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Millennium Service Manual - Superior Truck Equipment Inc.

1. 4000 Ibs Paa cH 4000 Ibs Nylon sling straps should be used for the removal of cylinders The following specifications should be used to deter mine the type of sling straps to use for lifting SLING STRAP SPECIFICATIONS USS 26 EN1 Rating vereal lil sie annhaeeey ox Sanat he owed thea Ana eee eee e aed we hedane chee 9 de awd 4800 Ibs eus m 3600 Ibs oa 9600 Ibs 2 4 depends type of lifting device used Chains should be used to lift and or support the lift arms top door packing ejection panel and tailgate The following specifications should be used to determine the type of chain and hardware to use for lifting CHAIN AND HARDWARE SPECIFICATIONS Chain D O F Double Brand Oblong Link Foundry Hook BIZ q O 7b Hammer d desde eode Pee BD e in 7b in 4 4 SECTION 4 GENERAL REPAIR PRACTICES TIGHTENING PROCEDURES FOR JIC FITTINGS The JIC 37 Flare fitting is probably the most common type of hydraulic connector used in the refuse industry These fittings are designed to be used with thin wall or medium thickness tubing or hydraulic hoses in
2. EE LPS EE LATCH ARM 7 2 x pui ny S Y LEACH 2 1 SECTION 2 INTRODUCTION INTRODUCTION The main purpose of the Leach Millennium is to safely and efficiently load compact transport and unload refuse The following describes how the unit performs those tasks in the most basic terms For a more detailed description of the unit and its components read the complete LEACH MILLENNIUM SERVICE MANUAL Before going further look at the accompany ing full page illustration of the Millennium and become familiar with the terms you will need to know LOADING J The Leach Millennium is designed for use with various containers The loading process begins by utilizing the fork tilt and lift arm controls to engage the container The lift arms then raise the container and the fork tilt control is utilized to keep the container level When in the dump position the fork tilt control is used to dump the refuse into the hopper rs d The now empty container can be lowered to the ground COMPACTION After the refuse has been deposited in the body hop per area the packing ejection panel moves rearward and compacts the material UNLOADING At the dumpsite the unit is unloaded in two easy steps First the tailgate is raised PA Second
3. CHECK MAIN RELIEF PRESSURE CHECK LIFT ARM PRESSURE CHECK PACKING EJECTION PRESSURE CHECK TAILGATE PRESSURE CHECK TAILGATE LATCHES CHECK SLIDING TOP DOOR PRESSURE RESIDENTIAL CART TIPPER SYSTEMS ADJUSTING POWER ON DEMAND VALVE CHECKING TIPPER PRESSURE CHECKING POWER ON DEMAND VALVE RELIEF PRESSURE ADJUSTABLE FORK SYSTEM ADJUSTING POWER ON DEMAND VALVE CHECKING RELIEF PRESSURE ADJUSTING ADJUSTABLE FORK VALVE CHECKING RELIEF PRESSURE CHECKING PILOT CHECK RELIEF VALVES CHECKING RELIEF PRESSURE HINGED TOP DOOR ADJUSTMENTS TOP DOOR SEQUENCE VALVES CHECKING UPPER SEQUENCE VALVE PRESSURE CHECKING LOWER SEQUENCE VALVE PRESSURE CHECK PACKING EJECTION PANEL WEAR BLOCKS CHECK AIR REGULATOR PRESSURE WITH AIR CONTROLS 0 7 2 7 1 SECTION 8 TROUBLESHOOTING GENERAL 8 1 COMPACTION 8 1 DIAGNOSTIC CHARTS 8 2 DESCRIPTION OF HYDRAULIC SYSTEM 8 8 SYSTEM COMPONENT NOMENCLATURE 8 8 HYDRAULIC SYSTEM FLOW CHARTS 8 9 SECTION 9 SERVICE AND REPAIR GENERAL SURE e i 9 1 MAIN COMPONENT LOCATION 9 1 TEST FOR BYPASSING CYLINDERS 9 2
4. POSITION POSITION WARNING e Do not pressurize water tank above 100 psi e Pressure must be relieved before opening the tank 33267 RUBBER SUPPORT CRADLE _ _ RETAINING BRACKET BODY TILT PROP OPERATION Raise lift arms and or extend packer panel to half pack position Raise body until body props clear support cradies and swing rearward CLOSED 108321 Lower body slightly to position props in support cradies 1 08321 4 To lower body secure rubber teathers to body props then raise body until props pulled forward and away of support cradles 5 Lower body until props clear supports then release rubber teathers allowing props ta swing rearward amp Continue to lower body props until they are secure in the retaining brackets 208733 Leach Co strongly recommends engine be kept below RPM when Front Mounted Pump is operating Failure to do so may resuit in YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS You are qualified by training and experience in the safe operation equipment failure of this machine 5 33291 Training includes complete knowledge of your employer s work rules ail governmental regulations and manufacturer s operator ACAUTION and safety manuals relative 10 this machines safe use AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO Serious pump damage will result if pump 1 108322 run dry Disconnect pump drive to
5. 10 1 GENERAL E ads 10 1 AIR LOGIC CONTROL MODULE COMPONENTS KEY 10 1 DESCRIPTION OF PNEUMATIC SYSTEM HOME POSITION 10 2 AUTO PACK 10 2 PACKING EJECTION PANEL CLEARS HOPPER AREA 10 2 RETURNS TO HOME POSITION 10 2 EJEC TIONIS s ocn shoe EROR 10 3 SIDE DOOR OPEN 10 3 LIFT ARMS MOVING 10 3 LIFT ARMS MOVING DOWN 10 3 FORKS MOVING 10 4 FORKS MOVING DOWN 10 4 SLIDING TOP DOOR OPEN 10 4 SLIDING DOOR CLOSED 10 4 TAILGATE OPEN 10 5 TAILGATE CLOSE 10 5 BASIC 5 10 5 ALCM DIAGNOSTIC PROCEDURES 10 6 LIFT ARM LOCKOUT DIAGNOSTIC PROCEDURES tura me Pp dd acti ems 10 6 PNEUMATIC JOYSTICK SERVICE 10 7 DISASSEMBLY 10 7 INSPECTION AND REPLACEMENT 10 7 REASSEMBLY 10 7 SECTION 11 ELECTRICAL ELECTRICAL SYSTEM 11 1 PROXIMITY SWITCHES DESCRIPTION 11 1 CHECKING 11 1 ADJUSTMENT 11 1 MANUALS AND LITERATURE ORDER FORM REWARD TABLE OF CONTENTS GENERAL The Leach Millennium has been designed with the
6. 4 bed pes Tr ae te e EXE Lesa beg 1 Igel TE RE 529 6 TFE DE _ kag _ js TEES HERES E TE TI FE 4 bed ig n jO AO A NP A AX ia 4 Zt R93 bug FE 5 4 TE FE peg LT TI b d KE gt get JIA n Lh Z lt gt 4 PROX SWITCH n REAR DOOR AJAR PROXI SWITCH ry TOP DOOR OPEN PROXI SWITCH TOP DOOR CLOSED mY a b m m T a IS PER THE 68 8 RD 61 e we pemnatatstiun ae CIERRA 3 38 89 one 11 pi E 3d 9 Md 9 id 9 a 6 NE ay Wak UT Peele a HIGHWAY ADMINSTRATION REGULATIONS 0 5 DEPARTMENT OF TRANSPORTATION NOTE COLORS FOR ALL LIGHTING FEDERAL WE WE REAR DOOR AJAR BAK 9 BK PROX SWITCH LIFT ARMS ABOVE BODY PROXI SWITCH MILLENNIUM ELECTRICAL SCHEMATIC 4 LEACH Parts Order Form Parts Fax 920 231 5597 Date OrderNumber Phone 920 231 2770 Ed company Name m Address Routing instructions City State Zip 7 Fax Model number Unit serial number REF NO PART NO DESCRIPTION QTY S Leach Company 2737 Harrison Street P O Box 2
7. 9 Apply a liberal amount of an anti seize compound to the wear block retainer capscrews and torque to 270 foot pounds 37 Newton meters 9 25 SECTION 9 SERVICE AND REPAIR REPLACEMENT OF THE TROUGH AND FLOOR WEAR BLOCKS 1 Remove the telescopic cylinders from the pack ing ejection panel and slide the panel approximate ly 12 inches rearward to completely expose the trough and floor wear blocks refer to removal of packing ejection panel Using a 3 4 socket with extension remove the wear block mounting capscrews 7 through the access holes on the bottom of the wear blocks Remove the wear blocks by prying downward on the wear block from either side Note the position and amount of any shims that may be located between the wear blocks and the mounting plates Thoroughly clean the wear block mounting area Install the new wear blocks in the approximate reverse order of the wear block removal Re install any removed shims in the same locations that they were removed from Apply a liberal amount of anti seize compound to the wear block mounting capscrews and torque to 39 foot pounds 5 4 Newton meters REPLACEMENT OF THE BODY SIDE WEAR BLOCKS 1 2 4 6 Thoroughly pressure wash the packing ejection panel side areas Using an allen wrench remove the side wear block mounting capscrews 30 Remove the wear blocks by pulling rearward with an adjustable pliers Thorough
8. 9 15 REMOVAL ieu ier e bv POS ERE 9 15 INSPECTION AND REPLACEMENT 9 15 SLIDING TOP DOOR CYLINDER DESCRIPTION REMOVAL DISASSEMBLY SECTION 9 SERVICE AND REPAIR Continued INSPECTION AND REPLACEMENT 9 17 REASSEMBLY AND INSTALLATION 9 17 SLIDING TOP DOOR DESCRIPTION 9 18 REMOVAL 9 18 INSPECTION AND REPLACEMENT 9 18 HINGED TOP DOOR CYLINDERS DESCRIPTION 9 19 REMOVAL 9 19 DISASSEMBLY 9 19 INSPECTION AND REPLACEMENT 9 20 REASSEMBLY AND INSTALLATION 9 20 HINGED TOP DOOR ADJUSTMENTS 9 20 HINGED TOP DOOR DESCRIPTION des E i e 9 21 REMOVAL yee ens 9 21 INSPECTION AND REPLACEMENT 9 21 PACKING EJECTION CYLINDER DESCRIPTION 9 22 REMOVAL 9 22 DISASSEMBLY 9 23 INSPECTION AND REPLACEMENT 9 23 REASSEMBLY AND INSTALLATION 9 23 PACKING EJECTION PANEL DESCRIPTION reed ens 9 24 REMOVAL ais sec aan k idoa i i med ies 9 24 INSPECTION AND REPLACEMENT 9 24 INSTALLATION 9 24 DESCRIPTION OF PACKING EJECTION PANEL WEAR BLOCKS 9 25 REPLACEMENT OF TRACK CHANNEL WEAR BLOCKS 9 25 REP
9. LEACH Keys Removed SECTION 9 SERVICE AND REPAIR CASE END PIN x TILT CYLINDER CYLINDER PIN Whenever dismantling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly crack or loosen the fittings 7 Disconnect both the case and rod end hoses Immediately cap or plug hoses and cylinder ports to keep fluid in and dirt out 8 Remove the capscrew and the retainer from the case end 9 Make sure cylinder weight is securely supported by hoists and carefully remove the pivot pin Check for pivot pin or pin hub wear 9 3 SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF FORK TILT CYLINDERS 1 Clean the mounting hardware and outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder components during disassembly Secure the case end of the cylinder to a work bench or floor mount and the rod end to an over head lifting device with a minimum lifting capacity of 500 Ibs to ease the disassembly of parts Remove the plugs from the ports and drain the fluid The head gland is secured by the means of a cap that is threaded over the outside of the cylinder case Rotate the head gland cap and unscrew it from the cylinder case WIPER SEAL INSPECTION AND REPLACEMENT OF FORK TILT CYLINDERS 1 9 4 Carefully and thoroughly inspect the bore of the cylinder case for cra
10. Main Control Valve Actuator Lower Tele Extend NOT USED Blue Auto Reset Button Valve Auto Pack Disable Gray Home Position Limit Valve Auto Pack to Neutral Black Main Control Valve Actuator Upper Tele Hetract Green Auto Pack Button Valve Auto Pack Enable Manual Pack Full Eject Brown Retract Limit Valve Auto Pack to Auto Retract Blue Main Control Valve Actuator Lower Port Lift Arm Raise Blue Joystick Valve Port L Lift Arm Raise Red Air Supply NOTE Individual components are labeled on the ALCM NOTE Module 8 is a requested feature All other com ponents are standard 10 1 SECTION 10 PNEUMATIC CONTROLS HOME POSITION NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator starts the unit engages the PTO and has at least 100 PSI in the chassis air system PNEUMATIC SYSTEM With the side door closed air is also available to the auto pack and retract palm buttons With the packing ejection panel in the home position air flows from the packer home limit valve through port H on the ALCM to RV2 and PS2 turning on the packing ejector panel home indicator light packing ejection panel par tially extended light turns off Air also flows from the auto reset button through port on the ALCM to RV3 AUTO PACK EXTEND NOTE
