MINIMAX
TM
MAINTENANCE MANUAL
MINIMAX™
MAINTENANCE MANUAL
Liability
Labrie Enviroquip Group assumes no liabilty 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 responsability of the user.
Although careful precaution has been taken in the preparation of this document, Labrie Enviroquip
Group assumes no responsiblity for errors or omissions.
December 2012
Table of Contents
Liability ........................................................................................ ii
Table of Contents ....................................................................... iii
Introduction ................................................................................ 1
About this Manual ............................................................................................................................................................................ 1
What You Will Find in this Manual .............................................................................................................................................. 1
Topics not included in this Manual ............................................................................................................................................ 1
About the Schematics ..................................................................................................................................................................... 1
Introducing the MINIMAX™ ............................................................................................................................................................. 2
Product Overview ............................................................................................................................................................................. 2
Service and Maintenance on the M
Warning ................................................................................................................................................................................................ 3
Warranty Registration Form ......................................................................................................................................................... 3
To Contact Labrie Plus .................................................................................................................................................................... 4
In the U.S. ...................................................................................................................................................................................... 4
In Canada ...................................................................................................................................................................................... 4
Safety ........................................................................................... 5
Conventions ....................................................................................................................................................................................... 5
Basic Safety Notions ........................................................................................................................................................................ 5
Responsibilities .................................................................................................................................................................................. 6
Employer’s Responsibilities ................................................................................................................................................... 6
Employee’s Responsibilities ................................................................................................................................................... 7
Things to Do ....................................................................................................................................................................................... 7
Things to Avoid ................................................................................................................................................................................. 7
General Precautions ........................................................................................................................................................................ 8
Welding ............................................................................................................................................................................................. 10
Fire ...................................................................................................................................................................................................... 10
Safety Kits ......................................................................................................................................................................................... 11
Safety Features ............................................................................................................................................................................... 11
Global Motion Sensors (Optional) .................................................................................................................................... 11
Back Up Alarm .......................................................................................................................................................................... 13
Tailgate Safety Prop ............................................................................................................................................................... 14
Camera System (optional) ................................................................................................................................................... 17
Tailgate Holding Valve .......................................................................................................................................................... 18
Prior to Start Up .............................................................................................................................................................................. 19
Locking Out and Tagging Out the Vehicle ........................................................................................................................... 20
Shutting Down the Vehicle ........................................................................................................................................................ 21
INIMAX™ ............................................................................................................................ 3
General Maintenance ................................................................ 23
Preventive Maintenance Chart ................................................................................................................................................. 24
Packer ................................................................................................................................................................................................ 25
Preparing for Packer Inspection ........................................................................................................................................ 26
Inspecting the Packer ............................................................................................................................................................ 27
Removing the Packer ............................................................................................................................................................ 28
Replacing Packer Wear Plates ............................................................................................................................................ 31
Reinstalling the Packer ......................................................................................................................................................... 32
Tailgate .............................................................................................................................................................................................. 35
Proximity and Limit Switches .................................................................................................................................................... 36
Limit Switch Adjustment ..................................................................................................................................................... 37
iv Table of Contents
Proximity Switch Adjustment ............................................................................................................................................. 37
Adjusting Packer Extend Limit/Proximity Switch ........................................................................................................ 38
Adjusting Packer Retract Limit Switch ............................................................................................................................ 42
Adjusting Tailgate Unlocked Proximity Switch ............................................................................................................ 44
Adjusting Tailgate Fully Open Proximity Switch ......................................................................................................... 46
Adjusting Left-Hand Side Hopper Door Limit Switch (optional) ........................................................................... 47
Adjusting Crusher Panel Up Limit Switch ...................................................................................................................... 48
Adjusting Fully Open Upper Door Limit Switch .......................................................................................................... 49
Adjusting Fully Closed Upper Door Limit Switch (optional) ................................................................................... 49
Adjusting Arm Stowed Limit Switch ................................................................................................................................ 50
Adjusting Arm Parked Limit Switch ................................................................................................................................. 52
Adjusting Mid-Height Limit Switch .................................................................................................................................. 54
Painting and Finishing ................................................................................................................................................................. 56
Lubrication ................................................................................ 57
Recommended Lubricants ......................................................................................................................................................... 57
Grease ......................................................................................................................................................................................... 57
Hydraulic Oil ............................................................................................................................................................................. 57
Engine Oil ................................................................................................................................................................................... 58
Transmission Oil ...................................................................................................................................................................... 58
Testing Hydraulic Oil ..................................................................................................................................................................... 58
Preparing to Take a Sample ................................................................................................................................................ 58
Taking an Oil Sample ............................................................................................................................................................. 59
Lubrication Charts ......................................................................................................................................................................... 62
Greasing the Crusher Panel ........................................................................................................................................................ 65
Tailgate .............................................................................................................................................................................................. 66
Greasing Tailgate Hinges, Locking Mechanism and Cylinder Pins ....................................................................... 66
Packer ................................................................................................................................................................................................. 68
Cylinder Pins ............................................................................................................................................................................. 68
Follower Panel Rollers ........................................................................................................................................................... 69
Hopper Door Hinges ..................................................................................................................................................................... 70
Hydraulic System ...................................................................... 73
General Maintenance ................................................................................................................................................................... 73
Inspecting Hydraulic Oil ....................................................................................................................................................... 74
Introducing the Dual Vane Pump ............................................................................................................................................ 75
Body Control Valve ................................................................................................................................................................. 76
Arm Control Valve ................................................................................................................................................................... 77
Inspecting the Pump .................................................................................................................................................................... 78
Pump Replacement ....................................................................................................................................................................... 78
Priming a New Pump .................................................................................................................................................................... 80
Inspecting the Hydraulic Tank .................................................................................................................................................. 81
Adjusting Hydraulic Pressure .................................................................................................................................................... 83
Adjusting Main Pressure on Body Control Valve ......................................................................................................... 83
Adjusting the Utility Section ............................................................................................................................................... 84
Adjusting Pressure on Arm Control Valve ...................................................................................................................... 85
Adjusting Gripper Pressure ................................................................................................................................................. 87
Adjusting Pressure on Cart Tipper Valve (if installed) ................................................................................................ 89
Emptying the Hydraulic Tank .................................................................................................................................................... 90
Replacing Hydraulic Oil ................................................................................................................................................................ 91
Cleaning the Strainer .................................................................................................................................................................... 92
Replacing Filter Elements ........................................................................................................................................................... 95
Inspecting Hydraulic Cylinders ................................................................................................................................................. 96
Detecting Cylinder Internal Leaks ..................................................................................................................................... 97
Table of Contents v
Main Hydraulic Schematic .......................................................................................................................................................... 99
Electrical System ..................................................................... 101
How the Electrical System Works ........................................................................................................................................... 101
Electrical Schematics ........................................................................................................................................................... 101
Control Panel .......................................................................................................................................................................... 101
Adjusting and Repairing Electrical Components ............................................................................................................. 103
Fuses and Circuit Breakers ................................................................................................................................................. 103
Electrical Schematics .................................................................................................................................................................. 105
Cab Adaptation ..................................................................................................................................................................... 105
Cab Console & Controls ...................................................................................................................................................... 106
Cab Controller ........................................................................................................................................................................ 107
Chassis ...................................................................................................................................................................................... 108
Body Module (rear side) ..................................................................................................................................................... 109
Body Module (front side) ................................................................................................................................................... 110
Tailgate Lighting ................................................................................................................................................................... 111
Panic Bars, Crusher Panel, Tipper Interlocks ............................................................................................................... 112
Cameras, Switchpack Details & Interlocks ................................................................................................................... 113
Pneumatic System ................................................................... 115
Air Dryer .......................................................................................................................................................................................... 116
Troubleshooting ..................................................................... 117
Tools ................................................................................................................................................................................................. 117
Troubleshooting Guide ............................................................................................................................................................. 120
Pump ................................................................................................................................................................................................ 124
Pump Cavitation ................................................................................................................................................................... 124
Tailgate Locking Mechanism ................................................................................................................................................... 125
Tailgate Unlocking Spontaneously ................................................................................................................................ 127
Tailgate Lowering Spontaneously .................................................................................................................................. 128
Multiplexing ............................................................................ 129
Labrie’s Multiplexed System .................................................................................................................................................... 129
Cart Counter (optional) ...................................................................................................................................................... 130
Warning and Caution Messages ...................................................................................................................................... 131
Hydraulic Oil Temperature Indicator (optional) ........................................................................................................ 137
Time and Date Indicator .................................................................................................................................................... 137
Main Menu .............................................................................................................................................................................. 137
Operational diagram of the Multiplexed System ..................................................................................................... 147
Warning Buzzer ..................................................................................................................................................................... 149
Plugging a Computer .......................................................................................................................................................... 149
Replacing the CAN Bus-Based Multiplexed System Joystick ................................................................................ 150
Allison Transmission Parameters ........................................................................................................................................... 150
Programmed Parameters .................................................................................................................................................. 151
Engine Programming Parameters ......................................................................................................................................... 153
Lifting Arm .............................................................................. 155
Daily Inspection ............................................................................................................................................................................ 155
Gripper Auto-Closing System ................................................................................................................................................. 158
Inspecting the Auto-Closing System ............................................................................................................................. 159
Auto-Packing ................................................................................................................................................................................. 159
Adjusting Adjustment Rod ................................................................................................................................................ 160
Bleeding Air Out of the Lifting Arm Hydraulic Circuit .................................................................................................... 161
Cylinder Cushion Adjustment ................................................................................................................................................. 162
vi Table of Contents
Adjusting Arm Speed ................................................................................................................................................................ 164
1
Introduction
About this Manual
This manual is designed to help qualified maintenance
personnel that have to repair, service and maintain
M
INIMAX™ vehicles.
What You Will Find in this Manual
This manual outlines maintenance procedures related
to the various components and systems of the
M
INIMAX™ (body, hopper, automated arm, packer,
electrical/hydraulic systems, etc.).
Topics not included in this Manual
Maintenance of the chassis
This is dealt in the chassis manufacturer’s service
manual.
Cameras and backing-accident prevention systems
For these options, refer to the appropriate
manufacturer’s service manual.
Operating the M
For procedures related to the operation of the
M
INIMAX™, please refer to the Operator Manual (part#
153164_R0).
Parts and assemblies
For parts and assemblies used on the M
their respective Labrie numbers for ordering purposes,
please refer to the M
153169_R0).
INIMAX™
INIMAX™ Parts Manual (part#
About the Schematics
For schematics concerning body parts, refer to the
M
INIMAX™ Parts Manual;
INIMAX™, with
2 Introduction
For maintenance of the chassis, refer to the chassis manufacturer’s service manual;
For electrical schematics, refer to the schematics provided with your M
For pneumatic and hydraulic schematics, refer to the schematics provided with your M
For details on how to operate the M
NOTE: A number of system schematics are included in this manual.
INIMAX™, refer to the MINIMAX™ Operator Manual.
Introducing the MINIMAX™
The MINIMAX™ is a side-loading refuse truck to be operated by only one person. It is designed
primarily for the automatic collection of garbage carts with the use of a joystick-controlled Helping
TM
Hand
arm. The lifting capacity of this arm is 450 lbs at a maximum reach of 60 inches. On some
units, a tipper may also be installed. Manual pickup of garbage bags or cans is also possible with the
M
INIMAX™.
Product Overview
On most MINIMAX™ units, a Helping HandTM arm is installed on the right-hand side of the body. This
arm has “close grab” capability, allowing the operator to pick up a cart within 12 inches from side of
vehicle with no “swing out” movement.
