP 1 RELAY CONFIGURATION SEE TABLE FIGURE 3 34 FIGURE 3 35 SPEED UP NOTE DEPENDING ON WHICH TYPE 2 RELAY CONFIGURATION OF ENGINE ONE OR TWO SEE TABLE RELAYS MIGHT BE INSTALLED INSIDE THE a gt CONSOLE SEE FIGURE 3 35 RELAY1 amp 3 36 Eg TABLE BELOW TO IDENTIFY 5 THE PROPER RELAY S AND THE WIRE NUMBER TO TEST FIGURE 3 36 TROUBLESHOOTING RELAY SOCKET LAYOUT AND PIN NUMBERS FIGURE 3 37 EXPERT 2000 3 43 SPEED UP RELAY S TO ENGINE ECM HARNESS TABLE ENGINE TYPE LOCATION Into console Body builder harness on L H side of the engine compartment Into console On ECM connectors Into console On ECM connectors Into console On ECM connectors International Navistar engine Cummins engine ISB ISC Cummins engine ISM Cummins engine M11 Cummins engine EPA 2004 ISB ISC ISL ISM Into console On ECM connectors On ECM Wire 3 Wire 46 Wire 56 Wire 795 connectors pin 3 pin 46 pin 56 pin 5 Caterpillar engine w Labrie cab or Sterling chassis Into console Caterpillar engine Labrie cab Volvo engine On R H side into cab ECM Module Into console Mack engine
8. Wire 557 black Set relay pin 30 Wire 46B grey Wire 560 black Remote PTO relay pin 30 Wire 560 pin 46 Wire 560 black Remote PTO relay pin 30 Wire 560 pin 34 Wire 560 black Remote PTO relay pin 30 Wire 560 pin 15 Wire 4 Remote PTO relay pin 87 Wire 4 4 Wire 3 Throttle advance relay pin 87 Wire 562 white WIRE NUMBERS AND TEST POINTS Wire 558 red Set relay pin 87 Wire 97CB purple Wire 34 Remote PTO relay pin 30 Wire 34 pin 34 Wire 46 Remote PTO relay pin 30 Wire 561 Black Remote PTO relay Remote PTO relay pin 30 Wire 560 Wire 560 Remote PTO relay Remote PTO relay pin 30 pin 14 blue connector Wire 526 pin 14 on ECM under driver s seat green connector Wire 526 white Speed up Mack relay pin 87 Wire V J2 9 0 8 on PTO switch from Mack Wire 559 green Enable preset relay pin 30 Wire 97DF purple Wire 56 Throttle advance relay pin 30 Wire V J1 6 0 8 speed control switch from Mack Wire 795 Remote PTO relay pin 87 On ECM Wire 562 Wire 561 connectors pin 3 pin 56 RELAY CONFIGURATION 2 Relay See Figure 3 39 1 Relay See Figure 3 38 1 Relay See Figure 3 38 1 Relay See Figure 3 38 1 Relay See Figure 3 38 2 Relay See Figure 3 39 1 Relay See Figure 3 38 1 Relay See Figure 3 38 1 Relay See Figure 3 38 FIGURE 3 38 A
9. DIFFERENT FACTORY SETTINGS Inorderto increase orto reduce the number of cycle use the set of DIP switches on the module Figure 3 29 Refer to the following table Figure 3 28 to set the module properly The same table is found on the module Figure 3 29 3 33 MULTI CYCLE PROGRAMMING TABLE FIGURE 3 26 MULTI CYCLE MODULE DIP SWITCH TOP OF THE MODULE TROUBLESHOOTING 3 34 3 10 PACKER MULTI CYCLE MODULE TROUBLESHOOTING a If the packer no longer performs the multi cycling more than one cycle when the start cycle button green is pressed apply the following procedure to verify the system TROUBLESHOOTING PROCEDURE FIGURE 3 28 1 Make sure the DIP switch setting is within the rectangle setting NOTE ALWAYS REFER TO THE found on the multi cycle ELECTRICAL SCHEMATIC programming table Figure 3 28 WHILE TROUBLESHOOTING improper DIP switch setting could keep the packer from cycling ENS sure the automatic cycle button Cor on the console is set to Manually retract the packer using the Retract button Yellow Lower the crusher panel if the crusher panel can move this indicates that the limit switch behind the packer is working properly Make sure the 3 Amps fuse at the bottom of the module is not blown or loos
10. System Maintenance 2 Speed up relay s inside the console is are NOT powered 3 Faulty wires between the console and the engine s ECM Engine Control Module EXPERT 2000 SOLUTION S 1 Check the speed up inhibitor switch on the console the speed up must be set to Enable Refer to section 3 11 Speed up Troubleshooting Test for continuity between the speed up relay s and the engine s ECM Refer to section 3 12 Speed up harness continuity test 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM The packer does not complete a full cycle PROBLEM The packer does not start at all when pressing Start Cycle green button POSSIBLE CAUSE S Body is full preventing the packer from reaching the fully extended position 2 An accumulation of garbage behind the packer prevents the packer from reaching the fully retracted position Packer limit switch operation affected by debris or out of adjustment Electrical feed or coil on valve is defective POSSIBLE CAUSE S PTO switch Emergency Stop buttons red Packer control station not selected Hydraulic Faulty harness between the packer module and the packer control station 6 Defective packer module 3 13 SOLUTION S 1 Empty the body Refer to the Operator s Manual section 3 4 9 Breaking the load 2 Clean behind the packer Refer to section 1 11 Cleanin
11. TROUBLESHOOTING EXPERT 2000 Table of contents 3 20 MAIN HYDRAULIC SCHEMATIC VANE PUMP 3 59 EXPERT 2000 3 5 3 0 TROUBLESHOOTING 3 1 INTRODUCTION This section contains information that will help Labrie end users to narrow down and solve problems that might occur on the standard Labrie Expert 2000 unit Procedures throughout this section require from the people who will perform troubleshooting tasks to have basic knowledge in electrical hydraulic and pneumatic systems The employer shall ensure that the maintenance personnel are trained prior to beginning troubleshooting Before proceeding to some maintenance on a vehicle make sure that all safety procedures are applied The lockout tagout procedure outline in the Operators Manual is mandatory to ensure the safety of those who works on and around the vehicle Refer to section 3 3 Troubleshooting guide in order to resolve commonly seen problems or contact LabriePlus to talk to one of our product specialists labrie plus Technical support 24 Hour Service Parts service and warranty During business hours 1 800 231 2771 TROUBLESHOOTING Intentionally left blank EXPERT 2000 3 7 3 2 TOOL REQUIREMENTS Two oil gages 0 4000psi To pinpoint the cause of a problem on a vehicle some hand tools are necessary to perform tests on components pneumatic hydraulic or electrical Here is a list and pic
12. between PIN 1 amp PIN 2 Figure 3 19 If the 12 volt signal is present on wire 108 remove clean and inspect the valve replace the solenoid valve if necessary If no 12 volt signal is found on the connector check connector J1 at the packer module and test for 12 volt signal on wire 108 change the harness between the module and the solenoid valve if the 12V signal is found EXPERT 2000 Problem 2 If the crusher panel seems to be working at all the time when the packer is cycling the crusher panel lock valve must be faulty or stuck Replace the lock valve IN 7 Packer fully retracted LOCK VALVE FIGURE 223 19 PACKER MODULE LED S LAYOUT OUT 1 OUT2 OUT3 OUT4 OUT5 ee FIGURE 3 20 Refer to Figure 3 27 for more information on LED s layout of the packer module 3 7 PACKER MODULE TROUBLESHOOTING The packer module was designed with set of LED s to indicate the status of the packer system These LED s are used to monitor the activity of the packer module during a normal cycle At any given time each LED refers to an input or an output For example if the start cycle button green is pressed the LED OUT 3 should turn ON and stay ON until the packer reaches the end of the stroke Figure 83 19 FIGURE 3 19 PACKER MODULE LED S LAYOUT IN 1 IN 5 OUT 1 OUT2 OUT3 OUT4 OUT 5 FIGURE 3 20 Refer to figure 3 2