11. 29 26 27 28 29 30 Before operating the vehicle the driver must be thoroughly familiar with the employer s safety pro gram concerning traffic rules warning devices and hand signals Know where to get assistance in the event of an emergency Know your machine Know the location and func tion of all controls gauges instruments and pro tective devices Wear your seat belt otart the engine following the manufacturer s rec ommended procedure Always set the parking brake before leaving the cab Turn on appropriate warning lights put on a safety vest protective glasses and protective shoes All service opening covers and access doors must be maintained and latched in place while operating equipment Ensure all co workers are in view before operating or moving any controls or the unit Ensure that there is sufficient overhead clearance before operating the unit otop the vehicle immediately if the warning lights for the TAILGATE TOP DOOR AJAR or LIFT ARMS ABOVE BODY system come on Always ensure that all persons are clear of the tail gate before raising or lowering It is the operators responsibility to warn all persons not to stand or cross under a tailgate Do not move the vehicle with the tailgate raised except during unloading and then only as neces sary to clear the load before lowering otand clear when the tailgate is being raised or low ered and during the unloading cycle If it is neces
12. 4 7 SECTION 4 GENERAL REPAIR PRACTICES 4 8 SECTION 5 SPECIFICATIONS LUBRICANTS SAE 10 or equivalent ae Be Si ee ee ee He Multiservice quantity grade Pneumatic 2 4044 a2 aoe e BE ee Dow Corning 44 or equivalent HYDRAULIC SYSTEM CAPACITY approximately TNE 40 gallon Total SV SION o tance a ace eee ee Bee Se dow he Bach oR os Berard So AEDS a a 55 gal System pressure setting 3000 PSI Type of fittings Steel tubing with brazed and flared fittings reinforced rubber hose with crimped full flow fittings static o ring fittings glcus mE Suction reusable wire mesh type Return line disposable filler element located in the return line to the tank PUMP 204071 cr Positive displacement gear type 50 1500 rpm LEACH HYDRAULIC FLUID RECOMMENDATION All Leach hydraulic systems are factory filled with a high quality anti wear hydraulic fluid meeting an ISO 32 specifi cation On units put into service where there are high ambient temperatures or sustained high duty cycles it may be desirable to change the fluid to an ISO 46 specification higher viscosity In colder climates or light duty an ISO 22 might be more app
13. Remove the lift arm retaining capscrews 7 Operate the lifting device to free the lift arm from the pivot tube INSPECTION AND REPLACEMENT OF LIFT ARM ASSEMBLY 1 Inspect all metal parts and pivot points for damage or wear Check hardware holes for enlargement breaks or weld cracks 2 See Section 4 GENERAL REPAIR PRACTICES for information pertaining to welding repairs 3 Repair to the lift arm is limited if structural damage is noted the entire assembly must be replaced REINSTALLATION OF LIFT ARM ASSEMBLY 1 Install the lift arm in the approximate reverse order of removal 2 Torque the pivot tube lift arm retaining capscrews evenly to 600 Ft Lbs and use thread adhesive 9 12 PIVOT ARM BUSHING LIFT ARM ASSEMBLY TAILGATE CYLINDERS DESCRIPTION OF TAILGATE CYLINDERS Two double acting hydraulic cylinders raise and lower the tailgate during unloading operations The cylinder rod end is connected to a pivot ear on the tailgate while the case end attaches to a bell crank bolted to the body The cylinder also moves the tailgate latching arm REMOVAL OF TAILGATE CYLINDERS Operational Status Truck Running PTO Engaged 1 The tailgate cylinders must be retracted and the tailgate closed Operational Status Truck Off Keys Removed 2 Secure nylon sling around the cylinder and attach to a suitable lifting device with a capacity of at least 500 16 Operate the hoist to sn
14. TOP DOOR TOP DOOR CYLINDER HOSES NYLON SLING Whenever disassembling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly crack or loosen the fittings LEACH DISASSEMBLY OF SLIDING TOP DOOR CYLINDER 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder compo nents during disassembly Secure the case end of the cylinder to a work bench or floor mount and the rod end to an over head lifting device with a minimum lifting capacity of 500 Ibs to ease the disassembly of parts Remove the plugs from the cylinder ports and drain the fluid Rotate the head gland and unscrew it from the cylinder case Slowly operate the hoist to carefully pull the piston rod assembly out of the case Unscrew the piston nut from the rod and remove and discard the rod o ring and piston seal Slide the head gland off the rod and discard the o ring wiper seal and rod seal PISTON ROD O RING HEAD GLAND WIPER SEAL CYLINDER CASE LEACH SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF SLIDING TOP DOOR CYLINDER 1 2 Thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear Check all cylinder components and mounting parts for damage and wear and replace as required Parts that must be replaced together o rings an
15. front of the body All pressures can be checked from this location Pressures should be checked and set before proceeding to the cycle time checkout procedures The cycle time checks listed are to determine the con dition of the hydraulic pump and related components front mounted dry valve flow regulator PTO etc SECTION 7 CHECK OUT When checking the cycle times the unit RPM should be raised to the RPM indicated on the dash mounted decal If a cycle time does not meet specifications re time the cycle the check cycle times for other systems to cross check results Correct cycle times verify that the hydraulic pump has an output rate of 50 GPM Please note that the addition of optional hydraulic equipment such as residential cart tippers may affect the flow rates thus requiring a higher RPM setting to achieve the correct cycle times PRESSURE amp CYCLE TIME SETTING CHART FUNCTION Main Relief Fork Tilt Lift Arm Lowered Lift Arm Raised Pack Ejection 3000 PSI 207 BAR 2000 PSI 138 BAR 2800 PSI 193 BAR 3000 PSI 207 BAR Tailgate Raised 3000 PSI 207 BAR Tailgate Lowered Sliding Top Door Open Sliding Top Door Closed 3000 PSI 207 BAR 900 PSI 62 BAR N A 13 15 Seconds Full Cycle NO 13 15 Seconds Full Cycle NO 26 30 Seconds Auto Pack PRESSURE SETTING ADJUSTABLE CYCLE TIME 50 GPM 18 20 Seconds Full Cycle 18 20 Seconds Full Cycle 18 24 Seconds F
16. the packing ejection panel is moved to the rear 2 A of the body pushing out the load 2 5 hits Wi E Following unloading the tailgate is lowered and latched 4 m M d RINI e 4 gt y f p i 3 r e Ld a F gt d 47 SAY A ne GS m pene lt NON ip em EA 1 L M Ae 2 8 E N AA UM o M i TE Le n LA i BERE de S j Op x T 4 7 E 4 0 0 005 iH Ji E 3 a LJ M Fo 4 d EI J a JL 2 2 LOCATION OF OPERATING CONTROLS INDICATOR LIGHT CONSOLE CABLE CONTROL WITH AUTO PACK DUAL AIR CONTROL AUTO PACK GENERAL This section will provide general and specific instruc tions necessary to operate the Leach Millennium Prior to attempting any operation of the unit make sure you are familiar with all the safety information contained in Section 2 SAFETY PRECAUTIONS DESCRIPTION OF OPERATING CONTROLS The following information is for descriptive purposes only It is not to be misconstrued as operating instructions For operating instructions refer to OPERATING PROCE DURES later in this section It is important that you know the function of each con trol before attempting to operate the unit All controls are located in the chassis cab Refer to the accompa nying illustrations NOTE Several types of controls are ava
17. Compaction rates of a unit will depend on the season the type of trash the weather and the operation and maintenance of a unit If the unit packs relatively con sistent loads and has been properly maintained accord ing to the Service manual then it is safe to assume that it is getting maximum compaction for your particular conditions 9 COMPACTION 8 1 SECTION 8 TROUBLESHOOTING GENERAL The first step in any repair process is identifying the cause of the problem When troubleshooting the air logic for instance the problem needs to be isolated to the mechanical hydraulic or pneumatic functions The troubleshooting charts shown in Section 8 TROUBLESHOOTING refer to the entire unit The diagnostic charts shown below sug gest possible remedies for problems POSSIBLE CAUSE REMEDY PACKING EJECTION PANEL WILL NOT MOVE Side door open Air line tubing plugged Air line on the auto pack button valve disconnected Crimped or kinked tubing to the main control valve Not enough air pressure Auto pack button valve defective Defective air actuator on the main control valve Defective auto pack button Air logic control module ALCM malfunctioning Close side door Clean out or replace air line Reconnect air line to the auto pack button valve Replace or straighten tubing Raise system pressure above 80 PSI Replace the auto pack button valve Replace air
18. PARTS Of growing concern to the Leach Company is the use of counterfeit will fit or substitute parts The use of non standard parts may affect the operation and perfor mance and void the warranty Ensure maximum relia bility and protect your investment insist on Leach original factory replacement parts SERVICE BULLETINS In addition to the information given in this Service Manual Service Bulletins are issued from time to time which cover interim changes and supplementary infor mation Service Bulletins should be consulted for addi tional information Check with your local authorized Leach Distributor LEACH 1 Original Factory Parts render it unsafe However please remember that these procedures are not all inclusive Since Leach Company could not possibly know evalu ate and advise the service trade of all possible ways in which service might be done or of the possible hazardous consequences of each way we have not undertaken any such broad evalua tion Accordingly anyone who uses a service pro cedure or tool which is not recommended by Leach must first thoroughly satisfy himself that neither his nor the operator s safety will be jeop ardized by the service methods selected p Service Dept 1 Eg C MEA 4 1 SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR R