INIMAX™ unit;
INIMAX™ unit;
The M
INIMAX™ is composed of a small curved wall body, with a capacity of 10 cubic yards, and a
2 cubic yard tailgate, making the total loading capacity of the vehicle to be 12 cubic yards.
The hopper swept volume is 0.92 cubic yard, using an 18-inch packer, which is also used to unload
the body through the tailgate opening. This feature is called “Auto-Eject Mode”.
The standard packer cycle time is 15 seconds at 1,200 RPM, and the “Auto-Eject Mode” cycle takes
40 seconds at 1,200 RPM.
The hopper may also be equipped with a full-size crusher panel (optional). It also features a hinged
door on the left-hand side and 1 or 2 hinged doors on the right-hand side (2 doors if an automated
arm is installed).
After many years of experience with side-loading refuse trucks, Labrie has developed this newly
designed M
INIMAX™ truck. This truck will deliver excellent performance and reliability thanks to its
new simpler, but sturdier construction.
The M
INIMAX™ is primarily designed to be operated by only one person.
If, however, the end-user chooses to operate the arm-equipped M
INIMAX™ with more than one
worker, they shall advise Labrie Enviroquip Group of this situation. Labrie will then determine and
supply, at the customer’s expense, the safety items that are required in such a case.
For more information on this, please contact LabriePlus (see page 4).
Introduction 3
Danger!
Failure to contact Labrie Enviroquip Group to report a situation where a unit is operated
by more than one worker at a time may result in unit and/or property damage, personal
injury or even death.
Service and Maintenance on the MINIMAX™
Maintenance on the MINIMAX™ is of paramount importance to ensure long-lasting durability of all its
moving parts as well as optimum performance in heavy work. Maintenance has to be done on almost
every system involved in the operation of the M
mechanical systems. Some parts are subjected to more wear and tear than others. Therefore, these
parts need regular maintenance and routine check-up to prevent signs of deterioration as soon as
possible.
In this manual you will find the most common maintenance and inspection procedures required for
the M
INIMAX™.
INIMAX™, such as the hydraulic, electrical and
Warning
Your MINIMAX™ unit MUST BE COMPLETELY LUBRICATED before its first use. Refer to the
lube chart near the hopper on the curbside to know where the lubrication points are located on the
vehicle and how often the parts should be lubricated.
Initial lubrication carried out by Labrie Enviroquip Group is sufficient for production and transport
purposes ONLY.
With your safety in mind, we would like to remind you that ONLY QUALIFIED MECHANICS
should service the hydraulic, electrical, and pneumatic systems on your refuse vehicle. In addition,
these mechanics should also be fully knowledgeable in the operation of this unit. Please read the
Operator Manual prior to attempting any maintenance work on your M
Warranty Registration Form
Do not forget to complete the Warranty Registration Form and send it to Labrie Enviroquip Group.
Make sure to indicate the “in-service” date. This date will be used to start the warranty period.
Otherwise, the date of delivery from the factory will be used instead.
INIMAX™ unit.
4 Introduction
To Contact Labrie Plus
In the U.S.
Address: 1981 W. Snell Road
Oshkosh, WI 54904
Toll Free: 1-800-231-2771
Telephone: 1-920-233-2770
General Fax: 1-920-232-2496
Sales Fax: 1-920-232-2498
Parts and warranty: During business hours, 7:00 AM to 7:00 PM Central Standard Time
Technical Support Service: Available 24 hours
In Canada
Address: 175 Route du Pont
Toll Free: 1-877-831-8250
Telephone: 1-418-831-8250
Service Fax: 1-418-831-1673
Parts Fax: 1-418-831-7561
Parts and warranty: During business hours, 8:00 AM to 5:00 PM Eastern Standard Time
Technical Support Service: Available 24 hours
Website: www.labriegroup.com
E-mail (Sales Dept.): sales@labriegroup.com
E-mail (Customer Service): service@labriegroup.com
St-Nicolas, QC G7A 2T3
IMPORTANT: For technical support and parts ordering, the serial number of your vehicle is required. Therefore,
Labrie Enviroquip Group recommends to keep record of the information found on the VIN plate,
which is located in the cab.
Safety
It is mandatory to read the entire Operator Manual
before performing any maintenance task on this
vehicle.
2
Conventions
Danger!
Warning!
Caution!
Indicates a hazardous situation which, if
not avoided, will result in serious injury or
death.
Indicates a hazardous situation which, if
not avoided, could result in serious injury
or death.
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
Basic Safety Notions
The following safety notions are related to the use of
the M
INIMAX™. It is important to point out that the
safe use of the vehicle remains the user’s responsibility.
He must heed all safety notions explained in this
manual and on the decals found on the vehicle.
Danger!
Always be aware of the vehicle’s
surroundings to make sure that no
pedestrians, passersby, bystanders, or
other people or vehicles are in any way
exposed to any danger caused by the
use of the M
INIMAX™.
6 Safety
Danger!
Never get in the hopper area when the engine is running.
Only authorized personnel may do so following a lockout/tagout procedure (See Locking
Out and Tagging Out the Vehicle on page 20).
Responsibilities
Safety is everybody’s responsibility. Both employer and employee must play their part to ensure the
safety of the operator, the vehicle, and its immediate surroundings.
Employer’s Responsibilities
It is the responsibility of the employer:
To ensure that the M
including all applicable regulations, the Occupational Safety and Health Act (
American National Standards Institute (
To ensure that employees are qualified for operating/servicing the vehicle and its equipment, and
that they all take safety measures when working on them.
To properly maintain all mobile equipment to meet all state/provincial and federal safety
standards.
INIMAX™ is operated in accordance with all safety requirements and codes,
OSHA), and the
ANSI).
To supply adequate instructions and training for the safe use of the vehicle and its equipment
before assigning an employee to operate/service such vehicle and equipment.
To keep the vehicle maintained and properly adjusted to meet the manufacturer’s standards and
recommendations. For help or for more information, please contact the manufacturer or any of its
authorized representatives.
To keep records of all vehicle breakdowns and malfunctions, as well as any inspection and
maintenance.
To ensure that all failures or malfunctions that may be affecting the safe use of the vehicle are
repaired before the vehicle is put back into operation.
To meet the appropriate lighting requirements for night shift work (if permitted).
To regularly accompany the vehicle operator and take measures to ensure the smooth and safe
operation of the vehicle.
To make sure that the backup alarm works properly when the vehicle is in reverse.
To take necessary measures to repair any damage or malfunction reported by an employee.
To establish and ensure the application of a “lockout/tagout” procedure (see page 20) any time
inspection, repair or maintenance is performed on the vehicle, regardless of whether it takes place
on the road or in the garage.
Employee’s Responsibilities
It is the responsibility of the employee:
To enforce all safety measures to meet the requirements established by the employer.
To operate the M
To perform routine daily unit inspections.
To immediately report any damage or malfunction of the vehicle to the employer or supervisor.
To make sure that nobody is near the vehicle before activating any of the controls, and to be
prepared to stop at any indication of possible danger.
IMPORTANT: Do not use damaged equipment.
INIMAX™ only after having received instruction and training.
Things to Do
Inspect the body and all systems at the start of each day.
Make sure that the area is clear of any people or possible obstructions.
Safety 7
IMPORTANT: Be extremely cautious in areas where small children may be present.
Wear safety glasses and footwear, gloves, and any other safety equipment when loading and
packing refuse.
Make sure that mirrors, windows, lights, and monitor equipment are clean and properly adjusted.
Check for explosive trash (e.g. televisions, paint cans, fluorescent light tubes, etc.).
Drive carefully when carrying an unevenly distributed load.
Inspect for overhead hazards (e.g. power lines) prior to using the arm.
Always use the tailgate safety prop before entering the area between the main body and the
tailgate.
Obey all warning and operation decals.
Things to Avoid
Do not operate any vehicle while under the influence of alcohol, narcotics or other intoxicants.
Do not talk on a cell phone or listen to loud music while driving.
Do not wear jewelry or loose clothing.
Do not leave the vehicle before it is brought to a complete stop and the work or parking brake is
engaged.
Do not enter the hopper or main body unless the engine is shut off, the key is removed and there is
an out-of-service tag on the steering wheel. Refer to “Locking Out and Tagging Out the Vehicle”
on page 20.
Do not drive with the tailgate fully open unless it is to unload refuse at the landfill.
8 Safety
Warning!
Prior to its first use, your MINIMAX™ must be completely lubricated, as shown on the lube
chart located on the curbside of the truck, near the hopper.
Initial lubrication carried out by Labrie Enviroquip Group is sufficient for production and
transport purposes only!
Only qualified personnel should service the hydraulic, electrical, and pneumatic systems of this vehicle.
They should also be fully versed in operating the vehicle.
General Precautions
Danger!
It is the employer’s responsibility to ensure that only qualified employees operate and maintain this
vehicle.
Read and make sure that you fully understand this manual and all safety decals before performing
maintenance on the vehicle. Maintenance personnel must also read and understand the Operator
Manual for this vehicle. In case of doubt, ask a supervisor for clarifications.
Operator and maintenance personnel must adhere to the following precautions at all
times. Failure to do so may result in vehicle and/or property damage, personal injury, or
even death.
Before every work day, inspect the body, the packing system, and any system that might
compromise public and/or operator safety.
Verify that the accelerator pedal, the steering wheel, mirrors, brakes, and turn signals are in good
working order.
When driving the vehicle, keep both hands on the steering wheel at all times.
Stop the vehicle completely and put on the parking brake before leaving the driving position.
When the vehicle is parked, the parking brake must be applied.
Vehicle operators must have a clear view of lifting arm operations at all times. To prevent injury to
surrounding people, and damage to property and/or to the lifting arm itself, operators must be
able to stop arm movement at any time.
Before activating the lifting arm, operators shall make sure that people and obstructions are far
away from the vehicle.
INIMAX™ vehicles are primarily designed to be operated by only one person. However, if Labrie
M
Enviroquip Group customers elect to operate the vehicle with more than one worker, additional
safety items shall be installed to protect the co-worker from hazardous situations.
IMPORTANT: In such cases, Labrie Enviroquip Group must be informed of every and all units that will be operated
by more than one worker. Labrie Enviroquip Group will then determine and supply, at the
customer’s expense, the required safety items. For additional information, please contact LabriePlus
at 1-800-231-2771 in the U.S. or 1-877-831-8250 in Canada.
Safety 9
Do not operate this vehicle if there are any signs of damage or incomplete repairs.
Report any doubts that you might have and any safety service requirements regarding this vehicle
to a supervisor.
When removing nylon locknuts, always replace them with new ones.
Before opening and closing the tailgate(s), make sure no one is behind the vehicle.
Do not get into the hopper compartment or try to repair anything behind the packer when it is
moving or when the hydraulic pump is still running. Personnel authorized to get into the hopper
must first lock out and tag out the vehicle, as required by the employer. For more information, see
Locking Out and Tagging Out the Vehicle on page 20.
Never stand underneath a raised arm/gripper.
Never, under any circumstances (maintenance or otherwise), stand underneath a loaded body.
Warning!
Warning!
Warning!
Danger!
Do not operate the automated arm until you have been fully trained, and have read and
understood the Operator and Maintenance Manuals supplied with this unit.
Make sure that all people and obstructions are sufficiently cleared from the automated
arm before moving it. Failure to do so may result in unit and/or property damages,
personal injury or death.
Make sure there is enough clearance between raised container and overhead power
lines. The automated arm or the container must not come in direct contact with the
electrical cables. If the unit comes in contact with a power line, stay in the cab and keep
away from any metal parts.
Never drive this vehicle if the automated arm is not fully retracted to its home position.