13. extend signal the spool will move accordingly PACKER AIR ACTUATORS 3 ACTUATORS BI QUICK EXHAUST 2 5 VALVES FIGURE 3 8 3 19 J VALVE a gI N Sl 3 FIGURE 3 9 Four quick exhaust valves two of which are located close to the body main valve Figure 3 8 and two under the hoist cylinder Figure 3 10 are designed to release the air pressure from lines going to the packer air actuator installed on the main control valve They release air when the packer reaches the end of a stroke allowing the spool to move in the opposite direction and to prevent working against pressurized lines vw 7 QUICK EXHAUST VALVES 2 _ Br re i n 77 E bd iini gol TROUBLESHOOTING 3 20 3 6 PNEUMATIC OVER HYDRAULIC VALVE TROUBLESHOOTING CONT D PACKER AIR SYSTEM TROUBLESHOOTING Troubleshooting Apply all safety measures to If the packer does not complete a full ensure safety around the vehicle cycle it may be related to the air system at all times In order to resolve the problem apply the Remove the optional cover if following procedure applicable over the valve to get access to the air tubes Remove the air tube from the actuator pushing on the green sleeve with screwdriver Figure 3 11 Pull the tube Figure 3 12 To ensure that the spool moves freely inside the valve inject pressurized air in one side of the actu
14. faulty parts if necessary Remove the auto neutral relay 1 from its socket put an alligator clip between the terminal 30 amp 87 Figure 3 44 If the transmission changes from Drive to Neutral replace the relay If all the previous tests are fine and the Auto neutral is still not working properly locate the transmission ECU inside the cab and perform the following tests Perform a continuity test between the Labrie wire 550 on the auto neutral switch and the Allison wire 153 on the ECU module connector RELAY SOCKET LAYOUT AND PIN NUMBERS FIGURE 3 44 TROUBLESHOOTING TROUBLESHOOTING PROCEDURE CONTINUES 10 Perform a continuity test between the Labrie wire 529 on the relay socket and the Allison wire 117 of the ECU module connector Perform a continuity test between the Labrie wire 528 on the relay socket and the Allison wire TROUBLESHOOTING PROCEDURE CONTINUES 13 The transmission ECU programming may be faulty preventing the ECU from engaging the Auto neutral sequence Refer to section 3 17 Allison Transmission Programming Parameters or contact LabriePlus 161 on the ECU module for further details regarding the connector ECU programming If one of the above tests fails check for broken wires or loose connections Replace the harness between the console and the ECU if necessary 4 OUTLETS WHITE PLASTIC CONNECTOR AMP LE 153 AUTONEUT
15. holes the pressure switch that triggers the service brake light may be defective Apply the following procedure in order to verify the pressure switch and the electrical wires This procedure requires the use a multimeter or a VOM and the main electrical diagram of the vehicle located inside the console NOTE ON SOME UNITS THE SERVICE BRAKE LIGHT AND THE NEUTRAL LIGHT ARE LOCATED DIRECTLY ON THE TOGGLE SWITCH BOX NEUTRAL 3 LIGHT m i SERVICE BRAKE SS LIGHT P i dt E FIGURE 3 46 3 49 TROUBLESHOOTING PROCEDURE Apply the lockout tagout procedure Remove the toggle switch panel in order to reach the pressure switch Figure 3 52 Disconnect the wires from the pressure switch Perform a continuity test between each terminal and the casing of the pressure switch If any continuity is found replace the pressure switch Part 100600 Connect the multimeter probes to the pressure switch between the terminals TTR and TLR See Figure 3 49 Move the toggle switch up in order to change the state of the pressure switch ON OFF The multimeter should indicate continuity when the toggle switch is set to ON If not replace the pressure switch Part 100600 R H SIDE DASH BOARD TROUBLESHOOTING 3 50 TROUBLESHOOTING PROCEDURE CONTINUES If the pressure switch state is fine perform a continuity test between the pressure switch wires and both the co
16. hydraulic cylinder Apply the following procedure TAILGATE HYDRAULIC TROUBLESHOOTING Apply all safety measures to FIGURE 3 64 ensure safety around the vehicle at all times Problem 2 Ensure that the parking brake is Tailgate is LOWERING by itself applied Pull out all Emergency Stop One other problem that may be found on Buttons the tailgate hydraulic system is that it Install a pressure gage on each would lower by itself A faulty velocity fuse port of the tailgate section on the might be involved Apply the procedure valve as shown on figure 3 64 below in order to verify and or replace the Start the engine and engage the velocity fuse hydraulic pump Press on the Start cycle button green to start the packer Gage 1 should always indicate OPSI and gage 2 should indicate a sudden pressure burst between 0 PSI to 3000 PSI each time the packer reaches the end of a stroke If gage 1 indicates pressure this may be caused by a faulty holding valve or hydraulic hoses not properly connected Refer to the main hydraulic schematic for proper connection TAILGATE HYDRAULIC TROUBLESHOOTING Apply all safety measures to ensure safety around the vehicle at all times Ensure that the parking brake is applied Remove the velocity fuse Figure 3 62 and verify that it is clean and that the plunger is moving freely A new velocity fuse may be necessary TROUBLESHOOTING 3 58 TAILGATE HYDRAULIC CIRC
17. state of a coil set up an ohmmeter on the female connector and take a mesurement of resistance Two scenarios may 3 23 PACKER TROUBLESHOOTING CONTINUES be found zero 0 reading means a short circuit and one 1 means an open circuit both readings indicate the coil is defective Any other reading would indicate the cause of the problem is elsewhere 11 Refer to Section 3 8 Packer Module Troubleshooting CRUSHER PANEL LS NEA Prata _ 050 E W PACKER A ES FIGURE 3 11 TROUBLESHOOTING 3 24 FIGURE 3 14 FIGURE 3 13 FIGURE 3 15 EXPERT 2000 3 7 CRUSHER PANEL TROUBLESHOOTING How it works Thecrusher panel is controlled by a manual lever located on the main hydraulic valve Figure 3 16 The crusher panel is not allowed to move down until the packer is stopped in its fully retracted position However it be raised at any time while packer is moving An interlock system is preventing the crusher panel from lowering when the packer is moving Garbage caught between the packer and the crusher panel could be blown outside the hopper Damage could also occur to the top of the packer and the follower panels When the packer has finished its series of cycles it returns to its fully retracted position where the R H side packer limit switch enables the packer module to send a 12 volt signal to the