19. TIPPER SYSTEMS ADJUSTING THE POWER ON DEMAND VALVE The residential cart tipper hydraulic circuit is designed to provide hydraulic fluid to the container handling device at a fixed flow rate that is determined by the type and manufacturer of the cart tipper When the cart tip per is not in use the hydraulic fluid is allowed to travel to the main system of the Leach Millennium This is accomplished by the use of a power on demand valve which is located on the right front of the body next to before the five 5 spool valve It incorporates an electric solenoid cartridge that when energized ON will direct the hydraulic fluid to the cart tipper CHECKING THE TIPPER PRESSURE Operational Status Truck Off Keys Removed 1 Disconnect the hose at port CF on the power on demand valve and plug the hose 2 Connect a 0 5000 PSI gauge to the port marked CF on the power on demand valve Operational Status Truck Running PTO Pump Engaged AWARNING Do not leave the pump engaged while doing this test for more than one 1 minute To do so will cause excessive heat build up in the hydraulic fluid CHECKING THE POWER ON DEMAND VALVE RELIEF PRESSURE Operational Status Truck Off Keys Removed 1 Remove the power on demand valve from the front of the body Plug all hoses and tubes to prevent contamination 2 Plug all of the ports on the power on demand valve EXCEPT ports IN and using the prop er
20. Walk completely around vehicle to make sure all persons are clear before starting the unit 1 1 SECTION 1 SAFETY PRECAUTIONS OPERATION GENERAL 1 It is the operators responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operators manual and in accordance with all applicable codes including Occupational Safety and Health Act OSHA and American National Standards Institute ANSI reg ulations Do not attempt to operate this equipment without proper training Move the vehicle as slowly as possible without stalling when traveling in reverse Always make sure the roadway is clear before trav eling in reverse Do not travel in reverse for distances greater than those dictated by local ordinances If reverse travel exceeds 10 feet use a spotter or move the vehi cle in 10 foot increments only and then check to make sure the roadway is clear between incre ments Do not attempt to dislodge any material unless wearing eye protection such as approved side shielded safety glasses or a full face shield Never use the unit to push or tow another vehicle Never unload uphill or against a pile of refuse or into the bank of a hill Never place head body fingers or any limbs into a scissors point or pinch point on the equipment 10 11 12 13 14 15 16 17 18 19 20 21 22 2 24
21. We do however reserve the right to redesign and or discontinue the manufacture of parts components or assemblies at any time The Leach Company has an aggressive manual and product improvement program In any conversation or correspondence dealing with information provided in any Leach manual please refer to the part number of that manual located in the lower right hand corner of the front cover The manuals provided with the unit are considered a permanent part of the unit and should be included in the event of a resale Additional manuals are available free of charge from your local authorized Leach distributor These manuals should be kept readily available for easy reference We ask that if you have comments or suggestions concerning this manual please contact us at 920 231 2770 We are here to be of service to you our valued customers _LEACH 92 Original Factory Parts TM EACH ORDERING PARTS WARRANTY FOREWORD TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS GENERAL DANGER WARNING amp CAUTION DECALS PRIOR TO START OPERATION HYDRAULICS FIRE PROTECTION HOUSEKEEPING CLEANLINESS SHUTDOWN DECALS ILLUSTRATIONS SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW INT
22. after the auto reset button valve is engaged Push and hold the blue button on RV3 Packing ejection panel will not move in manual pack mode Push and hold the blue button on RV4 packer lockout module If no response push and hold the bot tom button on SV2 Packing ejection panel will not move in manual retract mode Push and hold the top button on SV3 LIFT ARM LOCKOUT DIAGNOSTIC PROCEDURES if so equipped Lift arms will not raise with the packing ejection panel in the home position Push and hold the silver button on HV5 lift arm lockout module If no response check SOL2 lift arm lockout module for malfunction See Section 11 ELECTRICAL Lift arms are able to raise with the packing ejection panel out of the home position Check SOL2 lift arm lockout module for malfunction If no response push and hold the blue button on RV5 lift arm lockout mod ule These procedures may not be all inclusive At times there may be a combination of valves malfunctioning or a combination of symptoms not listed in this manual For more assistance call your local authorized Leach Distributor or the Leach Company Customer Support Service Department LEACH PNEUMATIC JOYSTICK SERVICE The joystick assembly is a serviceable component of the pneumatic system Many parts of the joystick assembly are available through your local authorized Leach Distributor When servicing the joystick remove it from the control console and clean
23. cap and unscrew it from the cylinder case 6 Slowly operate the hoist to carefully pull the piston rod assembly out of the case 7 Unscrew the piston nut from the rod and remove the piston Remove and discard the piston seal and o ring 8 Remove the check valve in the piston This is held in place by the piston nut and the o ring around the collar of the check valve Discard the o ring on the check valve 9 Slide the head gland off the rod remove and dis card the head gland o ring backup ring rod seal and rod wiper O RING BACKUP RING WI pt ROD SEAL HEAD GLAND ROD WIPER INSPECTION AND REPLACEMENT OF LIFT ARM CYLINDER 1 Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 2 Anew rod wiper rod seal o rings and piston seals must be installed any time the cylinder is disas sembled Pay particular attention to the way parts are positioned before disassembly Parts that must be replaced together are available in the form of a kit from your local authorized Leach Distributor 3 Inspect and clean the orifice in the recessed side of the piston Clean out all of the passages in the pis ton LEACH SECTION 9 SERVICE AND REPAIR PISTON SEALS O RING CHECK VALVE PISTON NUT PISTON ORIFICE PISTON ROD CYLINDER CASE REASSEMBL
24. check the packing ejection retract pressure setting 7 5 SECTION 7 CHECK OUT CHECK THE TAILGATE PRESSURE 1 Install a pressure gauge as described earlier in CHECK PRESSURES Operational Status Truck Running PTO Engaged 2 Move the tailgate control to fully extend the tailgate cylinders NOTE Maintain the engine RPM at the posted speed 3 Hold the control and read the gauge the pressure should be 3000 PSI IF NOT 4 Check the cylinders for bypass see Section 9 SERVICE AND REPAIR 5 Replace the port relief cartridge see Section 9 SERVICE AND REPAIR 6 Replace the hydraulic pump see Section 9 SER VICE AND REPAIR OTE The tailgate pressure setting is not adjustable 7 Repeat items 1 6 to check the tailgate retract pres sure settings CHECK TAILGATE LATCHES Operational Status Truck Running PTO Engaged Sol Sw ON 1 After the tailgate is closed power the latches down by holding the tailgate control Increase the engine RPM This will ensure that the latches are properly set NOTE Latches need not rest on top of the stop block but must pull the tailgate tight against the body IF NOT Add shims as required 7 6 TAILGATE SECTION 5 SPOOL CONTROL VALVE LAY NU lt NS mil SHIM AS REQUIRED LEACH CHECK THE SLIDING TOP DOOR PRESSURE 1 Install a pressure gauge as described earlier in CHECK P
25. enough for the tailgate to clear the ejected refuse when low ered Never enter under a raised tailgate TES 548 gt Wa een NO mL LE 5 Engage the PTO Pump The operator moves the tailgate control lever to lower and latch the tailgate TT The tailgate warning light and beacon will go out and the back up alarm will quit sounding as the hooks are latched securely 6 Disengage the PTO Pump prior to driving out of the unloading site 3 13 SECTION 3 OPERATION UNLOADING WITH AIR CONTROL OR TAILGATE RESIDENTIAL AIR CONTROL SWITCH Once the unit is full drive to an unloading site TAILGATE AJAR LIGHT While unloading it is recommended that the sliding top door be open 1 Engage the PTO Pump 2 The tailgate toggle switch is located between 2 guard ears on the main service panel Moving the tailgate toggle switch upward unlatches and then AUTO PACK raises the tailgate As the hooks begin to release PALM BUTTON the tailgate ajar indicator light illuminates indicating the tailgate is open EJECTING LOAD A CAUTION Be sure the area behind and above the unit is clear before raising the tailgate NOTE The backup alarm backup lights and tailgate ajar indicator light will come on 3 The operator depresses and holds the Auto Pack palm button Engine RPM must be maintained at the designated speed to provide enough force to empty the unit A
26. extend the lift arm cylinders NOTE Maintain the engine RPM at the posted speed 3 Hold the control and read the gauge The pressure should be 2000 PSI 4 Move the lift arm control to fully retract the lift arm cylinder The pressure should be 2800 PSI IF NOT 5 Check the cylinders for bypass see Section 9 SERVICE AND REPAIR 6 Replace the port relief cartridge see Section 9 SERVICE AND REPAIR 7 Replace the hydraulic pump see Section 9 SER VICE AND REPAIR NOTE The lift arm pressure setting is not adjustable CHECK THE PACKING EJECTION PRESSURE 1 Install a pressure gauge as described earlier in CHECK PRESSURES 2 Raise tailgate Operational Status Truck Running PTO Engaged 3 Move the packing ejection control to fully extend the packing ejection cylinders NOTE Maintain the engine RPM at the posted speed 4 Hold the control and read the gauge The pressure should be 3000 PSI IF NOT 5 Check the cylinders for bypass see Section 9 SERVICE AND REPAIR 6 Replace the port relief cartridge see Section 9 SERVICE AND REPAIR 7 Replace the hydraulic pump see Section 9 SER VICE AND REPAIR LEACH SECTION 7 CHECK OUT LIFT ARM SECTION INLET 5 SPOOL CONTROL VALVE 2000 PSI DOWN gt PACKER SECTION INLET 3000 PSI 5 SPOOL gs CONTROL c VALVE E NOTE The packing ejection pressure setting is not adjustable 8 Repeat items 1 7 to