The unit would be simply too wide to be driven. Failure to fully retract the arm will result
in unit and /or property damage, severe injury or even death. Warning red lights on
dashboard flash when the arm is not completely retracted to its home position.
Warning!
Remove all control levers from the proportional valve. These levers should be used for
maintenance purposes only.
10 Safety
Warning!
Welding
Danger!
Caution!
Units with two driving positions: Prior to changing driving position, stop the vehicle, apply
the parking brake, push the emergency button and stop the engine. Properly adjust
mirrors and set driving control switches including the arm-controlling joystick (if
applicable) to the new driving position before restarting the engine.
Remove paint before welding or heating. Do not weld near lines that are pressurized or
contain flammable fluids.
Disconnect all batteries and electronic modules prior to welding on packer body.
Fire
The employer must inform and train all personnel on the measures that must be taken in case of a
vehicle and/or loaded body catching fire.
Anytime a loaded vehicle is brought inside a garage, fire extinguishers shall be close at hand.
Danger!
The employer must also inform their employees of an appropriate place near the maintenance facility
to unload the body (preferably away from traffic, surface drains, and ditches).
M
fire extinguisher may be installed on the truck as an option (see Figure 2-1). Each fire extinguisher
must be checked regularly by qualified personnel.
Do not perform any repair or maintenance on a vehicle that has not been unloaded.
INIMAX™ vehicles are equipped with a 5-lb fire extinguisher, which is found inside the cab. A 20-lb
Safety 11
Figure 2-1
5-lb fire extinguisher
Fire extinguishers and first aid kit
Safety Kits
A first aid kit (see Figure 2-1), a flare kit and a triangle kit are provided with the truck.
Optional 20-lb fire extinguisher
First aid kit
Safety Features
Global Motion Sensors (Optional)
This OPTIONAL safety system is used to detect objects located behind the truck. This system is
turned on by placing the transmission in reverse.
Warning!
The main components of this system are a control box placed in the cab, a set of sensors fixed on the
rear bumper, and a solenoid valve mounted on the chassis.
The operator must read the installation manual of the system manufacturer before using
the system.
12 Safety
When the system is turned on, a green light on the cab control box should light up to indicate that the
system is operating. When an object is detected, a yellow light comes on and an audible alarm is
heard. The vehicle brakes are automatically applied. The brakes can be disabled by pressing the A
UTO
BRAKE OFF switch on the control box. This will cause a red warning light to turn on indicating the
brakes will not automatically engage. The yellow light and audible alarm will still operate in this mode
as a safety precaution.
Warning!
Sensor lenses must be kept clean to ensure proper operation of the system. If the lenses
are allowed to become dirty, system range will be decreased.
The sensors are installed on the rear bumper and adjusted in order to obtain low coverage to ground.
For details on how to adjust the sensors, refer to the Installation Manual of the sensor manufacturer.
Safety 13
Troubleshooting and Maintenance
For information on troubleshooting and maintenance, refer to the Troubleshooting Guide of Global
Sensor Systems Inc.
NOTE: Above illustrations taken from the Installation Manual of Global Sensor Sytems Inc.
Back Up Alarm
The back up alarm sounds when the truck is in reverse or the tailgate is open.
14 Safety
Tailgate Safety Prop
Setting the Tailgate Safety Prop
The tailgate safety prop (see Figure 2-2) is used to support and keep the tailgate open during
inspection or maintenance procedures. It is mandatory to set the safety prop each time the tailgate is
open for such purposes.
IMPORTANT: Make sure the body is empty before setting safety props.
Figure 2-2
Danger!
Tailgate safety prop
The safety prop shall be set each time the tailgate is opened for inspection and
maintenance purposes.
To set the tailgate safety prop:
1. Make sure that the body is empty.
2. Remove the tailgate-locking mechanism safety pins (see Figure 2-3).
Safety 15
Figure 2-3
3. Start the engine.
4. Turn on the pump.
Danger!
Safety pin
Prior to raising the tailgate, make sure that no one is standing behind the vehicle and that
the body is empty.
5. With the TAILGATE UP switch on the multiplexed control module (see Figure 3-7), raise the
6. Pull the safety prop upward and set it down (see Figure 2-4).
Figure 2-4
tailgate about 3 feet (enough to raise the safety prop).
Pulling the safety prop upward (left) and setting it down (right)
7. Lower the tailgate onto the safety prop.
16 Safety
Putting the Tailgate Safety Prop Back in Place
To put the tailgate safety prop back in its home position:
1. Start the engine.
2. Turn on the pump.
3. Raise the tailgate by about 3 feet.
4. Raise the tailgate safety prop.
Figure 2-5
5. Release your grip on the safety prop to set it in its home position.
Figure 2-6
Raising the tailgate safety prop
Setting the safety prop in its home position
6. With the TAILGATE DOWN switch on the multiplexed control module (see Figure 3-18), fully
close the tailgate.
The switch should turn from green to blue, indicating that the tailgate is completely closed.
7. Put the safety pins back in place.
Camera System (optional)
MINIMAX™ units can be equipped with up to four (4) cameras; one inside the hopper (see Figure
2-7), one on the tailgate (see Figure 2-8), one on the outside of the right hopper wall (see Figure 2-9),
and one on the left-hand side mirror (see Figure 2-10).
The operator can switch from one camera to the other thanks to a selector switch located on the 7”
LCD color monitor installed in the cab (see Figure 2-11).
Refer to the camera manufacturer’s manual for more information.
Safety 17
Figure 2-7
Figure 2-8
Camera inside the hopper
Camera on the tailgate
18 Safety
Figure 2-9
Figure 2-10
Camera on the right hopper wall
Camera on the left-hand side mirror
Figure 2-11
LCD color monitor
Tailgate Holding Valve
Located under the rear section of the body, this holding valve (see Figure 2-12) ensures that the
tailgate will not open during the packing cycle.
Safety 19
Figure 2-12
Tailgate holding valve
Prior to Start Up
Before starting the vehicle:
1. Inspect vehicle for leaks.
2. Make sure the main valve (ball valve) on the suction line is fully open before starting the vehicle
(see Figure 2-13).
Figure 2-13
Warning!
Main valve (ball valve) on suction line
Failure to fully open the main valve will cause immediate damage to the pump, even if
the pump is turned off.
3. Start the engine.
4. Engage the hydraulic system by pressing the pump switch (see Figure 2-14).
20 Safety
The switch should turn to a green light.
Figure 2-14
Hydraulic pump switch on the multiplexed module
Locking Out and Tagging Out the Vehicle
For any inspection, repair or general maintenance being done on the vehicle, whether on the road or
at the shop, it is the employer’s responsibility to establish and see to the application of a proper
lockout and tagout procedure.
To lock out and tag out a M
1. Park the vehicle on safe level ground, and apply the parking brake (see Figure 2-15).
INIMAX™ vehicle:
Figure 2-15
Parking brake sign
2. Make sure that the body is completely unloaded.
3. Switch off the hydraulic pump.
4. Turn off the engine, remove the key from the ignition, store it in a safe and controlled area
(preferably on yourself), and tape over the ignition switch.
5. Turn off and lock the master switch.
6. Chock all wheels.
IMPORTANT: If the MINIMAX™ is equipped with a master switch on the battery set (see Figure 2-16), you must turn
it off. This switch is offered as an option.
Safety 21
Figure 2-16
7. Put an “OFF SERVICE” tag on the driver’s wheel and on the front windshield.
8. Use safety props to block any system that could move by gravity (open tailgate, etc.).
9. Drain all air tanks.
Verify and inspect any security device and/or mechanism to make sure that there is no bypass and
that they are all functional.
Master switch
Shutting Down the Vehicle
If the vehicle has to be stored for an extended period of time, follow the chassis manufacturer’s
shutdown and maintenance requirements.
Also:
1. Park the vehicle on hard level ground, and apply the parking brake.
2. Make sure that all moving parts are in their home position (tailgate, arm, crusher panel, packer,
etc.).
3. Turn off, in sequence, the hydraulic pump, the electrical system, the engine and the master
switch.
4. Drain all air tanks (see Figure 2-17).
22 Safety
Figure 2-17
Drain valve on air tank
General Maintenance
3
Danger!
Cleanliness is part of safety.
As such:
Clean all vehicle lights, warning lights and safety
decals so that you and the vehicle surroundings are
safe at all times.
Clean the contact surface between the body and
chassis. Labrie Enviroquip Group recommends
cleaning the chassis after every unloading.
Remove any stacked garbage from the hopper area
after each body unloading.
Use the provided hoe to rake debris out of the
clean-out doors (see Figure 3-1).
Make sure that the side step and/or hopper step (if
installed) are clean and free of any slippery
material.
Always lock out and tag out the vehicle
when inspecting or performing
maintenance on the vehicle (see Locking
Out and Tagging Out the Vehicle on
page 20).
Caution!
Figure 3-1
Keep the cab floor dry and clean to
prevent slippage and accidents.
Clean-out door
24 General Maintenance
Preventive Maintenance Chart
Component/System Verification Daily Weekly Monthly Yearly Page
Limit switches Proper adjustment of
the limit switches is
imperative
Check and clean area
around switches
Lubrication Lubricate the packer
and its accessories.
See lubrication chart on
side of the vehicle
Wiring System Check for damaged
harnesses and/or bad
connections
Battery Cables Ensure cables are not
coming in contact with
an area that could rub
through the insulation
Operator controls Check for proper
operation
Air tanks Drain X See page 115
X
X See page 68
X
X See page 37
X See page 103
X
Air system Check for leaks X See page 115
Safety systems Check for proper
operation (tailgate
alarm and special
devices)
Lifting arm Check hydraulic
pressure
X See page 85
X See page 11
General Maintenance 25
Component/System Verification Daily Weekly Monthly Yearly Page
Hydraulic system Check oil level in tank,
X See page 81
and refill if necessary
Check if the ball valve
X See page 73
on suction line is open
Check on ground for
X
overnight leaks
Check cylinders, pump,
X See page 73
control valve and
system for leaks. Repair
or replace if required
Replace hydraulic filter
a
Twice a
See page 95
year
Clean strainer and refill X See page 92
Check pressure X See page 83
Hopper area Clean traps on each side X See page 23
Clean dirt around the
X See page 23
packer
Visual inspection Rollers, hydraulic
X See page 25
cylinder and cylinder
pins, hoses, pipes and
connections, wear of
floor and hopper sides.
Body and chassis Check for corrosion X
Keep the contact
X
surfaces clean between
the body and the
chassis.
a. Also replace the return filter after the first 50 hours of use.
Packer
The MINIMAX™ packer (see Figure 3-2) is submitted to intensive use during a work day (1000 to
3000 cycles). Therefore, some of its components have to be regularly looked at: the wear pads, which
are located at both sides of the packer and inserted in the body side rails, the follower panels, and the
rollers, which are also inserted in the body side rails (see Figure 3-3).
Labrie Enviroquip Group recommends that operators perform a daily visual inspection of the packer
and its components.
26 General Maintenance
Maintenance personnel must perform weekly inspection and maintenance. Greasing all moving parts
on a daily basis is very important and proper adjustment of the limit and proximity switches is
mandatory, especially on vehicles equipped with a multi-cycle feature. For more information on the
lubrication schedule, see Lubrication Charts on page 62.
Any problems found on the packing system must be corrected immediately. In case of problem,
contact your distributor.
Danger!
Figure 3-2
Figure 3-3
Always lock out and tag out the vehicle when inspecting it or performing maintenance
on it (see Locking Out and Tagging Out the Vehicle on page 20).