18. with the positive probe at each test point NOTE ITISNOT RECOMMENDED TO STRIP OR TO POKE THROUGH THEM TO PERFORM TESTS AS THIS COULD CREATE SHORTS AND OR WIRE DETERIORATION TEST DIRECTLY IN CONNECTORS AND SWITCHES Between steps 14 and 15 the transmission ECU is used as an interlock or safety for the PTO signal 12V input on wire 104 If the engine RPM is higher than 900RPM the transmission ECU will not allow the output signal 12V output on wire 149 preventing the pump from engaging at high RPM The transmission ECU will wait until the throttle drops under 900RPM allowing the 12 volt output signal on wire 149 test point 15 Continue following the path until reaching test point 19 If one of the test points failed try to pinpoint the source of the shortage between the previous test point and the failing test point NOTE NEITHER THE ENGINE THROTTLE NOR THE TRANSMISSION NOT BEING IN NEUTRAL WILL AFFECT THE PUMP OPERATION ONCE THE PUMP IS ENGAGED 3 17 31054029 OLNI 237979 1331 OL 1081 33055344 WOWJ N3MOd Old YIMOd 71051409 LHOIN OL 1437 1431 Ol dy OINVd WNOUdO 1331 QNos9 71091409 x 811 31BVN3 Old no3 XH 01 NO 10123NNO2 300ad ATVA dWna 8 V 3d NOLLOB 102 HIMOVd
19. 2 for more information on LED S layout of the packer module 3 27 If the packer does not start at all or moves forward only when holding the start cycle button green apply the following procedure to solve problem Note This procedure also applies to the retract button yellow PACKER MODULE TROUBLESHOOTING Apply all safety measures to ensure safety around the vehicle at all times Ensure that the parking brake is applied and start the engine Make sure all Emergency Stop Buttons Red are pulled out Remove the access panel on the R H side of the hopper Figure 3 17 This will give access to the packer module Start the engine Select the proper control station for multiple packer control stations Press the start cycle button green or the retract button yellow on the packer control station Left or right and see if the LED OUT 3 OUT 2 for retract button on the module turns ON and stays ON If the LED does not stay ON REPLACE THE PACKER MODULE If the LED OUT 3 OUT 2 for retract button stays ON and the packer does not move the solenoid valve inside the console might be stuck or defective TROUBLESHOOTING 3 28 9 Inside the console press on the override button on the solenoid valve Figure 3 17 The packer should be moving when manually overriding the valve If not make sure that
20. 21 PACKER MODULE LED LAYOUT Main power input Cut by in cab Emergency Stop button Main power input Cut by L H side Emergency Stop button R H side packer control station ON when selected L H side packer control station ON when selected R H side speed up switch ON Bunny button L H side speed up switch ON Bunny button Packer fully retracted limit switch ON when clicked Packer not fully retracted limit switch when not clicked Acceleration signal ON Packer is retracting or retract button yellow is ON or Packer fully extended Packer is extending or start cycle green button is ON Multi cycle output and Crusher panel enabled Packer fully retracted PTO power Cut by right outside Emergency Stop button FIGURE 3 22 EXPERT 2000 3 29 TROUBLESHOOTING 3 30 3 8 PACKER MODULE TROUBLESHOOTING How it works Reference Electrical schematic Figure 3 33 When pressing any start cycle button green on the packer control stations whether it is in the cab or outside the packer module will send a 12 volt signal to the packer extend coil on the hydraulic valve Figure 3 23 At the same time the built up solenoid is energized to allow the spool to move NOTE THE BUILT UP SOLENOID VALVE ALLOWS HYDRAULIC OIL TO MOVE THE SPOOLS TO AID THE ELECTRIC COIL COMPLETE THAT FUNCTION At the end of the
21. MMING PACKAGE FOR ALLISON TRANSMISSIONS IS 142 Some customer s chassis may have different programming packages Refer to your local Allison dealer for original programming packages For further information regarding ECU programming contact LabriePlus Parameters shown in this table are applicable on all standard Expert 2000 and units equipped with a Cool Hand or Helping Hand automated arm The table does not apply to Automizer units ALLISON TRANSMISSION PROGRAMMING PARAMETERS PARAMETERS Maximum engine speed for PTO Engagement Maximum engine speed for PTO Operation Maximum output speed for PTO Engagement Maximum output speed for PTO operation Maximum engine speed for Automatic Neutral value is adjusted in order to correspond to the truck s speed in Mph It may vary according to the differential gear ratios and tire sizes EXPERT 2000 EXPERT 2000 EXPERT 2000 Std Helping Hand Cool Hand 900 RPM 900 RPM 4000 RPM 2300 RPM 5000 RPM 5000 RPM 5000 RPM 930 RPM 500 RPM 200 RPM 7 MPH 3 MPH The following wires must be activated 117 Pack enable 118 Input PTO enable 112 Output PTO enable 153 Auto neutral pack enable 114 Output Neutral indicator PTO 3 55 3 18 CYLINDER INTERNAL LEAK If the packer cylinders are bypassing the DETECTION seal inside the cylinder may require to be replaced If an internal leak is suspected An internal leak i
22. POST BOTTOM VIEW PACKER CONTROL SELECTOR FT 1 D TN 147 MAIN VALVE BUILT UP SOLENOID Oa PACKER CONTROL CRUSHER PANEL 196 2 cus 130 gt 105 1 106 105 166 147 INTO CONSOLE 2 T LIC VALVE 105 11 CAB PACKER BLADE OPTIONNAL MULTI CYCLE SWITCH oo SPEED UP SWITCH dice CONTROL ELBo1700 2 o YELLOW PUSH BUTTON o GREEN PUSH BUTTON 3 36 TAILGATE close PACKER retract BODY lower RETRACTED FIGURE 3 33 Al 3 4 FULLY EXTENDED LIM SWITCH LIM SWITCH PACKER BLADE PACKER BLADE ON BODY EXPERT 2000 3 11 SPEED UP TROUBLESHOOTING The speed up system will rev up the engine speed to 1500 RPM every time the packer is used or when one of the speed up switch is activated on one of the packer control stations There a master switch called the speed up inhibit
23. RAL PACKER INPUT 550 161C GROUND 528 504 12V SIGNAL 118 PTO ENABLE INPUT 114 FROM AIR SUPPLY 112 PTO ENABLE OUTPUT 149 4 PRESSURE SWITCH 114 NEUTRAL INDICATOR FOR PTO 138 REF DWG 737979 OUTPUT 12V SIGNAL TO PTO RELAY PIN 86 REF DWG 737979 CIRCUIT POWER FROM PRESSURE SWITCH 504 POWER amp ECU PTO ENABLE INPUT 118 505 GROUND 528 INPUT GROUND 161 8 529 ECU INPUT PACK ENABLE 117 131 AUTO NEUTRAL OPTION FOOT VALVE TO RELAY AUTO NEUTRAL OPTION POWER TO RELAYS B N IRA NA R 149 P T O ENABLE 112 550 NEUTRAL PACKER INPUT 153 556 AUTO NEUTRAL OPTION FOOT VALVE TO WORK BRAKE SWITCH BLACK 237978 FIGURE 3 45 NOTE VOLTAGE MEASUREMENT ON THE THREE ALLISON WIRES 528 529 amp 550 CANNOT BE TAKEN AS A REFERENCE BECAUSE THEIR VALUE WILL VARY DEPENDING ON THE CASE EXPERT 2000 3 14 SERVICE BRAKE LIGHT TROUBLESHOOTING NOTE THISSECTION APPLIES ONLY TO VEHICLES WITH LABRIE INSTALLED SERVICE BRAKE SYSTEM If the service brake light Figure 3 51 is still ON after the toggle switch is lowered check the toggle switch exhaust holes behind the toggle switch panel Figure 3 47 The two air exhaust holes might be blocked preventing the air pressure from releasing If the air is exhausting from both