27. fatigue 2 Replacement of fork assembly components is not recommended Replace the entire assembly if damage is found INSTALLATION OF ADJUSTABLE FORK ASSEMBLY Install the fork assembly in the approximate reverse order of removal Adjusting Cylinder Stationary Fork Adjustable VA Fork Y Container Stop Y 9 5 SECTION 9 SERVICE AND REPAIR ADJUSTABLE FORK CYLINDER DESCRIPTION OF ADJUSTABLE FORK CYLINDER One 1 double acting hydraulic cylinder slides the adjustable fork to increase or decrease the distance between the forks The rod end is pinned to the adjustable fork weldment The case end is pinned to the fork tube REMOVAL OF ADJUSTABLE FORK CYLINDER Operational Status Truck Running PTO Pump Engaged 1 Operate the adjustable fork system to completely retract the adjustable fork cylinder rod Operational Status Truck Off Keys Removed 2 Relieve the hydraulic pressure to the cylinder by operating the adjustable fork valve in both direc tions 3 Remove the hoses from the cylinder and plug ends Unpin the rod and case ends and carefully remove the cylinder 9 6 DISASSEMBLY OF ADJUSTABLE FORK CYLINDER 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt from contami nating the cylinder components during disassem bly 2 Drain the hydraulic fluid from the cylinder 3 Secure the cylinder case to a work bench Care should be t
28. fluid samples taken on a regularly scheduled basis The cost is about 20 to 30 per sample The most important analyses are particle count Spectro chemical analysis water content and viscosity IN HOUSE HYDRAULIC FLUID TESTING After your sample has been allowed to stand for 20 to 30 minutes to eliminate all air bubbles hold the bottle up to the light to check for debris in the fluid and also check whether the fluid is clear or cloudy Any visible debris is an indication of a severe solid con tamination problem the source of which must be locat ed and corrected immediately Common sources of this kind of contamination may be component wear unsealed reservoir covers or dirty air breather filters If the sample is the least bit cloudy it is an indication of water contamination the source of which must be found and eliminated immediately Common sources are inadequate outdoor storage unsealed reservoir COVers or condensation 6 8 A BLOTTER SPOT TEST may also be performed to test for OXIDATION Place a DROP of fluid on a piece of white blotter paper Order Leach part number 102480 for 20 sheets NOTE The Blotter Spot Test will provide an indication that a more complete test may be necessary A f the blotter remains colorless or develops only a light yellow ring oxidation is under control B If color develops but is uniform throughout the fluid is still serviceable but should be checked for the correct ad
29. for proper grade of fluid See Section 5 Specifications Hydraulic fluid level too low Check fluid level Add fluid if necessary See Section 7 Check out By pass in cylinders Test for leaking cylinders See Section 9 Service and Repair Hydraulic fluid too cold Bring fluid to operating temperature Check for proper grade of hydraulic fluid See Section 5 Specifications Spools in control valves bent or binding Repair or replace See Section 9 Service and Repair Hydraulic strainer plugged Clean hydraulic strainer FLUID LEAKING FROM BETWEEN BODY AND TAILGATE 1 Latches not completely engaged 1 Hold the control after the tailgate has closed See Section 7 Check out 2 Latches not locking tight enough 2 Add shims to latch blocks See Section 7 Check out 3 Tailgate seal damaged 3 Replace tailgate seal See Section 9 Service and Repair 4 Material between the body and the tailgate seal 4 Clean the tailgate seal and the rear of the body TAILGATE DOES NOT CLOSE 1 Material left on edge of body opening Remove material See Section 2 Safety Precautions 2 Latch linkage out of adjustment Adjust linkage See Section 9 Service and Repair 3 Leaking or bypassing tailgate cylinders Repair or replace the tailgate cylinders See Section 9 Service and Repair 4 Tailgate relief pressure low Check the tailgate pressure See Section 7 Check out SECTION 8 TROUBL
30. installing the tie rods to the cylinder assembly tighten the rod nuts evenly and torque to 15 20 Ft Lbs Adjusting Cylinder Stationary Fork Pivot Adjustable Container Stop 9 7 SECTION 9 SERVICE AND REPAIR FORK ASSEMBLY DESCRIPTION OF FORK ASSEMBLY The fork assembly connects with a container for load ing and dumping of refuse The need for removal of the fork assembly is rare and is generally limited to replace ment of the entire assembly REMOVAL OF FORK ASSEMBLY Operational Status Truck Off Keys Removed 1 Disconnect the rod end cylinder pin of both tilt cylin ders as described earlier in this section NOTE See Section 4 GENERAL REPAIR PRAC TICES for detailed information about the cor rect use of slings and lifting chains 2 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 1600 Ibs to the fork assembly Operate the lifting device no more than necessary to support the weight of the fork assembly 3 Remove the capscrews and pivot pin 4 Operate the lifting device to free the fork assembly from the lift arms 5 Position the fork assembly on supports to facilitate inspection Supports must be capable of holding 1600 Ibs PIVOT PIN gt TILT CYLINDER FORK ASSEMBLY CAPSCREW hg ne INSPECTION AND REPLACEMENT OF ADJUSTABLE FORK ASSEMBLY 1 Inspect all portions of the fork assembly Check piv
31. need of ser vice or repair Death serious injury or dam age to the equipment could result 16 Report any problems found during the pre operat ing walk around inspection to the maintenance supervisor for service or repair then place a tag on the steering wheel inoperative and remove the keys Km h j 3 6 OPERATING INSTRUCTIONS GENERAL 1 Inspect and start the truck as described under Pre Operating Walk Around inspection Chassis operational checks should be accomplished follow ing chassis manufacturers recommended proce dure 2 Prior to moving the truck the unit should have the lift arms in the travel position and the tailgate latched All warning lights should be off 3 The PTO Pump should not be operating while the unit is being driven on the road The PTO Pump should be engaged after the unit is close to and aligned with the container to be lifted STANDARD TRANSMISSION The PTO on standard transmissions is engaged by stopping the truck shifting into neutral and then while depressing the clutch pedal moving the PTO control lever engaging the PTO gears with the transmission As the clutch pedal is released the PTO will start turn ing thus providing power to the hydraulic pump When engaged an indicator light will illuminate AUTOMATIC TRANSMISSION The PTO on an automatic transmission is engaged by shifting into any drive position while depressing the brake
32. of wear expendable components is not covered under war ranty This limited warranty is the sole and exclusive warranty of the Leach Company THE COMPANY MAKES NO WARRANTY AS TO MERCHANTABILITY FITNESS FOR USE LEGALI TY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF ANY KIND OR NATURE THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAM AGES OF ANY KIND OR NATURE OTHER THAN ITS LIMITED WARRANTY OF REPLACEMENT HEREIN NO OTHER PERSON FIRM OR CORPORATION CAN BIND THE COMPANY TO ANY WARRANTY OTHER THAN HEREIN ABOVE STATED To validate the new unit warranty an authorized Leach distributor must have completed a pre delivery inspection before the unit is placed into service and the delivery report form signed by both the cus tomer and distributor must be submitted to the Leach Customer Support Service Department Because Company products are engineered to work only with genuine Company parts this limited war ranty will be void and no effect if a Company products are modified other than as done at its factory or as authorized to be done by the factory in writing or b Parts or assemblies of any other manufac turer are used as Substitutes for genuine Company parts Genuine Leach replacement parts components and assemblies are also sold under a Limited Warranty to be free from defects in workmanship or material for a period of six 6 months This is a replacement only warranty and the item must be returned to t
33. rod bolts to 25 x1 Ft Lbs Lubricate the internal actuator seals liberally with Dow Corning 44 or equivalent grease DO NOT use other types of grease They may damage the internal components of the air logic system While installing the actuator to the valve section apply type Il grade N blue thread locking com pound to the threads of the fasteners Tighten the bolts evenly to prevent binding Torque the actuator retaining bolts to 10 1 Ft Lbs When installing the shoulder bolt through the actu ator into the spool end apply type II grade blue thread locking compound to the threads Torque this bolt to 11 14 Ft Lbs Operate the valve sections manually in both direc tions before installation to ensure there is no bind ing of the spools LEACH INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY 2 3 4 Secure the valve assembly to its mounting bracket with capscrews Connect all hydraulic lines and tighten securely Install the clevis and cotter pins between the cable clevis and spool ends Recheck the mail relief valve pressure as described under pressure checks Section 7 CHECK OUT NOTE When reinstalling the spool into the valve sec tion always install new o rings to prevent leak age 9 31 SECTION 9 SERVICE AND REPAIR ya a OF CONTROL LEVERS AUTO PACK The control levers located in the chassis cab on the dri ver s right side are used to control the operation of
34. size metal o ring plugs 3 Connect a porta power with a gauge capable of reading 0 5000 PSI to port IN i co system When de energized OFF the valve acts strictly as a manifold to direct the hydraulic fluid to the five 5 spool valve This type of hydraulic system reduces back pressure in the main hydraulic system which allows for less heat and wear on the various components of the unit Along with diverting the hydraulic fluid to the cart tipper system the power on demand valve also regulates the pressure of this circuit There is also a built in relief valve to guard against system damage in the unfore seen event of an unwanted pressure build up 3 Move the TIPPER CIRCUIT switch to the ON position and raise the engine speed to the RPM designated on the dash decal 4 Read the gauge The pressure should be 2500 PSI IF NOT 5 Replace the tipper cartridge Operational Status Truck Off Keys Removed 6 Remove gauge and reinstall the hose to the port marked NOTE On some cart tipper systems a directional valve is supplied by the manufacturer of the cart tipper container They may incorporate an additional pressure setting If so consult the tipper container manufacturer for adjustment procedures on these systems 4 Operate the porta power As the pressure rises watch port T When the pressure rises to 3100 PSI fluid should exit port T IF NOT 5 Loosen the locknu