The packer
Packer components
Preparing for Packer Inspection
To prepare the packer for inspection:
1. Park the vehicle on level ground and apply the parking brake.
2. Fully extend the arm.
3. Remove the tailgate safety pins (see Figure 3-6).
RollerSide rail
General Maintenance 27
4. Fully open the tailgate by pressing the TAILGATE UP switch on the multiplexed control module
(see Figure 3-7).
5. Fully extend the packer by pressing the green PACK button on the control packer station
(see Figure 3-8).
Danger!
6. When the packer has reached its fully extended position, press the red EMERGENCY STOP button
Never enter the hopper while the packer is moving.
on the control packer station (see Figure 3-10).
7. Install the tailgate safety prop.
Danger!
8. Perform the lockout/tagout procedure (see Locking Out and Tagging Out the Vehicle on page 20).
Always use the tailgate safety prop while working under a raised tailgate. The safety prop
should be used even if the tailgate is in fully raised position.
Inspecting the Packer
Proceed this way during the packer inspection:
1. Inspect the follower panel hinges and surface in search of any wear or damage.
2. Check for any sideways or up-and-down movement of the packer and inspect the wear pads
(plastic strips) on both sides of the packer.
3. Inspect the cover wear pads. These wear pads act as additional protection against intruding refuse
Figure 3-4
4. Inspect both body side rails and packer rollers for any premature wear (see Figure 3-3).
that may get inside the automated arm mechanism, where they can damage the cylinder and the
limit switches (see Figure 3-4).
Protective wear pads
28 General Maintenance
5. Inspect the hydraulic system, including hoses, pipes, connectors, and cylinder (see Figure 3-5).
There should neither be dirt or garbage on the cylinder rod ends nor scratches on the rod itself.
There should not be leaks on the hoses and pipes.
Figure 3-5
Packer hydraulic system
Pipes
Rod end
Connector
Removing the Packer
The following procedure details how to remove the packer for maintenance purposes.
To remove the packer:
1. Ensure the parking brake is applied.
2. Start the engine and engage the hydraulic system.
3. Remove the tailgate safety pins (see Figure 3-6) and fully open the tailgate by pressing the
T
AILGATE UP switch on the multiplexed control module (see Figure 3-7).
Cylinder rod
Figure 3-6
Safety pin
General Maintenance 29
Figure 3-7
4. On the packer control station, press the green PACK button to fully extend the packer (see Figure
Tailgate up switch
3-8). When the packer has reached its fully extended position (see Figure 3-9), press the red
E
MERGENCY STOP button to stop the packer (see Figure 3-10).
Figure 3-8
Danger!
Pack button
Never enter the hopper while the packer is moving.
30 General Maintenance
Figure 3-9
Figure 3-10
Packer in fully extended position
Packer
Emergency stop button
5. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
6. Unscrew the nut (see Figure 3-11) at the left-hand side of the packer tip to remove the cylinder
Figure 3-11
7. Remove the cylinder pin (see Figure 3-12).
Vehicle” on page 20.
pin.
Nut to unscrew
General Maintenance 31
Figure 3-12
Ring handle
8. On the packer control station, press the yellow PACKER RETRACT button to retract the cylinder
9. Install any safe lifting device and hook the packer by the ring handle (see Figure 3-12).
10. Pull the packer out of the side rails and place it in a safe work area.
Figure 3-13
Removing the packer
Cylinder pin
(see Figure 3-13).
Packer retract button
Warning!
When you pull out the packer, always ensure total clearance until it is placed in a safe area
to avoid any accidents.
Replacing Packer Wear Plates
When the packer wear plates are worn out, you must replace them to achieve packer optimal
performance.
To replace the wear plates, proceed this way:
1. Remove the packer from the body. See Removing the Packer on page 28.
2. Once the packer is placed in a safe work area, cut off the wear plate panel (see Figure 3-14).
32 General Maintenance
Figure 3-14
3. Weld the new wear plate panel to the packer (see Figure 3-15 for welding specifications).
Figure 3-15
Cutting the wear plate panel
Cut here
Welding specifications
NOTE: This operation is valid for the wear plate panels located on both sides of the packer.
Reinstall the packer inside the body (see Reinstalling the Packer below).
Warning!
When reinstalling the packer, always ensure total clearance to avoid any accidents.
Reinstalling the Packer
The following procedure details how to reinstall the packer inside the body of the MINIMAX™.
General Maintenance 33
To reinstall the packer, proceed this way:
1. Make sure the tailgate is properly open, and all packer components are properly assembled.
2. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
3. Use a safe lifting device and hook the packer by the ring handle (see Figure 3-12).
4. Lift the packer and align it with the side rails inside the body.
5. Insert the wear plate panels in the rails and push the packer in.
6. On the packer control station, press the green PACK button (see Figure 3-8) to fully extend the
packer cylinder.
Warning!
7. Insert the cylinder into the packer, then the pin through the tip of the packer and into the cylinder
to fix them properly.
8. Turn on the engine and the hydraulic system (PUMP switch set to “ON”).
Caution
9. On the packer control station, press the yellow PACKER RETRACT button to retract the packer to
its home position (see Figure 3-16).
Figure 3-16
Packer retract button
Slowly extend the cylinder in order to properly align it with the packer and to avoid impact
that could cause damage to the equipment.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
10. Extend and retract the packer in EJECT mode for a full cycle to make sure the packer has been
properly installed.
To activate this mode, press and hold the A
UTO-EJECT switch on the multiplexed control module
(see Figure 3-17).
34 General Maintenance
Figure 3-17
11. Put the tailgate safety prop back to its home position.
12. Close the tailgate completely by pressing the TAILGATE DOWN switch on the multiplexed control
Auto-eject switch
mudule (see Figure 3-18).
Figure 3-18
Tailgate down switch
Tailgate
The tailgate of the MINIMAX™ is subject to frequent movements, and therefore, must be frequently
inspected and maintained to keep its high level of performance. The hinges and pins are parts of the
tailgate that should particularly be looked at in search of any type of wear or metal fatigue. Tailgate
rubber seal should also be looked at for signs of wear or damage that may hinder its effectiveness.
Always replace the parts that are faulty.
General Maintenance 35
Figure 3-19
Tailgate
Tailgate
Cylinder
Rubber seal
Safety prop
36 General Maintenance
Proximity and Limit Switches
Proximity and limit switches act as remote electrical on/off switches and must be adjusted properly.
Warning
Figures 3-20 and 3-21 show where the proximity and limit switches are located on the truck.
Figure 3-20
Proximity and limit switches must function properly. Serious damage to the equipment,
injuries or death may occur if you operate the machinery with improperly adjusted
switches.
Switches on the street side
Left-hand side hopper door
limit switch (optional)
Tailgate fully
open prox switch
Figure 3-21
Fully open upper
door limit switch
Switches on the curb side
Crusher panel
limit switch
Arm stowed
limit switch
Tailgate unlocked
prox switch
Packer extend limit/
proximity switch
Fully closed upper door
limit switch (optional)
Packer retract
limit switch
Arm parked
limit switch
Arm mid-height
limit switch
Limit Switch Adjustment
The following is the general procedure for adjusting all the limit switches used on the MINIMAX™,
except for the mid-height limit switch, which calls for a different method of adjustment (see All limit
switches MUST be working at all times. Otherwise, the operator may not be aware that the arm is not fully
retracted or that the grabber is open or closed. This may cause an accident, injuries or property damages. on
page 55).
General Maintenance 37
To adjust a limit switch:
1. Loosen limit switch nut.
2. Move the lever arm to the approximate position where the switch is to be triggered.
3. Tighten nut.
4. To fine tune the adjustment, loosen nut slightly.
5. With a flathead screwdriver, turn the adjusting screw located at the center of the nut until a click
is heard.
6. Tighten the nut.
7. Test the operation.
8. If necessary, repeat steps 1 through 7.
Proximity Switch Adjustment
The following is the general procedure for adjusting all the proximity switches used on the
M
INIMAX™.
Switch
Nuts
38 General Maintenance
To adjust a proximity switch:
1. Loosen the proximity switch nuts.
2. Adjust the proximity switch so that there is a gap of approximetely 3/16 of an inch (4.8 mm)
between the plate (target) and the switch.
3. Tighten up the nuts.
4. Test the operation.
The proximity switch light should turn on when the target is detected; if not, repeat the adjustment
procedure.
In the following sections, you will learn how to adjust limit/proximity switches based on the function
for which they are used.
Adjusting Packer Extend Limit/Proximity Switch
Danger!
Always lock out and tag out the vehicle when inspecting it or performing maintenance
on it (see Locking Out and Tagging Out the Vehicle on page 20) .
Packer limit/proximity switches were adjusted at the factory for optimal packer operation. If the area
behind the packer is not properly cleaned daily, limit/proximity switches may no longer stop the
packer or may prevent automatic cycles from working properly.
Furthermore, over time, misalignment of the components may occur due to the frequent back and
forth motion of the packer. An adjustment might be necessary to prevent cylinders from completely
extending and retracting to the end of their strokes.
On some units, the packer range of motion is controlled by two limit switches and on other units, it is
controlled by a set of one limit switch and one proximity switch. The limit/proximity switch that
stops the packer during extension (packer extend) is located near the hopper floor, on the curbside,
just under the automated arm housing (see Figure 3-22). The limit switch that stops the packer
during retraction (packer retract) is located on front right-hand side hopper corner, behind the cab
(see Figure 3-23).
General Maintenance 39
Figure 3-22
The Packer Extend limit/proximity switch sends a signal to the controller module that the packer
panel has reached its extended packing position. Once the signal from the limit/proximity switch is
received, the module prompts the packer to retract to complete its packing cycle.
When this limit/proximity switch needs adjustment, the following procedure is recommended.
A. To adjust the packer extend limit switch:
Packer extend limit/proximity switches
Limit switch
Proximity switch
1. Set the parking brake.
2. Turn on the engine and the hydraulic system (PUMP switch activated).
Usually, the packer extend limit switch needs adjustment when the last follower panel moves past
the limit switch without triggering any signal. In such a case, the packer continues its forward
motion inside the body as in Eject mode.
3. Press and hold the Auto-Eject switch on the multiplexed control module (see Figure 3-17). Keep
this switch down until the tailgate is fully open and the last follower panel clears the limit switch
in the hopper.
As soon as you release the Auto-Eject switch, the packer will stop moving.
Caution!
4. Turn off the engine.
Make sure no one is standing behind the truck when you operate the tailgate.
40 General Maintenance
5. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Danger!
6. Get on the hopper area.
7. Free the limit switch from any dirt or debris that may cause the switch to malfunction.
8. Turn on the engine and the hydraulic system (PUMP switch activated).
Caution
9. Press the yellow PACKER RETRACT button (see Figure 3-13) to retract the packer and bring it
back to the position where the target, which is located at the tail of the last follower panel, must
make contact with the Packer Extend limit switch lever. Use the red E
stop retraction at such position (see Figure 3-10).
10. Turn off the engine.
11. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Never get on the hopper area while the engine is running.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
MERGENCY STOP button to
Danger!
12. Use an Allen key to loosen the locknut on the limit switch and determine the contact point where
the triggering should occur by moving the lever.
13. Once you have determined the contact point where the triggering should occur, tighten back the
locknut.
14. Turn on the engine and engage the hydraulic system (PUMP switch activated).
Caution
Never get on the hopper area while the engine is running.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
General Maintenance 41
15. Fully retract the packer and press the green PACK button to start a complete cycle and test the
efficiency of the limit switch.
NOTE: Repeat this procedure until you achieve the proper settings for the limit switch.