24. TROUBLESHOOTING 3 44 SPEED UP RELAY S TO ENGINE ECM HARNESS TABLE RELAY ENGINE TYPE LOCATION WIRE NUMBERS AND TEST POINTS CONFIGURATION Wire 526 black Wire 553 white Into console No relay relay connector Mechanical engine pin 2 pin 1 all w air actuator bimba Wire 526 Wire 553 on air actuator on air actuator pin 2 pin 1 FIGURE 3 38 B EXPERT 2000 3 13 AUTO NEUTRAL TROUBLESHOOTING NOTE THISSECTION APPLIES ONLY TO VEHICLES WITH LABRIE INSTALLED AUTO NEUTRAL SYSTEM With the auto neutral switch ON Figure 3 39 when the service brake on the R H side driving position is engaged toggle switch up the transmission will automatically shift from Drive to Neutral When the service brake is disengaged toggle switch down the transmission will stay into neutral position until the operator presses the R H side brake pedal Electrical principles When the service brake is engaged a pressure switch located behind the service brake panel Figure 3 38 is sending a 12 volt signal inside the console energizing the relays Figure 3 40 which are sending the signal to the Allison transmission ECU to shift from Drive to Neutral automatically The neutral light green on the R H side dashboard Figure 3 41 will turn ON as well as the service brake red Because both relays inside the console are PRESSURE SWITCH Auto neut
25. TROUBLESHOOTING EXPERT 2000 Release date March 2007 Part 47003 rev 1 3 2 EXPERT 2000 3 0 TROUBLESHOOTING EXPERT 2000 Table of contents TROUBLESHOOTING iii 3 5 3 1 INTRODUCTION Jemen 3 5 3 2 HAND TOOL REQUIREMENTS e eue 3 7 3 3 TROUBLESHOOTING GUIDE pha 3 8 3 4 PUMP TROUBLESHOOTING Ne 3 16 3 5 CAVITATION 3 18 3 6 MAIN VALVE TROUBLESHOOTING pe 3 19 3 6 1 PNEUMATIC OVER HYDRAULIC VALVE sese 3 19 3 6 2 ELECTRIC OVER HYDRAULIC VALVE ee 3 22 3 7 CRUSHER PANEL TROUBLESHOO TING siae 3 25 3 8 PACKER MODULE TROUBLESHOOTING c ca 3 30 3 9 PACKER MULTI CYCLE MODULE PROGRAMMING 3 33 3 10 PACKER MULTI CYCLE MODULE TROUBLESHOOTING 3 34 3 11 SPEED UP TROUBLESHOOTING KKK X EE 3 37 3 12 SPEED UP HARNESS CONTINUITY TEST 3 40 3 13 AUTONEUTRAL TROUBLESHOOTING uc rao aureo 3 45 3 14 SERVICE BRAKE LIGHT TROUBLESHOO ING 3 49 3 15 POOTBRAKE PEDAL TROUBLESHOOTING 3 51 3 16 ELECTRIC SCHEMATICS SYMBOLS 3 53 3 17 ALLISON TRANSMISSION PROGRAMMING PARAMETERS 3 54 3 18 CYLINDER INTERNAL LEAK DETECTION pp 3 55 3 19 TAILGATE LOCKING MECHANISM TROUBLESHOOTING 3 56 TROUBLESHOOTING 3 4
26. UBLESHOOTING The pump is operated using a control switch located onthe console Also ared warning light indicates when the pump is engaged Two conditions must be met for the pump to engaged and the warning light to turn ON 1 Air pressure of 90PSI 2 Engine speed lower 900RPM than The 90PSI condition is verified by a pressure switch while the engine speed 900RPM is verified by the transmission ECU If the pump does not engage when the pump PTO switch is turned ON it may be related to voltage supply problem in the pump circuitry The following test will help solving pump related problems but it is also mandatory before troubleshooting any Auto neutral and Speed up system related problem see section 3 13 Auto Neutral troubleshooting section 3 11 Speed up troubleshooting and section 3 12 Speed up troubleshooting on electronic engine 1 Prior to start testing ensure that all these conditions are met Parking brake applied Engine is running idle speed Transmission in Neutral All red emergency stop buttons pulled out 6 PTO switch ON Or s Refer to the electrical schematic 37979 Figure 3 6 to follow the numbered test points A test light or a multimeter VOM may be used by connecting the negative probe on the ground post Single screw in the console on which all the ground wire 105 are connected to and by taking a EXPERT 2000 FIGURE 3 5 reading
27. UIT FRONT END PRESSURE GAGE 2 AIRACTUATOR VELOCITY FUSE PRESSURE GAGE 1 RIGHT HAND SIDE TAILGATE TAILGATE HYDRAULIC HYDRAULIC CYLINDER REAR END CYLINDER FIGURE 3 65 EXPERT 2000 3 59 3 20 MAIN HYDRAULIC SCHEMATIC VANE PUMP a lt Di 5 FIGURE 3 67 TROUBLESHOOTING 3 60 EXPERT 2000 3 61 TROUBLESHOOTING 3 62 EXPERT 2000
28. ator the same process will have to be done for the other side of the actuator Figure 3 13 If the spool is not moving freely lubricate or replace the air actuator OTE IF AIR IS LEAKING BY THE OPPOSITE PORT OF THE PRESSURIZED SIDE OF THE ACTUATOR WHEN BOTH HOSES ARE REMOVED THIS COULD INDICATE THAT THE O RING ON THE PISTON O THE AIR ACTUATOR LEAKING IF DISASSEMBLE CLEAN AND LUBRICATE WITH GREASE OR REPLACE THE O RING PUSH ON THE GREEN SLEEVE FIGURE 3 12 EXPERT 2000 5 PACKER AIR SYSTEM TROUBLESHOOTING CONTINUES If the spool is moving freely try injecting air in the tube and see if air is exhausting from the quick exhausts valves underneath the body cylinder and close to the packer valve section actuator If not see if air lines are not blocked or bent then replace the quick exhaust valves if necessary FIGURE 3 13 AS THE AIR ENTERS IN THE ACTUATOR THE HYDRAULIC SPOOL MOVES BACK AND FORTH FIGURE 3 14 TROUBLESHOOTING 3 22 3 6 2 ELECTRIC OVER HYDRAULIC VALVE How it works The hydraulic valve is equipped with electric coils that activate the spools and therefore the different hydraulic functions Figure 3 8 As the packer reaches the end of a stroke the limit switches located behind it will prompt the electronic module the packer has reached the end of its stroke The electronic module will then operate the electric coils on the main valve corresponding to t
29. cle module 12 volt supply Test the continuity between terminal 1 of multi cycle module harness connector and the ground post inside the console it must have good continuity If not check electrical connections When connecting a voltmeter on terminal 5 wire 108 of the multi cycle harness connector it should read 12 volts If not follow the test points A through E to verify the path of the retracted packer signal 3 35 NOTE ALWAYS REFERTO THE MAIN ELECTRICAL SCHEMATIC INSIDE THE CONSOLE MODULE CONNECTOR LAYOUT Wire 105 Ground Wire 127 12 volt signal from the Automatic cycle switch on the control station Wire 107 12 volt signal when the packer is moving forward Wire 106 12 volt signal when packer is moving backwards Wire 108 12 volt signal when the packer is fully retracted Not Used MULTI CYCLE MODULE MULTE wr 5 igi FIGURE 3 30 TROUBLESHOOTING MAIN POWER FROM PTO RELAY OPTIONNAL MULTI CYCLE MODULE E 147 21031 CRUSHER PANEL NOT USED SOLENOID VALVE DEDE J GROUND