35. tank Clean the strainer 9 as described above Fill the hydraulic tank with fresh fluid as specified in Section 5 SPECIFICATIONS according to operat ing and weather conditions 6 Start the truck and operate as described in Section 3 OPERATION Leave all hydraulic cylinders in the retracted position and shut down the unit 7 Recheck the fluid level and add fluid as necessary to bring level to the NORMAL FILL LEVEL on the sight gauge 13 amp 6 6 9 Place the filter element 2 into the filter housing 4 sliding the filter element opening over the filter housing locator tube 10 Align the bypass valve tube on the filter housing cover 1 with the opening on top of the filter ele ment 2 11 Replace the filter housing cover by aligning the six capscrews in the large holes and pushing down ward gently Twist the housing cover counter clock wise until the cover capscrews are seated in the small holes 12 Tighten the filter housing cover retaining cap screws in a cross pattern to 170 foot pounds 1 16 Newton meters 14 Run the unit and check for leaks Extended operation of the unit without proper filtration will result in a reduced ser vice life of hydraulic system components NOTE Refer to Section 9 SERVICE amp REPAIR for detailed instructions pertaining to those items requiring repair or replacement LEACH WEEKLY PREVENTIVE MAINTENANCE 1 CLEANING Clean and paint exposed me
36. the correct use of slings and lifting chains 2 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 1 000 pounds to the top door Operate the lifting device no more than necessary to support the weight of the top door 3 Remove the four 4 capscrews that retain the cylin der support and remove the support 4 Remove the capscrews that retain the front bearing slide access covers 5 Manually slide the door toward the rear and posi tion the top door retainers in the access openings 6 Operate the lifting device to lift the top door from the body 7 Position the top door assembly on supports to allow inspection The supports must be capable of hold ing 1 000 Ibs TOP DOOR CYLINDER SLIDING TOP DOOR 9 18 DESCRIPTION OF HINGED TOP DOOR CYLINDERS The two 2 hinged top door cylinders raise the hinged top door to load refuse into the hopper and close the hinged top door during transport The case end is pinned to the roof of the body while the rod end is pinned to the hinged top door REMOVAL OF HINGED TOP DOOR CYLINDERS Operational Status Truck Off Keys Removed The hinged top door should be closed for removal of the hinged top door cylinders Remove the hydraulic hoses from the cylinder loosen ing them slowly to relieve any built up pressure Plug the hoses to prevent contamination Remove the pins from the case and the rod ends of the cylinder Carefully remove the cyli
37. the container as the lift arms move higher it will be necessary to tilt the forks to level the con tainer NOTE As the lift arms raise over the chassis cab the ARMS ABOVE BODY indicator light will illu minate 2 The lifting speed is determined by the distance the joystick is moved and the engine speed The oper ator controls the engine speed by depressing the accelerator 3 There is a mirror provided for the operator to observe the container being raised overhead and to assist in leveling the container The operator should maintain a constant RPM throughout the front loader s opera tion DO NOT exceed the RPM posted on the dash decal or serious unit damage may occur AWARNING Ensure that people are clear of the contain er before raising or lowering Do not attempt to dump overloaded con tainers LEACH SECTION 3 OPERATION MAINTAIN A CONSTANT R P M CAUTION LEACH CO STRONGLY RECOMMENDS ENGINE BE KEPT BELOW RPM WHEN 15 ENGAGED 3 9 SECTION 3 OPERATION DUMPING THE CONTAINER AFTER RAISING THE LIFT ARMS 1 To dump the refuse from the container into the body tilt the forks back after the lift arms have con tacted the lift arm stop pads 2 The container may be moved back and forth with the fork tilt to dislodge refuse and completely empty the container 3 There is a mirror provided for the operator to observe the position of the
38. the outside thoroughly to avoid con tamination during disassembly DISASSEMBLY OF THE JOYSTICK NOTE There are many small components inside of the joystick assembly Note the position and location of all parts during disassembly 1 Secure the joystick valve body to a workbench tak ing care not to damage the body casting 2 Grasp the joystick control lever and rotate it counter clockwise to unscrew it from the ball sock et assembly Remove the joystick control lever and the dust boot 3 Remove the four 4 phillips head capscrews from the top of the ball socket assembly and remove the assembly from the valve body Retain the four 4 valve actuator pins for reassembly Retain the pillow block support spring washer and the pillow block for reassembly The pillow block and spring washer are included in the seal kit Retain only the pillow block support 4 With adjustable pliers carefully grasp the four 4 black plastic collars protruding from the top of the valve one at a time and slowly pull them out of the valve body Note the location of all parts for reassembly Turn the valve body upside down to remove the U cup assembly and return spring from the valve body INSPECTION AND REPLACEMENT OF THE JOYSTICK ASSEMBLY Clean and inspect the inside of the valve body Check for cracks scoring or wear Replace all seals and o rings Parts that must be replaced together are avail able as a seal kit from your local authorized L
39. the pressure raises to 1850 PSI the sequence valve is shifted directing full fluid flow to the case end of the lift arm cylinders Operator Action The operator continues to hold the lift arm control in the lift arm down position Top 22 L p LEE Dr 25 gt A 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder Sequence Valve Pressure Exhaust RAISE TAILGATE Operator Action The operator moves the tailgate control p lis E HYDRAULIC SYSTEM E The operator action shifts the control valve directing the 2 pump flow to the case end of the tailgate cylinder As the cylinder extends return flow from the rod end of the cylinder is directed through the control valve and then SECTION 8 TROUBLESHOOTING the return line filter to the tank When the cylinder is fully extended the port relief will open at 3000 PSI KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pressure Top Door Cylinder Exhaust LEACH SECTION 8 TROUBLESHOOTING LOWER TAILGATE Operator Action The operator moves the tailgate control HYDRAULIC SYSTEM The operator action shifts the control valve directing
40. to 54 66 in Ib torque 4 Insert the shoulder bolt ITEM 5 through the spring retainer ITEM 6 centering spring ITEM 7 wash er ITEM 8 and spacer ITEM 9 Then insert the bolt through the housing assembly ITEM 2 and install in the adapter ITEM 1 Tighten to 11 14 ft Ib torque 5 Mount the bonnet ITEM 10 over the center spring ITEM 7 and onto the housing assembly ITEM 2 using 2 each of the provided screws ITEM 3 and washers ITEM 4 and tighten to 54 66 in Ib torque LUBRICATION The pneumatic actuator comes prelubed In the event the lubrication is wiped off liberally apply a high tem perature silicon based bearing grease with a NLGI 2 consistency to the piston seal ITEM 11 two rod seals ITEM 12 and all seal travel surfaces 9 30 TESTING AFTER INSTALLATION FOR PERFORMANCE AND LEAKAGE 1 2 ITEM ak XE It is important that the actuator be tested after installation Apply a soap solution to all of the actuator joints ports and connectors Reapply soap solution and repeat test while spool is being moved in the other direction If leakage is excessive ensure that the joints are tight and that the installation is correct Verify that the spool moves easily through its entire travel range and that there is no evidence of stick ing or binding If binding is detected the installation should be checked immediately Failure to do so c
41. toggle switch is a spring centered valve Movement of the tailgate may be stopped by releasing the tailgate toggle switch SECTION 10 PNEUMATIC CONTROLS BASIC CHECKS Before diagnosing the air logic control module ALCM a few basic checks should be made to ensure that the other components of the system are functioning prop erly Most of the auto packing malfunctions are caused by components other than the ALCM Auto pack control valves Located in the cab and include the auto pack green retract black emer gency stop red and auto reset green flat topped but ton valves Operate them to ensure that they work smoothly with no leaking Home and retract limit valves Located at the right front of the body on the outside of the front bulkhead cov ered by a metal box type canopy Check them for dam age correct adjustment and smooth operation Make sure the immediate area of these valves is free of refuse Main control valve actuator Located on top of the five 5 spool valve it controls the shifting of the hydraulic valve spool Check if the valve spool is shifting fully and returning to neutral freely Check for any air bypassing around the actuator piston seal Ensure the internal surfaces of the actuator are free of dirt and lubricated with Dow Corning 44 or equivalent DO NOT USE ANY OTHER LUBRICANT Damage to the ALCM may result Air regulator Located on the left chassis frame rail between the hydraulic r
42. 5 Note the amount of shims and their location on the hinge pin Remove the hinge pins and save the shims 6 Operate the lifting device to remove the top door from the body 7 Position the top door on supports capable of sup porting 1500 16 700 kg to allow inspection and repair Cushion Pads Hinge Pins Retainer Bolts LEACH SECTION 9 SERVICE AND REPAIR INSPECTION amp REPLACEMENT OF HINGED TOP DOOR 1 Inspect the top door for cracked welds and breaks Pay special attention to the hinge areas Repair or replace as needed 2 Inspect the hinge bearings for excessive wear and replace if needed 3 Check the cushion pads for excessive wear and replace if needed 4 Reinstall the top door in the approximate reverse order of removal Top Door 9 21 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PACKING EJECTION CYLINDER This three stage double acting hydraulic cylinder com pacts the refuse during loading and ejects it during the unloading operation The case end of the cylinder is pinned to the lower portion of the packing ejection panel while the cylinder rod eye is pinned to the front of the body REMOVAL OF PACKING EJECTION CYLINDERS Operational Status PTO Engaged Truck Running 1 Move the packing ejection control to extend the telescopic cylinders and move the packing ejection plate to the rear of the top door opening 2 Open the top door Operational Status Truck Off