B. To adjust the packer extend proximity switch:
1. Set the parking brake.
2. Turn on the engine and the hydraulic system (PUMP switch activated).
Usually, the packer extend proximity switch needs adjustment when the last follower panel
moves past the switch without triggering any signal. In such a case, the packer continues its
forward motion inside the body as in Eject mode.
3. Press and hold the Auto-Eject switch on the multiplexed control module (see Figure 3-17). Keep
this switch down until the tailgate is fully open and the last follower panel clears the proximity
switch in the hopper.
As soon as you release the Auto-Eject switch, the packer will stop moving.
Caution!
4. Turn off the engine.
5. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Danger!
6. Get on the hopper area.
7. Free the proximity switch from any dirt or debris that may cause the switch to malfunction.
8. Turn on the engine and the hydraulic system (PUMP switch activated).
Caution
Make sure no one is standing behind the truck when you operate the tailgate.
Never get on the hopper area while the engine is running.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
9. Press the yellow PACKER RETRACT button (see Figure 3-13) to retract the packer and bring it
back to the position where the target, which is located at the tail of the last follower panel, must
make contact with the Packer Extend proximity switch. Use the red E
MERGENCY STOP button to
stop retraction at such position (see Figure 3-10).
42 General Maintenance
10. Turn off the engine.
11. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Danger!
12. Adjust the Packer Extend proximity switch.
12 a. Loosen the proximity switch nuts.
12 b. Adjust the proximity switch so that there is a gap of approximetely 3/16 of an inch
12 c. Once you have determined the contact point where the triggering should occur, tighten
13. Turn on the engine and engage the hydraulic system (PUMP switch activated).
Caution
14. Fully retract the packer and press the green PACK button to start a complete cycle and test the
efficiency of the proximity switch.
Never get on the hopper area while the engine is running.
(4.8 mm) between the plate (target) and the switch.
back the nuts.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
The proximity switch light should turn on when the target is detected; if not, repeat the
adjustment procedure.
Adjusting Packer Retract Limit Switch
The Packer Retract limit switch (see Figure 3-23) sends a signal to the controller module that the
packer has reached its fully retracted position.
Figure 3-23
Packer retract limit switch
General Maintenance 43
When the Packer Retract limit switch needs adjustment, it is usually because it no longer stops the
packer (bottoming out) or prevents automatic cycles from working properly. A well adjusted Packer
Retract limit switch should prevent the packer from making a knocking noise when it stops during
retraction in speed-up mode.
When this limit switch needs adjustment, the following procedure is recommended.
To adjust the Packer Retract limit switch:
1. Set the parking brake.
2. Start the engine and engage the hydraulic system (PUMP switch activated).
3. Press the yellow button to retract the packer to (+/-) 1/16” before the fully retracted position
(this is the measurement between the packer blade and the arm base wiper).
NOTE: When in stowed position the packer blade must always make contact with the wiper.
4. When the packer reaches the correct position, push the red emergency STOP button (see Figure
3-10).
5. Disengage the hydraulic pump and turn off the engine.
6. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Danger!
7. Locate the Packer Retract limit switch lever (see Figure 3-24).
Figure 3-24
8. Use an Allen key to loosen the locknut on the limit switch and determine the contact point where
Never get on the hopper area while the engine is running.
Packer retract limit switch lever
the triggering should occur by moving the lever.
9. Once you have determined the contact point where the triggering should occur, tighten back the
locknut.
44 General Maintenance
10. Turn on the engine and engage the hydraulic system (PUMP switch activated).
Caution
11. Fully retract the packer and press the green PACK button to start a complete cycle and test the
Make sure the ball valve on the suction line is fully open before starting the vehicle.
efficiency of the limit switch.
NOTE: Repeat this procedure until you achieve the proper settings for the limit switch.
Adjusting Tailgate Unlocked Proximity Switch
Warning!
MINIMAX™ vehicles are equipped with a tailgate proximity switch located on the back left-hand side
body corner. When the tailgate is being unlocked (see Figure 3-26), the cylinder pushes the plate
downward which triggers the proximity switch. This switch then activates the backup alarm and a
warning buzzer inside the cab.
Ensure that no one is standing behind or near the tailgate when adjustment procedure is
carried out.
When the tailgate is being locked, the plate goes upward (see Figure 3-25). As the proximity switch is
no more triggered by the plate, the warning buzzer and the backup alarm stop sounding.
Figure 3-25
Tailgate proximity switch (locked position)
Plate
Proximity
switch
General Maintenance 45
Figure 3-26
Tailgate proximity switch (unlocked position)
Proximity
switch
To adjust the tailgate unlocked proximity switch:
1. Start the engine and engage the hydraulic system.
2. Loosen the nuts located on each side of the proximity switch bracket (see Figure 3-27).
NOTE: The second nut is on the hidden side of the body wall.
Plate
Figure 3-27
3. Adjust the proximity switch so that the switch can be triggered by the plate as the cylinder head
4. Tighten up both nuts.
5. Open the tailgate a little using the TAILGATE UP switch on the multiplexed control module
6. Repeat the procedure if need be.
Tailgate proximity switch
Plate
Proximity
switch
Nut
moves down. There should be a gap of approximately 3/16 of an inch between the plate and the
switch.
(see Figure 3-7), and listen if the warning buzzer and backup alarm start to sound as the tailgate
unlocks.
46 General Maintenance
IMPORTANT: Remove both tailgate-locking pins before proceeding with this test.
Warning!
Ensure that no one is standing behind or near the tailgate when adjustment procedure is
carried out.
Adjusting Tailgate Fully Open Proximity Switch
The MINIMAX™ has a feature that allows the operator to unload all the refuse collected during his run
with the press of a single switch. This feature is called “Auto-Eject mode”. And for this feature to work
correctly, the tailgate fully open proximity switch must be ajusted properly (see Figure 3-28).
Otherwise, the Auto-Eject mode will be inoperative.
In Auto-Eject mode as wellas in Manual Eject mode, the packer panel moves only when the tailgate is
fully open. If it does not, the tailgate fully open proximity switch may need adjustment.
Figure 3-28
Tailgate fully open proximity switch
This switch is located on the street side near the tailgate hinge.
To adjust the tailgate fully open proximity switch:
1. Open the tailgate to 90 degrees (see Figure 3-28).
Warning!
2. Adjust the switch so that it can detect the target.
Ensure that no one is standing behind or near the tailgate when adjustment procedure is
carried out.
General Maintenance 47
The proximity switch light should turn on when the target is detected.
3. Slightly close the tailgate a couple of inches.
As the target should not be detected by the proximity switch at such a position, the switch light
should be off.
4. Repeat the procedure until the proximity switch is properly adjusted.
Adjusting Left-Hand Side Hopper Door Limit Switch (optional)
This limit switch (see Figure 3-29) turns off all hydraulic power when the left-hand side hopper door
is not closed. It also allows control of the crusher panel from inside the cab.
NOTE: The left-hand side hopper door limit switch is found only on units equipped with an automated
arm.
NOTE: In Ontario, provincial regulations require the use of this limit switch.
Figure 3-29
If installed, this limit switch is located on the inside hopper door frame.
To verify that the switch needs adjusting, open the LHS hopper door by approximately 2 inches
(5 cm) and try to operate any hydraulic function. No hydraulic function should be working.
Warning
LHS hopper door limit switch
Injury or death may occur if you attempt to enter the body while the packer or arm is in
operation.
To adjust the LHS hopper door limit switch:
1. Unscrew the lever adjustement screws of the limit switch (see Figure 3-30).
2. Raise or lower the detection lever a little bit and tighten up the screws.
3. Test the operation.
The hydraulic system should be working when the LHS hopper door is closed.
48 General Maintenance
4. Repeat the adjustment procedure if need be.
Figure 3-30
Limit switch
Detection lever
adjustment screws
Adjusting Crusher Panel Up Limit Switch
The crusher panel up limit switch disables the arm operation when the crusher panel is not in its
stowed position and redirects the arm power to the crusher panel up function when the arm joystick
deadman switch is activated. This forces the crusher panel to rise to the up position in order to let the
arm works.
This switch is located behind the crusher panel itself.
NOTE: The crusher panel has to be lowered to access this limit switch.
To adjust the crusher panel up limit switch:
1. Lower the crusher panel.
2. Adjust the crusher panel up limit switch so that it is triggered when the crusher panel is in the up
position.
2 a. Unscrew the lever adjustement screws of the limit switch (see Figure 3-30).
2 b. Raise or lower the detection lever a little bit and tighten up the screws.
3. Depress deadman switch on joystick until crusher panel reaches the up position.
The crusher panel should go up, and the arm should start to move when the crusher panel
reaches the up position.
4. Repeat the procedure until the limit switch is properly adjusted.
Adjusting Fully Open Upper Door Limit Switch
When triggered the fully open upper door limit switch enables the arm operation (see Figure 3-31). If
the upper door is not fully open and properly latched, the operator cannot operate the arm. This
lockout function is provided to prevent the arm from colliding against the upper door.
General Maintenance 49
Figure 3-31
This switch is located on the right middle side post.
If the automated arm function cannot be activated by the operator despite of the fact that the upper
door is fully open, an adjustment of the fully open upper door limit switch may be required.
To adjust the fully open upper door limit switch:
1. Unscrew the lever adjustement screws of the limit switch (see Figure 3-30).
2. Raise or lower the detection lever a little bit and tighten up the screws.
Fully open upper door limit switch
The detection lever must touch the side of the upper door for the switch to be triggered.
3. Test the operation.
The automated arm should be working fine when the upper door is fully open.
4. Repeat the adjustment procedure if need be.
Adjusting Fully Closed Upper Door Limit Switch (optional)
When triggered the fully closed upper door limit switch (see Figure 3-32) prevents the arm from
colliding against the upper door so that no damage is done to the equipment.
50 General Maintenance
If the arm is still operative despite of the fact that the upper door is fully closed, an adjustment of the
fully closed upper door limit switch is required.
Figure 3-32
NOTE: In Ontario, provincial regulations require the use of this limit switch.
Fully closed upper door limit switch
If installed, this switch is located on the right front side post.
To adjust the fully closed upper door limit switch:
1. Unscrew the lever adjustement screws of the limit switch (see Figure 3-30).
2. Raise or lower the detection lever a little bit and tighten up the screws.
The detection lever must touch the inside of the upper door for the switch to be triggered.
3. Test the operation.
The automated arm should not be working when the upper door is fully closed.
4. Repeat the adjustment procedure if need be.
Adjusting Arm Stowed Limit Switch
The arm stowed limit switch turns on the ARM EXTENDED warning light on the dashboard
(see Figure 3-35) when the operator extends the arm or closes the gripper. If this limit switch is
misaligned, the warning light on the dashboard may continue to flash even if the gripper is fully open
and the arm is fully retracted. The arm stowed limit switch also activates an audible alarm when the
arm is out and the vehicle speed is greater than about 3 mph (5 km/h).
General Maintenance 51
Figure 3-33
This limit switch is located behind the left gripper finger when facing the arm.
To adjust the arm stowed limit switch:
1. Park the vehicle on safe and level ground.
2. Fully open the gripper and retract the arm alongside the body.
3. Adjust the limit switch in such a way that the ARM EXTENDED warning light on the dashboard
Arm stowed limit switch
stop flashing when the gripper is fully open and the arm is fully retracted. To do this:
Figure 3-34
4. Slightly close the gripper or extend the arm out (about 1 inch). The ARM EXTENDED warning
3 a. Loosen limit switch nut.
3 b. Adjust the rod (see Figure 3-34) so that the gripper finger will trigger the limit switch (click
sound) and turn off the warning light.