30. crusher panel lock valve Figure 3 17 This valve located in the hopper behind the protective panel above the crusher panel blocks the oil flow to the crusher THE CRUSHER PANEL SHOULD NOT MOVE DOWN WHEN THE PACKER IS MOVING 3 25 FIGURE 3 17 panel cylinder if it does not receive a signal from all limit switches involved in the interlocking system To prevent unnecessary procedures first make sure 1 the packer is fully retracted 2 thecarttipper if equipped is fully down 3 the chute if equipped is fully tilted to the opposite side from the crusher panel TROUBLESHOOTING 3 26 Problem 1 If the crusher panel does not work when the packer is fully retracted refer to the following troubleshooting procedure CRUSHER PANEL TROUBLESHOOTING Apply all safety measures to ensure safety around the vehicle at all times Start the engine and engage the hydraulic pump Fully retract the packer Fully lower the cart tipper if equipped Fully tilt the chute if equipped to the opposite side from the crusher panel Open the access panel to the packer module located on the left side of the vehicle Figure 3 18 See if LED IN 7 is ON Figure 3 18 If not make sure the limit switch on the R H side of the hopper is properly adjusted Refer to section 1 12 2 Limit switch adjustment When the LED IN 7 is ON check for a 12 volt signal on the solenoid valve connector
31. e in the socket Figure 3 30 If the fuse appears to be loose in the socket tighten the connector using the proper tool If the packer is still not functioning with multiple cycles disconnect the module and using a voltmeter check all the signals coming from the packer module on the FIGURE 3 29 connector o 79 EXPERT 2000 3 10 PACKER MULTI CYCLE MODULE TROUBLESHOOTING Cont d The multi cycle module counts the number of time the packer reaches the fully retracted position The limit switch sends pulses on wire 106 retract signal Until the preset amount of pulses is reached the multi cycle module will give an output signal on wire 107 forward signal for the packer to perform a complete cycle This signal has the same effect as pressing on any start cycle button green Before starting troubleshooting make sure that all these conditions are met 1 Parking brake is applied 2 Engine is running at idle speed 3 Transmission in Neutral 4 All emergency stop buttons red are pulled out Pump switch PTO turned There should be 12 volts on wire 147 attest point 1 figure 3 33 7 Multi cycle switch ON Figure 83 31 8 Packer fully retracted When connecting voltmeter on terminal 2 wire 127 of the multi cycle harness connector it should read 12 volts If not follow the test points 1 through 6 to verify the path of multi cy
32. essure switch wires and the console relay is required to ensure the reliability of the harness Apply the following procedure in order to resolve the problem This procedure requires the use of a multimeter or a VOM Refer also to the main electrical diagram of the vehicle located inside the console j 1 i 1 PRESSURE SWITCH SERVICE BRAKE FIGURE 3 53 TROUBLESHOOTING 3 52 TROUBLESHOOTING PROCEDURE Apply all safety measures to ensure safety around the vehicle Ensure the parking is applied Remove the panel behind the brake pedal assembly It is recommended to unbolt the pedal assembly support from the cab floor in order to reach the pressure switch behind the pedal assembly Figure 3 52 Disconnect the wires from the pressure switch Connect the multimeter probes to the pressure switch between terminals NC and C See Figure 3 54 Press the footbrake in order to change the state of the pressure switch ON OFF The multimeter should not indicate continuity when the footbrake is applied Check the continuity between the casing of the toggle switch and all poles of the pressure switch If one of the previous tests fails replace the pressure switch Part 00605 If the continuity test on terminals NC and C of the pressure switch is fine the harness between the footbrake and the console relays might be faulty EXPERT 2000 PRESSURE SWITCH
33. g the hopper area 3 Clean the area around the limit switches Refer to section 1 12 2 Limit switch adjustment Refer to section 3 6 Packer control valve troubleshooting SOLUTION S Make sure the PTO switch is turned ON Make sure all Emergency Stop buttons red are pulled out See if the packer control station selector switch is properly set to the one you are using Ensure that the hydraulic pressure is properly adjusted Refer to section 3 8 Packer module troubleshooting 6 Refer to section 3 8 Packer module troubleshooting TROUBLESHOOTING 3 14 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM The packer is moving forward when pressing the GREEN button but stops when releasing the button POSSIBLE CAUSE S 1 Faulty packer module 2 Faulty harness between the packer module and the console SOLUTION S Refer to section 3 8 Packer module troubleshooting Refer to section 3 8 Packer module troubleshooting PROBLEM The packer is moving backwards when pressing the Retract yellow button but stops when releasing the button PROBLEM Packer does not perform enough cycles POSSIBLE CAUSE S 1 Faulty packer module 2 Faulty harness between the packer module and the console POSSIBLE CAUSE S 1 Multi cycle module programming SOLUTION S Refer to section 3 8 Packer module troubleshooting
34. he packer functions 12 volt signals one for packer extend another for packer retract See also section 3 8 Packer module troubleshooting EXPERT 2000 MAIN HYDRAULIC VALVE FIGURE 3 8 PACKER Ne ma 5 nd BODY HOIST a FIGURE 3 9 PACKER TROUBLESHOOTING Apply all safety measures to ensure safety around the vehicle at all times Identify the packer section on the valve see Figure 3 11 Verify the hydraulics In order to verify the hydraulics and the proper valve operation get a lever from the pouch located in the cab see Figure 3 10 Install the lever on the packer valve section and move the lever to manually operate the packer If the packer moves as it usually does it indicates the problem is not in the hydraulics Verify the electrical part of the valve Open the protective loom about 10 inches from the coils on the right side of the valve From the coil corresponding to the packer valve section follow the harness to the first connector and get it out of the loom Figure 3 13 Set up a voltmeter on the male connector and press the yellow button on the controls station If you read 12 V take the same measurement on the connector located in the loom of the left side harness of the packer valve section only this time you press the green button If you read 12 V on that test point as well the problem may be found on the coil itself To verify the
35. ighten all connections at the pump Have the pump repaired by an authorized service center EXPERT 2000 3 3 PROBLEM The packer is moving vertical or sideways PROBLEM The tailgate is unlocking or lowering by itself PROBLEM The service brake light is still ON after releasing the service brake TROUBLESHOOTING GUIDE Cont d POSSIBLE CAUSE S The packer wear pads have too much wear Sliding shoes have too much wear POSSIBLE CAUSE S The velocity fuse is dirty or defective Inverted hydraulic hoses on the main hydraulic valve POSSIBLE CAUSE S Pressure switch behind the service brake toggle switch 3 11 SOLUTION S Inspect or replace the wear pad as indicated in section 1 12 5 Inspect or replace the sliding shoes as indicated in section 1 12 3 1 12 4 SOLUTION S Clean or replace the velocity fuse Refer to section 3 20 Tailgate locking mechanism troubleshooting 2 Test the power bleed on the tailgate section of the valve Refer to section 3 20 Tailgate locking mechanism troubleshooting SOLUTION S 1 Refer to section 3 14 Service brake light troubleshooting TROUBLESHOOTING 3 12 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM POSSIBLE CAUSE S Engine speed up does not 1 The speed up inhibitor control work Electronic engine switch only See description in section 1 19 Speed up