43. 608 Oshkosh Wisconsin 54903 2608 oMMiIT7 gt O A 9 Cy e S Thi LING Re SB Ok O d bs Prin 20 int e 99 on One genuine Leach hat to the first person to notify us of an error in any of our publications If you find what you believe to be an error in any of our publications please complete the requested information and mail If you are the first you will receive a hat by return mail believe found an error Millennium Service Manual manual Thanks for your help Return this form to Service Department Leach Company 2737 Harrison Street Box 2608 Oshkosh Wisconsin 54903 2608
44. 8 TROUBLESHOOTING 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Cylinder Exhaust LEACH 8 9 SECTION 8 TROUBLESHOOTING TILT FORKS DOWN Operator Action The operator moves the tilt control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the case end of the tilt cylinders As the cylinders extend return flow from the rod end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinders are fully extended the main relief will open at 3000 PSI directing the case end flow to the tank KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Cylinder Exhaust 8 10 RAISE LIFT ARMS Operator Action The operator moves the lift arm control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the rod end of the lift arm cylinders As the cylinders retract return flow from the case end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinders are fully retracted the port relief pressure will increase to 2800 PSI KEY Lift Arm Cylinders Hydraulic Tank Pack
45. C Purple Retract Palm Button B White Side Door Interlock F Orange Auto Pack Reset Palm Button Valve D Black Hydraulic Valve Actuator Green Pack Palm Button 1 Blue Auto Pack Reset Palm Button E Gray Packer Home Limit Switch H Black Hydraulic Valve Actuator J Brown Packer Extend Limit Switch G OPTIONAL LIFT ARM LOCKOUT CONNECTIONS Blue Hydraulic Valve Actuator Lift Arm Raise K Blue Lift Arm Control 2 5 L Red Constant Air P 10 9 SECTION 11 ELECTRICAL The unit s electrical system includes all of the body run ning and marker lights dash warning lights back up warning alarm and all interconnected wiring as shown on the accompanying wiring diagram TESTING To locate a defective component or break in the wiring perform a continuity check across and between sus pected components as described in Section 4 GEN ERAL REPAIR PRACTICES PROXIMITY SWITCHES DESCRIPTION OF PROXIMITY SWITCHES The electrical system on the Leach Millennium utilizes proximity switches to activate warning lights for the tail ga
46. Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator depresses the green packing ejection button PNEUMATIC SYSTEM A continuous air signal is sent through port A1 on the ALOM to pilot port B on RV4 and pilot port A on RV1 RV4 shifts sending an air signal to pilot port B on RV3 enabling the auto mode RV1 provides a continu ous air signal through SV2 out port I to the air actuator on the main control valve extending the telescopic cylinders As the packing ejection panel extends from the home position the air supply to RV2 and PS2 through port is discontinued The packer panel home light is turned off and the packer panel par tially extended light is turned on SOL1 is energized to allow continuous air flow from RV4 10 2 PACKING EJECTION PANEL CLEARS HOPPER AREA TELESCOPIC CYLINDER P a PACKER RETRACT LIMIT NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action None PNEUMATIC SYSTEM The packer retract limit valve sends an air signal through port on the to pilot port B on RV4 and pilot port B on RV1 RV4 shifts discontinuing the air supply from port A1 on the ALCM RV1 shifts sending a continuous air signal to pilot port A on RV2 and
47. E LUM J ET XUL OAC 6 7 SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE CONTAMINATION It is estimated that as much as 90 of all hydraulic problems may be traced directly to the fluid It is of utmost importance that all foreign matter be kept from the hydraulic fluid Invisible quantities of abrasive type contamination may cause serious pump wear malfunc tioning of pumps and valves and sludge accumulations within the system in relatively short periods of time It is also essential that moisture and water be kept from the hydraulic fluids and system COMMERCIAL HYDRAULIC FLUID TESTING Hydraulic fluid samples should be taken periodically for laboratory analysis The actual sampling method is crit ical It should be done based on ANSI Standard B93 19M R1980 This standard is available from the National Fluid Power Association 3333 N Mayfair Rd Milwaukee WI 53222 Samples should be taken from the center of the reser voir when the fluid is at operating temperature and placed in a clean dry glass bottle with a non shedding screw on cap The bottle should be labeled with the date type of fluid and model and serial number of the machine Two identical samples should be taken One for labora tory analysis and one for your own preliminary analysis while you are waiting for the lab report We recommend the use of commercial laboratory ser vices for analysis of routine
48. E AND REPAIR REPLACEMENT OF THE TRACK CHANNEL WEAR BLOCKS 1 Pressure wash the body track channels complete ly and the packing ejection panel lower side areas completely 2 Remove the capscrews 8 fastening the wear block retainers remove the wear block retainers 3 Using a length of flat steel bar stock drive the upper rear track channel wear blocks out of the packing ejection panel by placing the bar stock between the packing ejection panel and body side near the center of the panel Note the position and amount of any shims that may be located between the wear blocks and the mounting plates 4 Remove the upper front track channel wear blocks by inserting the bar stock through the opening left by the rear upper war block and driving the blocks forward Note the position and amount of any shims that may be located between the wear blocks and the mounting plates 5 Using 1 cold chisels 4 raise the packing ejection panel by driving the chisels under the panel near the lower track channel wear blocks 6 Drive the lower wear blocks out in the same fashion as the upper wear blocks 7 Thoroughly pressure wash the area between the packing ejection panel and the body track chan nels to completely remove any debris that may inhibit the installation of the new wear blocks 8 Assemble in the approximate reverse order of the wear block removal Reinstall any removed shims in the same locations that they were removed from
49. ED TOP DOOR CYL e FLOW Dome ACTING CYLINDER ACTING CYLINDER REAR DOOR DOUBLE ACTING CYLINDER LIFT ARM AIR LOGIC CONTROL MODULE gt Un O UA CB FDI 1 6 GENERAL The Air Logic Control Module ALCM directs pneumat ic control signals to shift the hydraulic control valve acti vating the telescopic packing ejection cylinders Features could include modules to restrict the move ment of the lift arms LIFT ARM LOCKOUT AIR LOGIC CONTROL MODULE ALCM COMPONENTS KEY 1 Shuttle Valve 2 5 2 To Tele Extend 2 Relay Valve 1 RV1 Extend Retract Select 3 Relay Valve 3 RV3 Auto Mode Disable Enable 4 Shuttle Valve 1 SV1 To Side Door E Stop Inhibit 5 Pressure Switch 1 PS1 Side Door Open Indicator 6 Pressure Switch 2 PS2 Packer Panel Position Indicator 7 Relay Valve 2 RV2 Home Position Reset 8 Lift Arm Lockout Module A Solenoid 2 SOL2 RV5 Control B Relay Valve 5 RV5 L A Lockout Inhibit 9 Packer Lockout A Solenoid 1 SOL1 RV4 Control B Relay Valve 4 RV4 Packer Panel Inhibit 10 Shuttle Valve 3 SV3 To Tele Retract LEACH Al SECTION 10 PNEUMATIC CONTROLS Yellow Emergency Stop Button Valve Auto Pack Disable Purple Retract Button Valve Auto Retract Enable Manual Retract White Side Door Valve Auto Pack Disable Orange Auto Reset Button Valve Air Supply Black
50. EPAIR 1 Set the parking brake 2 Put the vehicle in park or if equipped with a manu al transmission put the unit in gear and remove the ignition key 3 Place an OSHA approved chock block in front of and behind the front tire SAFETY DURING SERVICE AND REPAIR h Always wear safety glasses 2 Disengage the PTO turn off the ignition and remove the keys before a Leaving the truck cab b Examination or lubrication of the PTO pump or drive shafts c Entering the front of the body d Entering the tailgate 3 Always check to make sure the body access door is locked shut before entering the cab WELDING PRECAUTIONS ELECTRIC WELDERS 1 Electric arc welders should have a separate fused disconnect circuit 2 Welders must be used according to the manufac turers specifications 3 All electric welding should be done in a well venti lated area 4 The radiation given off by the arc will destroy the retina of the eye so wear an approved welders hel met 5 Welding radiation will produce severe burns on unprotected skin similar to sunburn so wear heavy clothing Use natural fiber or leather avoid syn thetic fiber clothing OXY ACETYLENE TORCHES 1 Acetylene is a highly explosive gas which should be treated with the greatest care At pressures above 15 psi acetylene will explode by decomposi tion without the presence of air No other industrial gas has such a wide explosive range 2 Oxygen will s
51. ESHOOTING POSSIBLE CAUSE REMEDY PUMP NOISE IS EXCESSIVE NOTE All pumps make a certain amount of noise 1 Pump starving for fluid Hydraulic fluid too cold PTO driveshaft and or u joints badly worn or out of balance Pump gears end plates or bearings badly worn Improper grade of hydraulic fluid fluid foaming Air entering the system FORKS WILL NOT TILT 1 Control does not open control valve Leaks in hydraulic system Defective or worn pump Defective control valve Leaking or by passing fork cylinders Main relief valve out of adjustment Fork tilt relief pressure low Main relief pressure low Pump defective or worn Packing ejection cylinder leaking externally or by passing Packing relief pressure low Material binding packing ejection panel 1 Check fluid level Check hydraulic fluid filter and tank See Section 1 Open gate valve 6 Preventive Maintenance Check for obstruction in suction lines hoses kinked or collapsed Bring fluid to normal operating temperature Change hydraulic fluid to proper grade for oper ating conditions See Section 5 Specifications Repair replace and or balance all parts Replace pump Replace with proper grade of hydraulic fluid See Section 5 Specifications Tighten the suction hose Tighten packing on the gate valve stem Replace the pump shaft seal Replace t
52. FORK TILT CYLINDERS DESCRIPTION aici kk m ose tede s 9 3 REMOVAL sac Sosa S CREER 9 3 DISASSEMBLY 9 4 INSPECTION AND REPLACEMENT 9 4 REASSEMBLY AND INSTALLATION 9 4 ADJUSTABLE FORK ASSEMBLY DESCRIPTION 9 5 REMOVAL 9 5 INSPECTION AND REPLACEMENT 9 5 INSTALLATION 9 5 ADJUSTABLE FORK CYLINDER DESCRIPTION 9 6 REMOVAL 232 me ERE RUE RE 9 6 DISASSEMBLY 9 6 INSPECTION AND REPLACEMENT 9 7 REASSEMBLY AND INSTALLATION 9 7 FORK ASSEMBLY DESCRIPTION 9 8 REMOVAL 9 8 INSPECTION AND REPLACEMENT 9 8 INSTALLATION 9 8 LIFT ARM CYLINDERS DESCRIPTION ER Ss 9 9 REMOVAL 9 10 DISASSEMBLY 9 11 INSPECTION AND REPLACEMENT 9 11 REASSEMBLY AND INSTALLATION 9 11 BOLT ON LIFT ASSEMBLY DESCRIPTION 9 12 REMOVAL OF 9 12 INSPECTION AND REPLACEMENT 9 12 9 12 TAILGATE CYLINDERS DESCRIPTION 9 13 REMOVAL 9 13 DISASSEMBLY 9 14 INSPECTION AND REPLACEMENT 9 14 REASSEMBLY AND INSTALLATION 9 14 TAILGATE DESCRIPTION