Limit switch rod
3 c. Tighten back up nut.
light should start flashing.
52 General Maintenance
5. Repeat the procedure until the limit switch is properly adjusted.
Danger!
Caution!
Figure 3-35
All limit switches MUST be working at all times. Otherwise, the operator may not be aware that
the arm is not fully retracted or that the grabber is open or closed. This may cause an accident,
injuries or property damages.
This procedure must be done correctly before adjusting the gripper auto-closing system.
Arm extended warning light
Adjusting Arm Parked Limit Switch
Centrally located inside the Helping-HandTM arm assembly, near the top cover, the arm parked limit
switch (see Figure 3-36) sends a signal to the controller module that the automated arm is in parked
travel position inside the hopper and turns off the A
To adjust this limit switch, apply the following procedure:
1. Take down the grabber completely by using the joystick.
2. Fully extend the arm.
Danger!
3. Turn off the engine.
4. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Vehicle” on page 20.
Do not stand directly in the path of the arm while carrying out these tasks.
RM EXTENDED warning light on the dashboard.
General Maintenance 53
5. Open the black plastic spring equipped retracting cover that is on top of the arm base (see Figure
3-37).
Use a stepladder for easy access to that part of the arm.
6. Unscrew the lever screws of the limit switch (see Figure 3-38).
7. Raise or lower the detection lever a little bit and tighten up the screws (see Figure 3-38).
The detection lever or actuator must touch the black curved plastic cover when the arm is in the
hopper for the switch to be triggered.
Warning
8. Close the black plastic springed cover.
9. Start the engine and engage the hydraulic pump.
Caution
10. Test the operation.
11. Repeat the procedure until the limit switch is properly adjusted. The ARM EXTENDED warning
Figure 3-36
Injury or death may occur if you attempt to enter the body while the packer or arm is in
operation.
Make sure the ball valve on the suction line is fully open before starting the vehicle.
light should turn off when the arm is in parked travel position (see Figure 3-35).
Arm parked limit switch
54 General Maintenance
Figure 3-37
Figure 3-38
Helping-HandTM arm base
Top cover plate
Arm parked limit switch adjustment
Curved cover plate
Screws
Detection lever
Adjusting Mid-Height Limit Switch
The mid-height limit switch is located at the base of the Helping-HandTM arm (Figure 3-39). This
limit switch is part of the grabber auto-closing system. Each time the grabber reaches a certain height,
it closes automatically in order not to hit the vehicle.
Figure 3-39
Mid-height limit switch
Backward Forward
Screws to loosen
To adjust the mid-height limit switch:
1. Fully extend the arm.
General Maintenance 55
Danger!
2. If not already done, raise the grabber to 90 degrees.
3. Turn off the engine.
4. Proceed with the tagout/lockout procedure. Refer to “Locking Out and Tagging Out the
Do not stand directly in the path of the arm while carrying out these tasks.
Vehicle” on page 20.
5. Locate the mid-height limit switch at the base of the Helping-Hand
6. Loosen the two screws indicated in Figure 3-39.
7. Slide the limit switch forward or backward to achieve proper contact with the target.
8. Tighten back up the screws.
9. Test the operation.
10. Repeat the procedure until the limit switch is properly adjusted.
TM
arm.
NOTE: The roller located at the front end of the limit switch must be vertically positioned. In case it is
not, you will have to unscrew all 4 screws that secure the front end to the rest of the switch, and
turn the front end either clockwise or counterclockwise in order to position the roller
vertically. Then replace all 4 screws and tighten them up.
IMPORTANT: All limit switches MUST be working at all times. Otherwise, the operator may not be aware that the
arm is not fully retracted or that the grabber is open or closed. This may cause an accident, injuries
or property damages.
56 General Maintenance
Painting and Finishing
Type of surface finishing and painting finishing recommended:
SURFACE PREPARATION:
Grit blasting or sandblasting for a 1.5 to 2.5-mil deep profile.
PRIMARY COAT:
Urethane Primer to get a minimum thickness of 2 mils (dry).
FINISHING COAT:
Topcoat polyurethane: 2-mil deep single coat (dry).
At the end of the painting process, the product must have a minimum of 4-mil surface thickness.
4
Lubrication
LUBRICATE, LUBRICATE, LUBRICATE!
Insufficient lubrication is a major cause of component
failure on all refuse vehicles. The MINIMAX™, like most
equipment, has many points that require grease.
See the following sections for detailed lubrication
points on packer, cylinder pins, hopper door hinges
and body-chassis hinges.
Also, refer to the lubrication chart located on the side
of the vehicle for a complete list of lube locations and
the frequency with which they should be greased.
Recommended Lubricants
You will find below the recommended types of
lubricants.
Grease
Any lithium-base commercial multipurpose grease
may be used.
Hydraulic Oil
Minimum requirements for hydraulic oil:
Viscosity of 320 cSt at 104 °F (40 °C) and 6.4 cSt at
212 °F (100 °C).
The oil must contain anti-wear and anti-foam
additives, rust and oxidation neutralizers and selfprotecting agents. It must also meet MIL-H-5606 or
SAE IOW “MS” standards. TOTAL Equivis ZS32
hydraulic oil (or equivalent) may be used in the
M
INIMAX™. For Nordic regions, TOTAL Equivis
SMG22 hydraulic oil is strongly recommended.
IMPORTANT: It is the customer’s responsibility to use oil that is
appropriate to the climate.
58 Lubrication
Caution!
Do not mix different brands of oil. In doubt, drain and refill with new oil.
Engine Oil
Refer to the engine manufacturer’s maintenance manual for recommended type of engine oil.
Transmission Oil
Refer to the transmission manufacturer’s maintenance manual for recommended type of
transmission oil.
Testing Hydraulic Oil
It is recommended to have hydraulic oil tested and analysed by a lab to prevent hydraulic system or
pump failures. This will also optimize the oil change frequency. Apply the following procedure to take
oil samples on Labrie vehicles.
NOTE: The procedure may differ from other laboratories sample kits.
Caution!
Highly contaminated hydraulic fluid must be changed promptly to avoid any damage on
the hydraulic system.
Preparing to Take a Sample
Before taking hydraulic oil samples:
1. Apply all safety measures to ensure safety around the vehicle at all times.
2. Start the engine and raise the body.
3. Install the body safety prop and lower the body onto it.
4. Disengage the pump and turn off the engine.
5. Locate the oil sample coupler. It is located behind the filter cover which is on top of the hydraulic
tank.
Lubrication 59
Figure 4-1
Oil sample coupler
Filter cover
6. Remove the cap from the sample coupler and clean the coupler with a clean rag.
7. Push on the coupler spring ball using a small tip to purge oil before taking a sample. The residual
pressure in the system will push the oil out of the coupler. Use a small container to recuperate the
oil that will come out. Let the oil leak for a few seconds (about half a cup). In this operation, the
pump must be engaged.
Taking an Oil Sample
Once you have released the residual pressure, you can take the sample.
Sample
coupler
Hydraulic
tank
To do so:
1. Remove the sample kit from its bag and, using a screw driver, remove the vent cap from the bottle
Figure 4-2
2. Remove the protective cap from the probe.
cap.
Vent cap
60 Lubrication
Figure 4-3
3. Install the probe on the coupler to fill the sample bottle. Use an EMA coupler with M16 × 2.0
4. Fill the bottle to the level mark (the pump must be engaged to do this). Remove excess oil
Figure 4-4
Probe cap and tip
threads.
through the vent. D
Recommended oil level
O NOT OPEN THE BOTTLE!
Tip
Cap
5. Once the sample is taken, remove the probe from the coupler and pull out the probe to remove it
Figure 4-5
from the bottle (see Figure 4-5).
Pulling out the probe from the bottle
6. Put the seal cover over the bottle cap.
Lubrication 61
Figure 4-6
7. Fill the identification form (sticker) and apply it on the sample bottle.
Figure 4-7
Sealing the bottle
Sealed sample
Identification form (sticker)
62 Lubrication
Lubrication Charts
Lubrication charts found in this manual may differ from the ones displayed on the vehicles. For
indications regarding lubrication, always refer to the charts on the vehicles.
Figure 4-8
Lubrication charts on a M
INIMAX
™ vehicle
Lubrication 63
8
DETAIL (A)
Figure 4-9
2
Lubrication chart - M
LUBRICATION CHART, MINIMAX
3
INIMAX
™
VIEW FROM
LEFT-HAND SIDE
7
4
5
9
VIEW FROM
VIEW FROM
UNDERNEATH
UNDERNEATH
THE PACKER
THE PACKER
6
SEE DETAIL (A)SEE DETAIL (A)
1
LUBRICATION CHART *
NO. DESCRIPTION
1
TAILGATE CYLINDER LOWER PIN
2
TAILGATE CYLINDER UPPER PIN
TAILGATE HINGES
3
4
HOPPER DOORS HINGES
5
CLEANING TRAP DOOR HINGES
FOLLOWER PANEL ROLLERS
6
PACKER CYLINDER REAR PIN
7
8
9
PACKER CYLINDER FRONT PIN
TAILGATE PINS
* REFER TO MAINTENANCE MANUAL FOR PROPER LUBRICANT
FREQUENCY
WEEKLY
WEEKLY
WEEKLY
WEEKLY
WEEKLY
TWO TIMES/WEEK
WEEKLY
WEEKLY
WEEKLY
64 Lubrication
Figure 4-10
Lubrication chart - Helping Hand arm
Lubrication 65
Caution!
Caution!
Never grease the side rails and the outside of rollers. Sand and other abrasives stick to
grease. This results in premature component wear.
Because of their intensive use, the packer and its accessories must be lubricated every
working day.
Greasing the Crusher Panel
To properly maintain the crusher panel:
1. Grease the crusher panel cylinder heads through grease fittings.
2. Grease the crusher panel bushings.
Figure 4-11
Grease areas
Grease fittings
Grease fittings
66 Lubrication
Tailgate
Greasing Tailgate Hinges, Locking Mechanism and Cylinder Pins
It is important to lubricate the tailgate hinges, locking mechanism and cylinder pins with
multipurpose grease (see Recommended Lubricants on page 57) as per the lubrication schedule.
Caution!
Also, inspect the welds around hinges. The proper working condition of the following components is
also to be checked:
Tailgate hydraulic cylinders
Cylinder pins and circlips
Tailgate hinges and pins
Wear on the locking mechanism
Wear on the tailgate lock pins
Tailgate rubber seal
Danger!
Excessive wear might compromise the proper working condition of the tailgate.
Do not operate this equipment if there are any signs of damage or incomplete repairs.
Figure 4-12
Grease fitting - Tailgate hinge
Lubrication 67
Figure 4-13
Figure 4-14
Grease fitting - Cylinder upper pin
Locking mechanism and cylinder lower section
Safety
pin
Cylinder
lower pin
Tailgate
lock pin
68 Lubrication
Packer
Packer components that need to be lubricated include follower panel rollers and cylinder rear/front
pins. Use multipurpose grease (see Recommended Lubricants on page 57) to lubricate these
components as per the lubrication schedule.
Caution!
Before you proceed with lubrication, make sure all safety measures have been properly
taken.
Cylinder Pins
To lubricate the packer cylinder front pin:
1. Fully open the tailgate and install the tailgate safety prop.
2. Extend the cylinder in EJECT mode to get the front of the cutter blade out of the body.
3. Proceed with the locking out procedure. See Locking Out and Tagging Out the Vehicle on page 20.
4. Underneath the front of the cutter blade, locate the grease fitting of the cylinder front pin.
5. Apply lubricant.
Figure 4-15
Front pin grease fitting
To lubricate the packer cylinder rear pin:
1. Turn off the engine and disengage the hydraulic pump.
2. Proceed with the lockout procedure. See Locking Out and Tagging Out the Vehicle on page 20
3. Locate the remote grease fitting near the right-hand side clean-out door (see Figure 4-16).
This remote grease fitting consists of a hose going into the cylinder rear pin.