36. lts If not check the fuse wire 123 and replace if necessary If the fuse is fine the speed up relay might be faulty Test with a new relay Check for a ground signal on wire 153 Connect the multimeter probe between the fuse block and wire 153 at test point 3 The voltage should read around 12 volts Repeat this procedure for each packer control stations installed on the vehicle If all the previous tests are fine and still the speed up system is not working refer to section 3 12 Speed up Harness Continuity Test EXPERT 2000 3 39 J SID Od NOILINOI Z37977 1531 ALINNILNOO 303 3 18V1 LNIOd 303HO Sd TIN 3HIM 33S 3NION3 9INOH12313 tot A Q318VN3 SI NC 1OSNOO SAV 33 dN q dS 2091405 YIMOYVd JNO AV NIL 1v LOH 01 SMIHLO YOLVNLOV VENIE NO 3A1VA GION310S OL gt 2OVd HOIY lt CISINC MINOO FINGON JOS NOO 7 M IVIS TOYXLNOO MOLIBIHNI 03345 IIMOVd VO N FIGURE 83 33 OM OLD3NNOO 30059 OL NOILdid9sS30 TROUBLESHOOTING 3 40 3 12 SPEED UP HARNESS CONTINUITY TEST
37. n not clicked OUT 1 Acceleration signal ON extended OUTPUT LED s OUT 2 Packer is retracting or retract button yellow is ON or Packer fully OUT 3 Packer is extending or start cycle green button is ON OUT 4 Multi cycle output and Crusher panel enabled Packer fully retracted OUT 5 PTO power Cut by right outside Emergency Stop button FIGURE 3 27 EXPERT 2000 3 9 PACKER MULTI CYCLE MODULE PROGRAMMING The multi cycle module is used to control the number of cycle the packer will do when the Start Cycle button START green is pressed Cl The number of cycles needs to be adjusted depending on the type of route the vehicle has to collect For example a residential area if the houses are numerous and close to one another it may be required to increase the number of cycle This will allow the hopper to be clear for the next house pickings Located inside the console the multi cycle module can be programmed to allow the packer to perform from 2 to 8 cycles The factory default is 3 cycles Each time the packer is completing a full cycle a signal is sent to the packer module by the limit switch located on the R H side behind the packer The module then counts the amount of cycles that the packer does The module will stop the packer after the preset amount of cycles has been reached NOTE THE MULTI CYCLE FEATURE IS OPTIONAL AND SOME UNIT MAY HAVE
38. nsole and the dashboard Check continuity using the multimeter between wire 105 and the ground post inside the console Refer to the electrical diagram inside the console Remove the dashboard front panel and locate the main connector and wires 105A See Figure 3 50 Check continuity using a multimeter between the wire 105A behind the toggle switch and the wire 105A located behind the dashboard If one or both previous tests fails change the faulty wires PRESSURE SWITCH SERVICE BRAKE LIGHT FIGURE 3 48 PRESSURE SWITCH rs E Pi x DASHBOARD MAIN i CONNECTOR FIGURE 3 50 lt CUL 105 105A FIGURE 3 49 EXPERT 2000 3 15 FOOTBRAKE PEDAL TROUBLESHOOTING NOTE THISSECTION APPLIES ONLY TO VEHICLES WITH LABRIE INSTALLED AUTO NEUTRAL SYSTEM The footbrake pressure switch cuts off power to the auto neutral relay 1 which is ordering the transmission ECU to shift from Neutral to Drive If the transmission does not shift in gear when the footbrake is pressed the problem might be related to a faulty pressure switch located behind the footbrake and accelerator pedals assembly Figure 423 51 amp 83 52 FOOTBRAKE PRESSURE SWITCH FIGURE 3 52 3 51 On the other hand a faulty harness between the pedal assembly and the console might be involved as well A continuity test between the footbrake pr
39. on 3 6 to inpect the coil However ifthe LED on the module is ON and no signal is present inside the console check the continuity of the electrical harnesses between the module and the hydraulic valve Replace one or both harnesses if necessary In order to check the continuity between the packer module and the console two harness sections require to be tested The first section of the harness goes from the packer module to the body hinges where 12 pin connector can be found Figure 3 26 The other section goes from the hinge at the rear of the vehicle and returns to the console in the cab Unplug the 12 pin connector and test the continuity on wire 105 106 and 107 using a multimeter or VOM Note that a probe extension of 30 feet is necessary and two insulated alligator clips are required to connect the multimeter to both ends of the harness di L H SIDE REAR MUD FLAP FIGURE 3 25 PACKER MODULE LED LAYOUT Main power input Cut by in cab Emergency Stop button Main power input Cut by L H side Emergency Stop button INPUT LED s R H side packer control station ON when selected L H side packer control station ON when selected R H side speed up switch ON Bunny button L H side speed up switch ON Bunny button Packer fully retracted limit switch when clicked Packer not fully retracted limit switch whe
40. or Figure 3 32 That will cancel the all speed up control switch on all packer control stations Prior to performing the following troubleshooting procedure refer to electrical diagram 37977 Figure 3 33 for test point numbers This procedure applies to both electronic and mechanical engine Make sure that all these conditions are met 1 Parking brake is applied 2 Engine is running at idle speed 3 Transmission in Neutral 4 All emergency red buttons are pulled out 5 Pump switch PTO turned ON 6 There should be 12 volts on wire 147 attest point 1 Figure 3 36 NOTE AN ELECTRONIC MULTIMETER OR VOM IS NECESSARY TO PERFORM THIS TEST SEE FIGURE 3 1 3 37 SPEED UP SWITCH BUNNY BUTTON FIGURE 7 23 31 SPEED UP INHIBITOR 4 SWITCH FIGURE 3 32 TROUBLESHOOTING 3 38 SPEED UP TROUBLESHOOTING PROCEDURE Apply all safety measures to ensure safety around the vehicle at all times Select the R H side packer control station if more than one packer control station Set the speed up button to ON Figure 3 34 Using a multimeter or a VOM check the wire 101 at test point 1 The voltage indicated should be around 12 volts If not check the fuse and refer to section 3 4 Pump troubleshooting Set the speed up inhibitor switch on the side of the console to Enable Check wire 124 at test point 2 The voltage indicated should be around 12 vo