53. GH RED T TOP DOOR OPEN E 37 CABLE SLIDING TOP DOOR CONTROL TOGGLE SWITCH On units with the sliding top door the oper ator must fully open the door prior to lifting the container Damage to the container or the front loader may result if the container is dumped onto a closed door TAILGATE CLOSE TAILGATE OPEN TAILGATE LEVER TAILGATE SIW TOGGLE SWITCH TEST BUTTON OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the Leach Millennium including specific instructions for loading packing and unloading the unit It s important that the operators and main tenance personnel understand these proce dures prior to operating or repairing the unit PRE OPERATING WALK AROUND INSPECTION Each day before starting the unit perform the following walk around inspection 1 Refer to the decal location illustration in Section 2 SAFETY PRECAUTIONS of this manual and make sure all decals are in place and readable Replace any decals that are not NOTE Decals are available free of charge from your local authorized Leach Distributor 2 Check for fluid leaks on and around the unit Check for fluid leaks at the hydraulic cylinders valves and fittings 3 Inspect the mounting points Make sure everything is tight and that there are no broken loose or excessively worn parts Check capscrews and fas teners for looseness visibl
54. INDER 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder compo nents during disassembly Secure the case end of the cylinder to a work bench or floor mount and the rod end to an over head lifting device with a lifting capacity of 1 000 pounds to ease the disassembly of the cylinder Remove the plugs from the ports and drain the fluid Remove the setscrews from the packing nut and remove packing nut Slowly operate the hoist to carefully pull the sleeve assembly from the cylinder 5 Replace the packing set for each section CASE SETSCREW PACKING SET PACKING NUT SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CYLINDER 1 Thoroughly inspect the inside and outside of each section for cracks scoring or uneven wear 2 Check all cylinder components for damage and wear and replace as required NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering the cylinder REASSEMBLY AND INSTALLATION OF PACKING EJECTION CYLINDER Coat all seals and o rings with clean fresh hydraulic fluid before assembly Reassemble and install the packing ejection cylinder in the approximate reverse order of disassembly For more detailed information on servicing of the pack ing ejection cylinder contact the Leach Company Customer Support Service Departmen
55. Keys Removed NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains Secure a nylon sling around the cylinder and attach it to a suitable lifting device with a capacity of at least 1 000 lbs Operate the hoist to snug the sling 4 Raise and support the tailgate as described earlier in this section 5 Remove the pin access cover and the pin retaining capscrew from the face of the packer ejection panel 6 Make sure the cylinder is securely supported by the hoist and carefully remove the case end pin Check for pivot pin or pin hub wear Operational Status PTO Engaged Truck Running 7 Slowly move the packing ejection control to com pletely retract the cylinder Operational Status Truck Off Whenever dismantling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly crack or loosen the fittings Keys Removed 22 N ACCESS COVER CAPSCREW gt V CYLINDER PIN PACKING EJECTION PANEL 8 Disconnect both the case end and the rod end hoses Immediately cap or plug hoses and cylinder ports to keep fluid in and dirt out 9 Remove the capscrew from the rod end cylinder pin Make sure the cylinder is securely supported by the hoist and carefully remove the pivot pin Check for pivot pin or pin hub wear LEACH DISASSEMBLY OF PACKING EJECTION CYL
56. LACEMENT OF TROUGH AND FLOOR WEAR BLOCKS 9 26 REPLACEMENT OF BODY SIDE WEAR BLOCKS 9 26 CAB GUARD CYLINDER DESCRIPTION 9 27 TEST FOR LEAKS 9 27 REMOVAL aee eee Ga eee 9 27 DISASSEMBLY 9 27 INSPECTION AND REPLACEMENT 9 27 REASSEMBLY AND INSTALLATION 9 27 5 SPOOL CONTROL VALVE ASSEMBLY DESCRIPTION 9 28 REMOVAL 9 28 DISASSEMBLY 9 29 DISASSEMBLY OF SPOOL SECTIONS 9 29 INSPECTION OF VALVE SECTION 9 29 DESCRIPTION OF PNEUMATIC ACTUATORS 9 30 ACTUATOR INSTALLATION 9 30 LUBRICATION 9 30 TESTING AFTER INSTALLATION 9 30 MAIN CONTROL VALVE ASSEMBLY DISASSEMBLY OF MAIN RELIEF SECTION 9 31 REASSEMBLY 9 31 INSTALLATION 9 31 LEACH TABLE OF CONTENTS SECTION 9 SERVICE AND REPAIR Continued CONTROL LEVERS LINKAGE DESCRIPTION 9 32 REMOVAL DISASSEMBLY 9 32 INSTALLATION AND ADJUSTMENT 9 32 LEACH HYDRAULIC PUMP DESCRIPTION 9 33 REMOVAL 9 33 NEW PUMP PREPARATION 9 33 INSTALLATION OF HYDRAULIC PUMP 9 33 TESTING A NEW PUMP 9 33 SECTION 10 PNEUMATIC CONTROLS AIR LOGIC CONTROL MODULE
57. LEACH Leach Millennium Service Manual This Book is Printed on Recycled Paper Part No 105297 TO ORDER PARTS Contact your local Leach Signature Original Factory parts distributor Your Authorized Leach Distributor provide the following information A Company name Date Your order number Routing instructions Quantity part number and description F Model and serial number of unit m O Uu Accept only Leach Signature Original Factory Parts LEACH MILLENNIUM P SERIAL NUMBER LOCATION Copyright Leach Company 2737 Harrison Street Box 2608 Oshkosh Wisconsin 54903 2608 May 15 1998 WARRANTY LEACH SILVER SHIELD SERVICE Refuse bodies manufactured by Leach Company Company are supplied and sold under a Limited Warranty that they are and will remain free of defects in workmanship or material for a period of six 6 months from date of original sale under reasonable conditions of use and operation providing required preventive maintenance services are performed Additional optional warranties are available for pur chase If a failure occurs during said period because of such defect in the opinion of the Company the component or part shall be repaired or replaced by an authorized Leach Distributor at no cost to the customer provided the unit is brought to the distributor s service facility After three 3 months perfor mance of adjustments or the replacement
58. MICRON RESERVOIR Cos wu STRAINER PUMP 141 DISPLACEMENT MICRDN 9 23 CU IN RE V Nu 1 NN um E ux 1 UNS WED 1 Uum oum 5 3000 PSI 1 E RELIEF i E i 5 mem mmo a em ccm rmi ey I eee gt m pec hime t 1 CLOSED TELESCOPIC DOUBLE ACTING CYLINDER TELESCOPIC DOUBLE ACT ING CYLINDER LIFT ARM LIFT ARM DOUBLE ACTING CYLINDER SLIDING TOP DOOR _ RR FREE FLOW REAR D ODOR DOUBLE ACTING CYLINDER HYDRAULIC SCHEMATIC HINGED TOP DOOR ee aia ep iste 3000 PSI MAIN RELIEF M F RK DOUBLE ACTING R CYLIND FDRK DOUBLE ACTING CYLINDER FORKS DOWN ee a Eos gu j Ee 1 UND PUMP DISPLACEMENT uum 30519e 223 CU IN RE V TELESCOPIC DOUBLE ACTING CYLINDER TELESCOPIC DOUBLE ACTING CYLINDER DOUBLE ACTING NDER LIFT ARM ARMS DOWN REAR DOOR i DOUBLE ACTING CYLINDER AJ 1 222 HINGED TOP DOOR CYL FREE FLOW FREE HING
59. NT QUANTITY OI Latch linkage 2 e Lover PIVOT 33 5 eee rr duco WAVES ERR E cane eee 2 Tailgate cylinder pivot rod 2 94 Tailgate cylinder pivot case 2 NS ooo sss ES Tailgate NING seraa wet pecs ee a Brew Poe wo ope ee oct Ge 2 Top door hinge hinged top door 2 a ee Packing Ejection cylinder rod end 2 e8 Packing Ejection cylinder case end Tilt cylinder pivot case end 2 10 gt Tilt cylinder pivot rod 2 OIl Lau LUE DIVOP eee 2 ee Lift cylinder pivot rod 2 13 PTO driveshaft GAS EEG 4 4 2 e14 Lift cylinder pivot case end 2 1S ERETITEL AET Fork assembly pivot 2 INSTRUCTIONS Weekly or every 40 hours of operation whichever comes first with MOBILUX EPI SERVICE grease or equivalent Weekly or every 40 hours of operation w
60. O Disengaged 1 A pressure gauge is attached to the air regulator With chassis air system at full pressure air regula tor pressure should be exactly 105 PSI PRESSURE GAUGE If 105 psi cannot be reached replace regulator n AIR REGULATOR A CAUTION Exceeding the recommended pressure set tings could damage the unit 7 13 SECTION 7 CHECK OUT GENERAL Troubleshooting is a matter of quickly and logically iso lating the cause of a problem and taking corrective action Factory trained mechanics experienced opera tors a thorough understanding of the information in this manual and accurate maintenance records are the best troubleshooting tools available Occasionally it may be best for a service person who is trying to isolate a problem to go on the route or consult with operators to determine how the unit is acting under actual work ing conditions For the most part problems with the unit will be limited to hydraulic and electrical system Component malfunc tions or control linkage adjustment Hydraulic flow diagrams are provided later in this sec tion These diagrams can be helpful in determining which parts are associated with a particular function For example the packing ejection cylinder is part of the load pushout function COMPACTION Before troubleshooting a unit it is important to remem ber that the compaction may vary with the following conditions 1 Type of refuse Tree branches dry le
61. RESSURES Operational Status Truck Running PTO Engaged To check the sliding top door open pressure 2 Move the top door control to fully retract and open the top door NOTE Maintain the engine RPM at the posted speed 3 Hold the control and read the gauge The pressure should be 900 PSI 100 PSI Exceeding the recommended pressure set ting could damage the top door cylinder IF NOT Operational Status Truck Off Keys Removed 4 To adjust the top door open pressure loosen the locknut on the port relief cartridge located at the center section of the 5 spool control valve assem bly Turn the adjustment clockwise to increase pressure and counter clockwise to decrease pres sure IF 900 PSI CANNOT BE ACHIEVED 5 Check the cylinder for bypass see Section 9 SER VICE AND REPAIR Operational Status Truck Running PTO Engaged 6 To check the sliding top door closed pressure move the top door control to fully extend and close the top door NOTE Maintain the engine RPM at the posted speed 7 Hold the control and read the gauge The pressure should be 600 PSI 100 PSI Exceeding the recommended pressure set ting could damage the top door cylinder IF NOT 8 Repeat steps 4 and 5 LEACH SECTION 7 CHECK OUT TOP DOOR SECTION INLET ssPooL O CONTROL E VALVE 900 PSI OPEN RETRACT EXTENDED CLOSED 600 PSI CLOSED 7 7 SECTION 7 CHECK OUT RESIDENTIAL CART