4. Apply lubricant with a grease gun.
Lubrication 69
Figure 4-16
Figure 4-17
Remote grease fitting
Cylinder rear pin and remote grease fitting hose
Rear pin
Follower Panel Rollers
To lubricate the follower panel rollers (see Figure 4-18):
1. Fully retract the packer.
2. Turn off the engine and disengage the hydraulic pump.
3. Proceed with the lockout procedure. See “Locking Out and Tagging Out the Vehicle” on
page 20.
4. On the hopper front wall behind the cab, locate the access cover plates (see Figure 4-19).
5. Remove the access cover plates.
6. Proceed with the lubrication of the follower panel rollers.
7. Once the lubrication process completed, replace the access cover plates.
Hose
70 Lubrication
Figure 4-18
Figure 4-19
Follower panel rollers
Access cover plates
Hopper Door Hinges
To protect and reduce wear on hopper door hinges, lubricate them regularly with multipurpose
grease (see Recommended Lubricants on page 57).
To lubricate the hopper door hinges:
1. Turn off the engine and disengage the hydraulic pump.
2. Proceed with the lockout procedure. See Locking Out and Tagging Out the Vehicle on page 20.
3. Fully open all hopper doors.
4. Locate the grease fitting on top of each door hinge.
5. Apply lubricant with a grease gun.
There are 2 hinges on each hopper door for a total of 6.
Lubrication 71
Figure 4-20
Grease fitting on top of door hinges
72 Lubrication
5
Hydraulic System
Maintenance on the hydraulic system must be
carefully and regularly done. The hydraulic system
supports most of the functions of the M
As with all hydraulic systems, it may be necessary to
periodically check and adjust the pressure relief
settings. It may be that a major hydraulic component
has been changed, that the vehicle is not performing in
terms of payload, or that the vehicle has recently been
put into service and the system requires adjustment
following a run-in period.
INIMAX™ body.
Danger!
Danger!
Danger!
Always lock out and tag out the vehicle
(see Locking Out and Tagging Out the
Vehicle on page 20) when inspecting or
performing maintenance on the vehicle.
Human skin can be easily penetrated by
high pressure oil (2000 psi and above).
Failure to take appropriate safety
precautions may result in serious injury or
death.
Because of extreme overhead dangers,
equipment must be properly supported
when servicing sections on the hydraulic
system.
General Maintenance
To keep the hydraulic system efficient and reliable, the
following care must be taken:
Every day, check that hydraulic lines and
connections are not leaking. Correct if necessary.
Inspect the pump for leaks or unusual noise.
When maintenance is carried out, protect all hoses,
fittings, pipes, or any other ingress points from dirt
that would eventually get into the oil. Plug hoses
that are not connected.
Inspect the hydraulic system at lease once a month,
and adjust pressure if necessary (see Steel hydraulic
tank on page 82).
74 Hydraulic System
For new vehicles, change the return filter element after 50 hours of use, and twice a year
afterwards or when the filter restriction indicator is in red (see Figure 5-1), whichever comes first
(see Replacing Filter Elements on page 95).
Clean the strainer inside the hydraulic tank after the first 50 hours of use, and twice a year
afterwards or when the filter restriction indicator is in red (see Figure 5-1), whichever comes first
(see Cleaning the Strainer on page 92).
Hydraulic oil must be replaced at least once a year, or when contaminated (see Emptying the
Hydraulic Tank on page 90).
NOTE: The ball valve on the hydraulic tank must be completely open before engaging the pump or
starting the engine.
Labrie Enviroquip Group requires that the hydraulic fluid and return oil filter be changed and that the
strainer be cleaned before changing the hydraulic pump.
Manufacturer’s warranty on hydraulic pumps provided or sold by Labrie Enviroquip Group could be
declared void if the hydraulic fluid and return oil filter are not changed, and if the strainer is not
cleaned prior to replacing the hydraulic pump.
Therefore, it is mandatory to change the return oil filter and clean the strainer after the first 50 hours
of pump operation, then twice a year or when the filter restriction indicator is in red (see Figure 5-1),
whichever comes first. The hydraulic fluid must be changed once a year. Hydraulic fluid
contamination will severely damage hydraulic components.
Figure 5-1
Filter restriction indicator
Inspecting Hydraulic Oil
Inspecting hydraulic oil is a very important maintenance task that must be done as per your Preventive
Maintenance Chart. The most important items to look at when inspecting hydraulic oil are:
color
amount
texture (usually in the form of air bubbles or foam) and
Hydraulic System 75
temperature
To inspect the hydraulic oil color:
1. Make sure the MINIMAX™ is parked in a safe area for maintenance.
2. Turn on the engine and then the hydraulic system.
3. Return all hydraulic devices to their “home” position (retract the packer, close the tailgate, etc.).
NOTE: The “home” position is where there is litttle or no hydraulic oil in the cylinders, which are
completely retracted. Most of the oil has flowed back into the tank.
4. Turn off the engine.
5. Use a folding stepladder to gain visual access to the oil gauge located on the hydraulic tank.
6. Inspect the oil through the gauge.
It is recommended to have the hydraulic fluid tested and analyzed by a lab to prevent hydraulic
system or pump breakdown. This will also optimize the frequency of hydraulic fluid changes.
NOTE: Evidence of maintenance and/or fluid samples could be requested when filing warranty claims
concerning the hydraulic system or pump.
Introducing the Dual Vane Pump
MINIMAX™ vehicles equipped with an automated arm features a dual vane pump. This pump is fitted
to the rear of the PTO drive shaft and is activated by an electric solenoid coil, which is mounted on
the hotshift PTO (see Figure 5-2). The electrical signal that activates the coil is sent by the pump
switch on the control panel.
Figure 5-2
Hydraulic pump (left); electric solenoid coil (right)
Dump valves are no more used on MINIMAX™ vehicles. The hydraulic flow is instead controlled by
modulated electrical signals produced by our new multiplex control system. This sophisticated
system makes dump valves unnecessary.
76 Hydraulic System
When the dual vane pump is turned on, the IFM electronic control module (ECM) starts monitoring
vehicle and engine speed, and allows the vane pump to engage (or not). If the vehicle is going faster
than 15 mph (25 km/h) or if engine speed exceeds 900 rpm, the vane pump will not engage. After the
pump is engaged, it will stay engaged at any engine speed under 2,300 rpm (for more information, see
Allison Transmission Parameters on page 150).
The first section of the vane pump, known as the body vane pump, powers all body functions (tailgate,
crusher panel, packer, and cart tipper [if installed]) through the body control valve (see below). It is
capable of delivering a flow of 20 gallons per minute (gpm) at 1200 rpm. If the engine speed exceeds
1200 rpm, the IFM multiplexed system, installed on the truck, will send an electrical signal to the
body control valve in order to vary the spool position of a specific valve section. On M
vehicles, only the packer section spool will vary its position according to that signal. There are no
restrictions on the flow coming into the other body valve sections.
The second section of the vane pump, known as the arm vane pump, powers arm functions (arm up/
down, arm in/out, and grabber open/close) through the arm control valve (see Arm Control Valve on
page 77). It is capable of delivering a flow of 14 gpm at 1200 rpm. If the engine speed varies, the IFM
multiplexed system, installed on the truck, will send an electrical signal to the arm control valve in
order to vary the spool position of a specific valve section. On M
spools except the one that controls the grabber will vary their position according to that signal.
INIMAX™
INIMAX™ vehicles, all arm valve
Body Control Valve
MINIMAX™ vehicles are equipped with a body control valve (see Figure 5-3). As part of the body vane
pump, this control valve powers all body functions (tailgate, crusher panel, packer, and cart tipper [if
installed]).
Figure 5-3
Body control valve
Packer
Tailgate
Crusher panel
• Tailgate: 4 ways, 3 positions
• Packer: 4 ways, 3 positions
• Crusher panel: 4 ways, 3 positions
NOTE: All sections are electro-hydraulically actuated.
For more information on the body control valve, see Main Hydraulic Schematic on page 99. To learn
how to adjust hydraulic pressure, see Adjusting Hydraulic Pressure on page 83.
Arm Control Valve
MINIMAX™ vehicles are also equipped with an arm control valve (see Figure 5-4). As part of the arm
vane pump, this valve powers all arm functions (gripper open/close, arm extend/retract, and arm up/
down).
As such, the amount of flow coming out of it will be according to the position of the spool. This
feature, called proportional control, allows infinite control of the speed and movement of the arm.
Each section of this valve is actuated by an electric coil located behind the valve.
Hydraulic System 77
Figure 5-4
Grabber open
Grabber close
Arm up
Arm down
Arm extend
Arm retract
Arm control valve
• Input/output cover: provided with main relief valve
• Gripper section (open/close): not proportional, with load sensor relief
• Lifting arm section (extend/retract): proportional, no load sensor relief
78 Hydraulic System
• Lifting arm section (up/down): proportional, no load sensor relief
Inspecting the Pump
The hydraulic pump is powered by the vehicle engine through a drive shaft and a PTO. The pump
should be visually inspected every working day.
Figure 5-5
When inspecting the pump:
1. Start the engine and engage the hydraulic pump.
2. Check for oil leaks under the pump and at connection points.
3. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 20).
Pump
The pump should turn freely without excessive noise or vibrations.
If electrical problems occured with the pump, see Pump on page 124.
Caution!
If the unit has to be driven away for repairs on the hydraulic system (e.g. following
detection of an oil leakage), turn the PTO switch to the “OFF” position.
Pump Replacement
It is important to apply the following procedure after making a pump replacement or a pump drive
shaft replacement.
For standard drive shaft, do the following:
1. Locate the hole with the yoke bolt (the yoke must be fully engaged on shaft).
Hydraulic System 79
2. Apply Loctite 243 (medium strength) on the bolt before assembly.
3. Install a steel wire on the yoke bolt (the wire must be fixed tight around the bolt).
80 Hydraulic System
Figure 5-6
Drive shaft
Yoke
Steel wire on yoke
Bolt
Steel wire
4. Use the following parts: QUB00700 (bolt) and 154503 (steel wire).
Priming a New Pump
To prevent cavitation or air in the hydraulic system after installing a new pump or even when flushing
the hydraulic system, make sure to prime the pump before starting the engine.
Apply the following procedure for any new installed pump:
1. Make sure the parking brake is applied and the vehicle is tagged out for maintenance purposes
(refer to “Locking Out and Tagging Out the Vehicle” on page 20)..
Danger!
2. With the ball valve closed, fill the suction line before installing it on the pump.
3. Fill the pump housing with new oil.
4. Reinstall the pressure hose on the pump housing.
5. Open the ball valve on the suction line.
6. Crank the engine repeatedly — about five times — without letting it start in order to fill the
suction hose and the pump with hydraulic oil and to push the air back into the tank.
Apply the lockout / tagout procedure at all times when maintenance or inspection is
carried out on the vehicle.
7. Start the engine. You can slowly raise the engine RPM only after 5 minutes. When you raise the
RPM, always make sure that the pump does not make excessive noise.
8. Before putting the vehicle back in service, recalibrate the system pressures.
NOTE: For units equipped with a vane pump.
Inspecting the Hydraulic Tank
Verify that the oil in the tank is clean (not colored) and always at the appropriate level.
Hydraulic System 81
Caution!