41. ral FIGURE 3 38 3 45 latched by the pressure switch on the footbrake pedal the transmission will stay into Neutral position even after the operator disengaged the service brake PACKER CONTROL SELECTOR FIGURE 3 39 AUTO NEUTRAL RELAYS 1 amp 2 INSIDE THE CONSOLE sos M SERVICE BRAKE 2 LIGHT TE FIGURE 3 41 TROUBLESHOOTING 3 46 NOTE THE SERVICE BRAKE LIGHT RED WILL TURN OFF WHEN THE SERVICE BRAKE 15 RELEASED When the operator presses the footbrake a pressure switch located behind the footbrake pedal assembly Figures 3 42 amp 3 43 will cut the power tothe relays and the transmission goes back to Drive The neutral light green will turn OFF FIGURE 3 42 VIEW FROM BEHIND THE PEDAL ASSEMBLY PRESSURE SWITCH E t FOOTBRAKE Ng EXPERT 2000 The Auto neutral system is using three 3 wires from the Allison transmission ECU Connected together these three 3 wires engage or disengage the transmission Auto neutral See electrical diagram 37978 for wires 528 529 amp 550 The wires 529 and 550 are connected to the Auto neutral switch on the console See figure 3 48 The relay 1 connects the wire 528 to both 529 amp 550 wires allowing the Allison transmission ECU to perform the Auto neutral sequence The second contact of the Auto neutral switch supplies voltage to the relays and the Auto neutral red pilot ligh
42. s caused by a damaged the following procedure to verify it seal inside the hydraulic cylinder 1 Because the cylinder is leaking oil inside INTERNAL LEAK DETECTION bypassing a certain amount of pressure FOR PACKER CYLINDERS is lost reducing the cylinder efficiency and its capacity to push or pull Apply all safety measures to ensure safety around the vehicle at all times Ensure that the parking brake is applied Pull out all Emergency Stop Buttons red Start the engine and engage the hydraulic pump Fully extend the packer cylinders Disengage the hydraulic pump Disable the fully extend limit switch located on the L H side by removing the arm of the limit switch This will preventthe packer from returning to its initial position Disconnect hose A and install a plug at the end of it Engage the hydraulic pump Press the green button and see if oil is leaking from port A then press the Emergency Stop Button If oil leaks out from port A when pressure is applied this could mean there is an internal leak Replace or repair the cylinder INTERNAL LEAK DETECTION FOR PACKER CYLINDERS H e 222222 lt FIGURE 3 61 TROUBLESHOOTING 3 56 3 19 TAILGATE LOCKING MECHANISM TROUBLESHOOTING The tailgate locking mechanism is equipped with hydraulic safety systems that prevent accidental unlocking of the tailgate d
43. stroke the limit switch located on the L H side of the hopper Figure 3 21 will signal the module to cut the 12 volt signal on wire 107 and to switch the signal packer retract on wire 106 refer to the electrical schematics provided with the truck The packer will stop and then retract to its initial position completing a full cycle When the packer is returning to its initial position the limit switch located on the right hand side of he hopper will cut the 12 volt signal on wire 106 stopping the packer EXPERT 2000 NOTE FOR INFORMATION REGARDING THE MULTI CYCLE OPTION REFER TO SECTION 3 9 PACKER MULTI CYCLE PROGRAMMING AND SECTION 3 10 PACKER MULTI CYCLE TROUBLESHOOTING L H SIDE ACCESSPANEL REMOVED FIGURE 3 22 The packer module is designed with a set of LEDs to indicate the status of the packer system These LEDs are used to monitor the activity of the packer module during a normal cycle At any given time each LED refers to an input or an output For example if the start cycle button green is pressed the LED OUT should turn ON and stay ON until the packer reaches the end of the stroke Figure 3 23 QUT 3 GREEN BUTTON IS PRESSED FIGURE 3 23 PACKER MODULE LEDS LAYOUT IN 1 IN 5 OUT 1 OUT2 OUT3 OUT4 OUT 5 FIGURE 3 24 Refer to figure 3 27 for more information on 5 layout of the packer module
44. t on the console AUTO NEUTRAL SWITCH VIEW FROM INSIDE THE CONSOLE WIRE 528 amp 529 AUTO NEUTRAL LIGHT i z FIGURE 3 44 Troubleshooting Prior to applying the following troubleshooting procedure ensure that all these conditions are met ae Ic Parking brake is applied Engine is running idle speed Transmission in Drive Air pressure above 90PSI Auto neutral switch ON Pump switch PTO All red emergency stop buttons are pulled out TROUBLESHOOTING PROCEDURE Apply all safety measures to ensure safety around the vehicle at all times Ensure that the service brake is OFF Toggle switch down Using a multimeter or VOM check for 12 volts on test points 1 and 2 See diagram 37978 If no voltage is present check fuses and refer to section 3 4 pump troubleshooting for proper voltage supply of the Auto neutral circuit Check for continuity between both auto neutral switch poles at test point 9 If test fails replace the Auto neutral switch Apply the service brake toggle switch up Oncethe service brake is applied check for a 12 volt signal at test point 4 5 6 7 8 If no voltage is found it could be either a service 3 47 TROUBLESHOOTING PROCEDURE CONTINUES brake pressure switch malfunction or a broken wire between the console and the pressure switch Refer to Figure 23 40 and perform a continuity test on the pressure switch and the harness Replace
45. the air lines are not blocked or bent Also refer to section 3 6 Packer air system troubleshooting 10 When either LED IN 7 or IN 8 is 11 INPUT LED s OUTPUT LED s ON check for a 12 volt signal at the valve coming from the packer module on wire 106 packer extend and wire 107 packer retract If the signal is present inside the console remove clean and inspect the valve replace the solenoid valve if necessary However ifthe LED onthe module is ON and no signal is present inside the console check the continuity of the electrical harnesses between the module and the console Replace one or both harnesses if necessary In order to check the continuity between the packer module and the console two harness sections require to be tested The first section of the harness goes from the packer module to the body hinges where a 12 pin connector can be found Figure 3 26 The other section goes from the hinge at the rear of the vehicle and returns to the console in the cab Unplug the 12 pin connector and test the continuity on wire 105 106 and 107 using a multimeter or VOM Note that a probe extension of 30 feet is necessary and two insulated alligator clips are required to connect the multimeter to both ends of the harness a LHSIDEREAR MUD FLAP RP T S PACKER MODULE AND CONSOLE JUNCTION f 12 PIN CONNECTOR 1258754 FIGURE 3
46. ti foaming oil Refer to section 2 1 5 Lubrication for the proper type of oil to use Refer also to section 1 14 6 Hydraulic oil replacement procedure PROBLEM POSSIBLE CAUSE S SOLUTION S Cavitation excessive noise 1 Ball valve on the hydraulic tank Fully open the ball valve on the vibration of the pump is not fully open hydraulic tank Refer to section 1 9 Prior to start up 2 Low oil level Add oil to the required level Refer to section 1 14 5 3 Oil too thick See section 2 1 Recommended Lubricants for proper type oil to use Refer also to section 1 14 6 Hydraulic oil replacement procedure 4 Air the system Refer to section 3 5 Pump Cavitation 5 Particle contamination or dirty strainer Clean the strainer inside the tank and change the return filter Fill with clean oil Refer to section 1 14 6 1 14 7 amp 1 14 8 Take an oil sample for further analysis Refer to section 2 1 5 Hydraulic oil test 6 Suction hose blocked Unblock or replace the hose 7 Flow control is dirty or faulty May also be noisy Remove and clean the flow on system with gear pump control if hot If afterwards it gets hot replace it Refer to section 1 15 Hydraulic Vane Pump Systems or section 1 16 Gear Pump Systems for pressure adjtment procedure TROUBLESHOOTING 3 10 3 3 TROUBLESHOOTING GUIDE Cont d PROBLEM The pump PTO does not engage PROBLEM No hydra