To inspect the hydraulic tank:
1. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 20).
2. Clean the strainer and replace the filter element inside the tank after the first 50 hours of service
Figure 5-7
Maximum temperature for hydraulic oil is 77 °C (180 °F).
(see Cleaning the Strainer on page 92 and Replacing Filter Elements on page 95).
Filter housing element
For more information on maintenance schedule, see Preventive Maintenance Chart on page 24.
3. Make sure that the filler cap is not obstructed and works properly.
4. Make sure that the hydraulic oil is clean (not colored) and at least at 3/4 on the oil level gauge
(with all cylinders retracted).
The complete system requires between 50 and 60 gallons of oil.
82 Hydraulic System
Figure 5-8
Figure 5-9
Oil temp/level gauge
Steel hydraulic tank
Adjusting Hydraulic Pressure
A 0–4000 psi pressure gauge as well as a set of ball-end hex keys are required to adjust system pressure
(see Figure 5-10).
Hydraulic System 83
Figure 5-10
The pressures of the various hydraulic functions of the Minimax are set up at the factory for optimal
performance. However, when you perform maintenance work on the hydraulic system of the truck,
you may need to adjust the hydraulic pressure for a number of reasons. For more information, see
Troubleshooting Guide on page 120 or Preventive Maintenance Chart on page 24.
Pressure gauge and ball-end hex key
Adjusting Main Pressure on Body Control Valve
MINIMAX™vehicles is equipped with an electro-hydraulic body control valve to power body hydraulic
functions, including the tailgate, the packer, and the crusher panel, if installed.
Warning!
To adjust the pressure:
1. Start the engine and engage the hydraulic system.
2. Install a 0–4000 psi pressure gauge on the quick-connect coupler located on the hydraulic valve.
Make sure that the ball valve on the suction line is completely open before starting the
engine. Failure to do so may damage the hydraulic system.
84 Hydraulic System
Figure 5-11
3. Disconnect the packer retract proximity switch. Activate the packer retract until it reaches end of
4. Check the pressure on the gauge to make sure the pressure builds up in the system.
5. Adjust the body control relief valve as needed by loosening the locknut and by turning the
6. Set the pressure to 2,500 psi.
0–4000 psi pressure gauge
stroke.
adjustment screw.
Adjusting the Utility Section
To adjust the utility section:
1. Disconnect the closed tailgate solenoid (see H in Figure 5-12).
2. Connect a 0 – 600 psi pressure gauge to the inlet cover (see E in Figure 5-12).
3. Start up the engine and let it idle.
4. Turn the pump on.
5. Toggle and hold the tailgate control switch in the “Closed” position.
6. Adjust the generated pilot pressure to 420 +/- 30 psi.
When facing the valve, the adjustment screw is on the right side of the valve (see A in Figure
5-12).
7. Once the adjustment made, disconnect the pressure gauge.
8. Reconnect the tailgate solenoid.
9. Install a 0 -600 psi pressure gauge on the maximum pilot pressure port (see D in Figure 5-12).
10. Toggle and hold the tailgate control switch in the “Closed” position.
Hydraulic System 85
11. Using the adjustment screw located on the front of the valve, adjust the maximum pilot pressure
to 550 +/- 50 psi (see G in Figure 5-12).
Warning!
Replace the 0 - 600 psi pressure gauge with a 0 - 5000 psi pressure gauge for step 12.
NOTE: The generated pilot pressure port and the main relief valve pressure port are the same.
12. To adjust pressure in the main relief valve, install a 0 - 5000 psi pressure gauge on the inlet cover
port (see E in Figure 5-12).
13. Activate the packer retract function until the packer reaches the end of its stroke.
14. Adjust the main relief valve pressure to 2,500 psi (See F in Figure 5-12).
Figure 5-12
Valves and ports
A
F (main relief valve adjustment screw)
This section, known as the utility section, is fixed to an electro-hydraulic
valve only
E
D
H (behind)
C (behind)
Adjusting Pressure on Arm Control Valve
MINIMAX™ vehicles use an extra valve stack to control the arm. This valve is of the proportional type,
meaning that the amount of flow coming out of it will be according to the position of the spool.
G
B
86 Hydraulic System
Control levers (see Figure 5-13) are delivered with the vehicle to make pressure adjustments and to
manually operate the arm if neccessary.
Figure 5-13
IMPORTANT: Before performing the following procedure, make sure that all function levers and their adjustment
Control levers and quick coupler
Control levers
Quick coupler
screws have been properly identified on the valve.
NOTE: A helper may be needed when adjusting arm pressure. Use all necessary safety precautions
around the vehicle at all times.
To adjust the arm valve main relief pressure:
1. Secure the arm working area using safety tape or barricades.
Warning!
2. Install the control lever on the arm up/down function of the proportional valve (see Figure 5-4).
3. Move the lever back and forth to remove any residual hydraulic pressure in the system.
4. Connect a 0–4000 psi gauge to the quick coupler located on the left front of the arm control valve
Stay out of the path of the arm while manually moving the Helping HandTM.
Failure to do so may result in severe injury, or even death.
(see Figure 5-13).
Warning!
5. Start the engine and engage the hydraulic system.
6. Retract and maintain the arm at the end of its stroke using lever.
Make sure that the ball valve on the suction line is completely open before starting the
engine. Failure to do so may damage the hydraulic system.
Hydraulic System 87
7. Adjust the main relief valve to 2000 psi using the adjustment screw, turning the hex wrench
clockwise to raise pressure, or counterclockwise to lower pressure.
Figure 5-14
Relief adjustment screw
Adjusting Gripper Pressure
Main relief valve
Danger!
Do not stand directly in the path of the arm while carrying out these adjustments.
The section of the arm control valve that controls the gripper is the first section next to the inlet cover,
and it is equipped with a built-in relief valve that allows gripper pressure adjustment (see Figure
5-16).
To adjust the gripper pressure on built-in relief valves:
1. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 20).
2. Secure the area around the path of the arm with barrier tape or barricades.
3. Move the manual levers back and forth to release any residual pressure.
4. Make sure that all hoses are tight and not leaking.
5. Connect a pressure gauge (0–4000 psi) to the quick-connect coupler on the arm control valve
(see Figure 5-15).
88 Hydraulic System
Figure 5-15
Warning!
6. Put the transmission in Neutral, start the engine and engage the hydraulic pump.
7. Adjust gripper pressure:
Quick-connect coupler
Make sure that the ball valve on the suction line is completely open before starting the
engine. Failure to do so may damage the hydraulic system.
7 a. Close the gripper using the corresponding lever on the valve.
7 b. While maintaining the lever in place, adjust the relief valve of the “gripper close” side of the
valve section to 1200 psi (screw or unscrew depending on the gauge readout).
7 c. Open the gripper and maintain the lever in place.
7 d. While maintaining the lever in place, adjust the relief valve of the “gripper open” side of the
valve section to 750 psi (screw or unscrew depending on the gauge readout).
Figure 5-16
Gripper relief valve adjustment screws
“Gripper close”
relief adjustment
screw
“Gripper open” relief
adjustment screw
Adjusting Pressure on Cart Tipper Valve (if installed)
This section describes the procedure for adjusting the cart tipper hydraulic pressure on the tipper
control valve (see Figure 5-17).
Hydraulic System 89
Figure 5-17
For this procedure, use a 0 - 4000 psi pressure gauge.
Tipper control valve
Lever
Relief valve
To adjust the cart tipper pressure:
1. Start the engine and engage the hydraulic system.
2. Remove rubber cover from the quick-connect coupler located on the flow divider (see Figure
5-18).
3. Install a 0 - 4000 psi pressure gauge on the quick-connect coupler (see Figure 5-18).
4. Push the tipper lever (see Figure 5-17) and hold it while you read the pressure on the gauge.
5. Check the pressure on the gauge to make sure the pressure builds up in the system.
6. Set the pressure at idle to 2,000 psi by adjusting the relief valve (see Figure 5-17). To do so,
loosen the locknut of the relief valve and turn the adjustment screw clockwise or
counterclockwise to get the proper pressure.
7. Once the pressure is adjusted, tighten back the locknut.
8. Replace rubber cover on the quick-connect coupler (see Figure 5-18).
90 Hydraulic System
Figure 5-18
Flow divider
Emptying the Hydraulic Tank
Quick-connect coupler
Rubber Cover
To empty the hydraulic tank:
1. Prepare the vehicle:
1 a. Apply the parking brake
1 b. Start the engine
1 c. Engage the hydraulic pump
1 d. Retract all cylinders (packer, crusher panel, tailgate, etc.)
1 e. Raise the body and install the safety prop
1 f. Disengage the hydaulic pump
1 g. Stop the engine
2. Lock out and tag out the vehicle (see Locking Out and Tagging Out the Vehicle on page 20).
3. Close the ball valve on the succion line (see Figure 2-13).
4. Disconnect the succion line from the pump.
5. Place a clean container (minimum capacity: 60 gallons) under the disconnected end of the
succion line to empty the hydraulic tank.
6. Open the ball valve to let the oil flow into the container.
7. When the bulk of the oil has been emptied from the tank, remove the drain plug (see Figure
5-19) to allow the rest of the oil drain from the tank.
Place a small container under the plug.
8. Once the tank has been completely emptied, replace the drain plug and reconnect the succion
line to the pump.
Hydraulic System 91
Figure 5-19
Drain plug
Replacing Hydraulic Oil
Caution!
Highly contaminated hydraulic fluid must be changed promptly to avoid damaging the
hydraulic system.
To do so:
1. Empty the hydraulic tank (see Emptying the Hydraulic Tank on page 90).
2. With a clean dry cloth attached to a stick, remove all metal particles and debris accumulated at
the bottom of the hydraulic tank:
2 a. Remove the access panel (see Figure 5-20).
2 b. Remove the strainer. See Cleaning the Strainer on page 92.
2 c. Clean or replace the strainer if necessary.
2 d. Remove the return filter housing (see Figure 5-20).
2 e. Insert your hand inside and clean the interior of the tank with a dry clean cloth.
2 f. Clean the return filter housing with a dry clean cloth.
3. Change the return filter element (see Replacing Filter Elements on page 95).
4. Using a filtering screen, refill the tank with high quality oil until it reaches the 3/4 mark on the oil
gauge (see Recommended Lubricants on page 57 for specifications).
The entire system will require between 50 and 60 gallons of oil.
Caution!
It is not recommended to mix different brands and/or grades of oil in the hydraulic tank.
5. If the suction line has been replaced, fill the line until oil reaches the pump (see Pump Cavitation
on page 124).
92 Hydraulic System
6. Reinstall the access panel, the strainer and the return filter housing.
7. Reinstall the filler cap and fully open the ball valve.
Caution!
8. Start the engine.
Failure to open the ball valve may seriously damage the pump and the hydraulic system.
Cleaning the Strainer
To clean the strainer:
1. Empty the hydraulic tank (see Emptying the Hydraulic Tank on page 90).
2. Remove the hose clamp from the suction hose.
3. Slide the hose over the pipe until it clears the nipple (slide towards the frame of the vehicle).
4. Remove the strainer from the tank port (see Figure 5-20 and Figure 5-21).
5. Clean the strainer using solvent, and check for damage; replace if necessary.
6. Replace the seal if necessary.
7. Reinstall the strainer.
8. Using a filtering screen, refill the tank with high-quality oil until it reaches the 3/4 mark on the oil
gauge (see Recommended Lubricants on page 57 for specifications).
The entire system will require between 50 and 60 gallons of oil.
Caution!
It is not recommended to mix different brands and/or grades of oil in the hydraulic tank.
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