47. tures of the minimum required tools to perform troubleshooting procedures throughout this manual Theses are only suggestions product brand names may differ 0 4000PSI PRESSURE GAGE HYF00910 REQUIRED HAND TOOLS Digital Multimeter or VOM Volt Ohm Milliammeter COUPLER Part NOTE THE AMMETER MUST HYF10195 SUPPORT AT LEAST 10 AMPS FIGURE 3 3 Ball end Hex Key Metric amp SAE FIGURE 3 1 Jumper wire with alligator clips FIGURE 3 2 FIGURE 3 4 TROUBLESHOOTING 3 8 3 3 TROUBLESHOOTING GUIDE This troubleshooting guide will help identify the most commonly seen problems on the Labrie Expert 2000 Side Loader This table will also provide the possible cause of the problem and give solutions to resolve the problem For further information regarding customized options that might not be found in this troubleshooting guide contact LabriePlus PROBLEM Insufficient packing ratio PROBLEM hydraulic oil is over heating Temperature higher than 180 F 77 C EXPERT 2000 POSSIBLE CAUSE S 1 Low oil pressure 2 The packer hydraulic cylinders are internally bypassing 3 Defective pump POSSIBLE CAUSE S 1 Oil level in hydraulic tank is too low 2 Hydraulic pressure is too low or too high 3 Not the proper grade of oil i e too thin in hot temperatures or too thick in cold temperatures 4 Contaminated oil
48. ulic pressure PROBLEM The pump is leaking oil POSSIBLE CAUSE S Air pressure Red emergency stop button s Panic bar if installed Engine speed is higher than 900 RPM Electrical Faulty PTO solenoid valve POSSIBLE CAUSE S Pump is not engaged Pressure adjustment Hydraulic line Hydraulic spool inside the valve POSSIBLE CAUSE S Loose connections 2 The pump shaft seal is damaged SOLUTION S 1 Make sure the air pressure is above 90 PSI 2 Ensure that the red button s on packer control station s is are pulled out 3 Make sure that the button behind the panic bar s is are pulled out 4 Reduce engine speed below 900 RPM If the RPM cannot be reduced under 900RPM contact your local chassis dealer 5 Check fuses inside the console and the main fuses located at the battery Refer to section 3 4 Pump troubleshooting 6 Replace the PTO air solenoid valve on the pump or into console dry valve only SOLUTION S 1 Turn the PTO switch 2 Check the pressure adjustment Referto section 1 15 Hydraulic Vane Pump Systems or section 1 16 Gear Pump Systems for pressure adjtment procedure Perform a circuit analysis with the main hydraulic schematics section 3 210r section 3 22 Make sure that no spool inside the directional valve is stuck in a position that could send the hydraulic flow to the tank SOLUTION S T
49. ure hose fitting located at the top of the main control valve Figure 3 7 A mixture of oil and air will come out Keep bleeding the oil until the pump noise stops DO NOT ACTIVATE ANY HYDRAULIC FUNCTION DURING SYSTEM BLEEDING Use a pan or a bucket to collect the oil Tighten the pipe hose fitting when the noise has stopped Cycle the packer to ensure that there is no leaks and the pump is running smoothly Disconnect the gage 3 6 MAIN VALVE TROUBLESHOOTING 3 6 1 PNEUMATIC OVER HYDRAULIC VALVE How it works The hydraulic valve which controls some of the vehicle s hydraulic functions is equipped with air actuators Figure 3 8 The packer air actuator pushes back and forth on the hydraulic spool of the valve resulting in a movement of the packer extend or retract As the packer reaches the end of a stroke the limit switches located behind the packer will send the signal to the electronic module telling that the packer has reached the end of its stroke The packer module will then operate the air solenoid valve inside the console Figure 3 9 with a 12 volt signal one signal for packer extend one signal for packer retract See also section 3 7 Packer module troubleshooting When receiving the 12 volt signal extend or retract from the module the air solenoid valve inside the console Figure 3 9 enables the air pressure to reach the actuator on the main control valve Whether it is the retract or
50. uring operation One of the systems is the velocity fuse with the power bleed and the other is the holding valve The spool inside the tailgate section of the valve is designed in such a way that it will allow pressure to pass through it each time the pressure is building up in the hydraulic system i e when the packer is working The pressure burst goes to the holding valve into port D1 and then out to the cylinder by port U1 This will keep the tailgate cylinders pressurized and the tailgate closed when packing material The velocity fuse located on the left hand side of the valve Figure 3 29 will make sure to drain any slow moving oil coming from the piston side of the tailgate cylinders Since the rod side is being HOLDING VALVE PORT U2 PORT U1 pressurized with the Power bleed system the other side has to drain to avoid any pressure build up The velocity fuse makes the piston side open to tank when the oil is moving under 3 gallons per minutes and will shut when a flow signal is sent NOTE REFER TO THE MAIN HYDRAULIC SCHEMATIC FIGURE 3 65 FOR GEAR PUMP OR 3 66 FOR VANE PUMP x lt A DN 2 us O FIGURE 3 63 EXPERT 2000 3 57 Problem 1 Tailgate is UNLOCKING by itself If the tailgate seems to unlock by itself when using the packer the power bleed inside the valve might not work on the right side of the
51. ve for pack IL packer dX 01914 Multi cycle module ELM01605 CES p oTo p 2 N O 2 N C 3 positions switch M Bipolar switch ELB02505 Li ELB00260 2 X ELB00270 Tj 1 2 N C limit switch OQ EL100550 ELC00200 amp ELI00850 1 diode ELD00100 v 6 Single pole switch Emergency red button ELB002200 17N 12 volt buzzer on console ELR01000 EIN V CL EXPERT 2000 12 volt red pilot light PNI00500 772 CF OPTIMIZER Na 12 volt green pilot light N O NORMALLY OPENED PNI00500 amp ELL00300 N C NORMALLY CLOSED To ground post into console 12 volt solenoid NOTE PART NUMBERS ARE INDICATED WITHIN volt speed up air actuator 10 A 10 fuse Typical TROUBLESHOOTING 3 54 3 17 ALLISON TRANSMISSION PROGRAMMING PARAMETERS The following section shows how the Allison electronic transmissions ECU are programmed for Labrie trucks If the ECU module of the Allison transmission is replaced the ECU must be reprogrammed in order to set back the operating parameters of the vehicle The transmission ECU module programming affects the engine speed PTO engagement and operation as well as the Auto neutral system Refer to the following table to reprogram the transmission ECU NOTE ON CHASSIS SUPPLIED BY LABRIE ENVIRONMENTAL GROUP THE PROGRA
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