62. RODUCTION LOADING COMPACTION UNLOADING SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS GENERAL sa aspa a DESCRIPTION OF OPERATING CONTROLS PTO PUMP CONTROL PUMP SWITCH ENGINE 5 FORK TILT CONTROL DUAL OPERATING CONTROLS AIR LIFT ARM AUTO PACK BUTTON EMERGENCY STOP BUTTON AUTO RESET BUTTON TOP DOOR OPEN WITH CABLE CONTROL AUTO PACK SLIDING TOP DOOR SWITCH AIR CONTROL HINGED TOP DOOR TAILGATE OPEN WITH CABLE CONTROL AUTO PACK TAILGATE TOGGLE SWITCH TEST BUTTON OPERATING PROCEDURES PRE OPERATING WALK AROUND INSPECTION zu OPERATING INSTRUCTIONS GENERAL STANDARD TRANSMISSION AUTOMATIC TRANSMISSION HOT SHIFT OR DRY VALVE LOADING OPENING THE TOP DOOR LIFTING THE CONTAINER DUMPING THE CONTAINER AFTER RAISING THE LIFT ARMS LEACH 1 1 1 1 TABLE OF CONTENTS SECTION 3 OPERATION Continued LOWERING THE CONTAINER 3 10 TRAVEL POSITIONS 3 11 COMPAC
63. S Swivel Nut Torque Tube size Tube O D inches Foot Pounds Newton Meters 18 24 24 32 24 30 32 40 34 42 46 56 59 67 80 90 80 96 109 129 114 130 156 176 125 141 172 192 159 175 216 238 Do not lubricate the fitting SECTION 4 GENERAL REPAIR PRACTICES CAPSCREW MARKING AND TORQUE VALUES Usage Much Used Used at Times Used at Times Capscrew Diameter To 3 4 120 000 To 5 8 140 000 150 000 amp Minimum Tensile To 1 115 000 To 3 4 133 000 Strength PSI Quality of Material Min Commercial Med Commercial Best Commercial SAE Grade Number 5 6 or 7 8 CAPSCREW HEAD MARKINGS Manufacturers marks may vary These are all SAE Grade 5 3 line DI Capscrew Body Size Torque Torque Torque Inches Thread Ft Lb kg m Ft Lb kg m Ft Lb kg m 10 1 38 19 2 63 34 4 70 55 7 61 85 11 76 120 16 60 167 23 10 40 80 54 63 60 16 81 60 91 28 440 60 85 D 37 34 280 38 72 660 91 28 NOTES 1 Always use the torque values listed above when specific torque values are not available 2 The above is based on use of clean dry threads 3 Reduce torque by 10 when engine oil is used as a lubricant 4 Reduce torque by 20 if new plated capscrews are used 5 General Formula for calculating Torques is as follows Torque in Inch Lbs 2 x Nominal Diameter of Screw x Loads in Lbs where Load 80 of Yield Strength expressed in Lbs not pounds per square inch LEACH
64. TE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator action The operator moves the joystick control handle to the lift arms up position PNEUMATIC SYSTEM When the joystick control handle is moved chassis supply air flows in from the red line through the joystick valve and flows through a blue line to the air actuator on the lift arm work section of the 5 spool hydraulic control valve NOTE The operational speed of the lift arm cylinders can be controlled by feathering the joystick control handle The joystick control is a self centering valve Movement of the lift arm cylin ders may be stopped by releasing the joystick control handle LIFT ARMS MOVING DOWN NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the joystick control handle to the lift arms down position PNEUMATIC SYSTEM When the joystick control handle is moved chassis supply air flows in from the red line through the joystick valve and flows through a blue line to the air actuator on the lift arm work section of the 5 spool hydraulic control valve NOTE The operational speed of the lift arm cylinders can be controlled by feathering the joystick control handle The joystick control is a self centering valve Movement of the
65. TION 3 11 AUTO PAUK 3 12 UNLOADING WITH CABLE CONTROL WITH AUTO PACK 3 13 UNLOADING WITH AIR CONTROL OR RESIDENTIAL AIR CONTROL 3 14 SHUTDOWN 3 14 BODY TILT GENERAL ena 3 15 OPERATION 3 15 RAISING new hee ee 3 15 POWERING 644200 eee tans 3 15 SECTION 4 GENERAL REPAIR PRACTICES PREPARATION FOR SERVICE 4 1 REPLACEMENT 5 4 1 SERVICE BULLETINS 4 1 SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR 4 2 SAFETY DURING SERVICE AND REPAIR 4 2 WELDING PRECAUTIONS ELECTRIC 5 4 2 OXY ACETYLENE TORCHES 4 2 REMOVAL DISASSEMBLY AND REPAIR 4 3 REASSEMBLY AND INSTALLATION 4 3 ELECTRICAL TESTING CHECKING FOR VOLTAGE 4 3 CHECKING CONTINUITY 4 3 WELDING 4 4 LIFTING 5 5 4 4 CAPACITY OF LIFTING DEVICE REQUIRED FOR REMOVAL 4 4 SLING STRAP SPECIFICATIONS 4 4 CHAIN AND HARDWARE SPECIFICATIONS 4 4 TIGHTENING PROCEDURES FOR JIC FITTINGS 4 5 CAPSCREW MARKINGS AND TORQUE VALUES 4 7 SECTION 5 SPECIFICATIONS LUBRICANTS 5 1 H
66. Y AND INSTALLATION Coat all seals and o rings with clean fresh hydraulic fluid before reassembly Reassemble and install the cylinder in the approximate reverse order of disassem bly When installing the piston to the rod torque the piston nut to 502 24 Ft Lbs NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 12 may be nec essary to properly reassemble the cylinder SECTION 9 SERVICE AND REPAIR BOLT ON LIFT ARM ASSEMBLY DESCRIPTION OF BOLT ON LIFT ARM ASSEMBLY The bolt on lift arm assembly allows the individual replacement of specific components REMOVAL OF ARM Operational Status Truck Off Keys Removed 1 Remove the tilt cylinders and fork assembly as described in this section REMOVAL OF LIFT ARM ASSEMBLY 2 Place blocks or stands under the front of the lift arm assembly to support it during removal 3 Disconnect the rod end of the lift arm cylinder on the appropriate side 4 Disconnect the hydraulic hoses between the lift arm and body end cap NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains 5 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 2 000 Ibs to the lift arm Operate the lifting device no more than necessary to support the weight of the arm 6
67. YDRAULIC SYSTEM 5 1 PUMP 204071 5 1 LEACH HYDRAULIC FLUID RECOMMENDATION 5 1 HYDRAULIC FLUID 5 1 SECTION 6 PREVENTIVE MAINTENANCE GENERAL 6 OPERATING amp MAINTENANCE RECORDS 6 DAILY PREVENTIVE MAINTENANCE 6 LUBRICATION CHART ILLUSTRATION 6 6 6 6 HYDRAULIC SYSTEM ILLUSTRATION HYDRAULIC SYSTEM SERVICE CHECK FLUID LEVEL DAILY TABLE OF CONTENTS SECTION 6 PREVENTIVE MAINTENANCE Continued CHECK REPLACE RETURN LINE FILTER ELEMENT 2 aaa t asaris CLEAN TANK BREATHER WEEKLY LUBRICATION POINTS WEEKLY REPLACEMENT OF FILTER ELEMENT CAST ALUMINUM FILTER HOUSING STEEL FILTER HOUSING CLEANING HYDRAULIC STRAINER MONTHLY FLUSHING HYDRAULIC SYSTEM YEARLY WEEKLY PREVENTIVE MAINTENANCE MONTHLY PREVENTIVE MAINTENANCE YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE CONTAMINATION COMMERCIAL HYDRAULIC FLUID TESTING IN HOUSE HYDRAULIC FLUID TESTING SECTION 7 CHECK OUT PRESURE amp CYCLE TIME SETTING CHART GENERALE ce x Y pu ages B ope CHECK HYDRAULIC TANK FLUID LEVEL CHECK ELECTRICAL SYSTEM CHECK DUMPING CYCLE TIME CHECK PACKING CYCLE TIME CHECK SLIDING TOP DOOR CYCLE TIME CHECK TAILGATE CYCLE TIME CHECK PRESSURES
68. actuator Replace button Repair or replace the ALCM See Section 10 Pneumatic Controls for diagnostic procedures Air line loose or disconnected from the actuator Reconnect the air lines ensure that they are on the main control valve fully engaged into the push lock connectors on the actuator PACKING EJECTION PANEL WILL NOT GO TO NEUTRAL IN THE HOME POSITION Home position air limit switch out of adjustment Adjust the home position limit switch See Section 9 Service and Repair Home position air limit switch defective Replace home position limit switch Air line on home position limit switch kinked Replace or un kink the air line Air line on home position limit switch disconnected Reconnect the air line Air logic control module ALCM malfunctioning Repair or replace the ALCM See Section 10 Pneumatic Controls for diagnostic procedures O O PACKING EJECTION PANEL WILL NOT RETRACT IN AUTO PACK MODE Retract limit switch not adjusted Adjust air limit switch Retract limit switch defective Replace the retract limit switch Air actuator loose or binding Replace air limit switch Limit switch air line kinked or disconnected Replace or un kink the air line Air line on the actuator on the main control valve Reconnect the air lines ensure that they are loose or disconnected fully engaged into the push lock co
69. aken so that the cylinder case diameter is NOT distorted 4 Remove the four 4 nuts retaining the tie rods on the case end of the cylinder Remove the tie rods by sliding them out of the head gland 5 Carefully remove the case end cap of the cylinder 6 With a large wooden dowel at least 24 long care fully push the piston rod assembly out of the cylin der case 7 Unscrew the piston nut from the rod and remove and discard the rod o ring and piston seal 8 Slide the head gland off the rod and discard the o ring backup ring and rod wiper Also remove and discard the o ring from the case end cap Adjusting Cylinder SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF ADJUSTABLE FORK CYLINDER 1 Thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear 2 Check all cylinder components and mounting parts for damage and wear and replace as required Parts that must be replaced together o rings and seals are available as a repair kit from your local authorized Leach Distributor REASSEMBLY AND INSTALLATION OF ADJUSTABLE FORK CYLINDER Coat all seals and o rings with clean fresh hydraulic fluid before reassembly Reassemble and install the adjustable fork cylinder in the approximate reverse order of disassembly When installing the piston to the rod coat the threads of the piston nut with Lok tite 262 or equivalent Torque the piston nut to 150 175 Ft Lbs When
70. are provided Install these in the grooves located in the openings at each end of the filter element 2 8 Place the filter element 2 into the filter housing 4 sliding the filter element opening over the filter housing locator tube 9 Remove the gasket from the filter bypass valve and discard place the filter bypass valve into the open ing on top of the filter element 2 with the exposed spring facing upward 10 Lubricate and install a new filter housing cover o ring 3 into the groove on top of the filter housing 11 Place the filter bypass valve locator spring over the filter bypass valve locate the filter housing cover 1 over the spring the spring is centered by an extrusion on the inside of the filter housing cover Push downward on the cover locating the cover retaining flanges in front of the retaining cap screws Twist the cover counter clockwise until the cover retaining bolts are seated inside the cover retaining flanges 12 Tighten the filter housing cover retaining cap screws in a cross pattern to 120 foot pounds 68 Newton meters 13 Run the unit and check for leaks Extended operation of the unit without proper filtration will result in a reduced ser vice life of hydraulic system components 6 5 SECTION 6 PREVENTIVE MAINTENANCE REPLACEMENT OF FILTER ELEMENT For units with steel filter housing identifiable by the steel cover secured with six capscrews 1 Clean the filter housing
71. area completely to avoid contamination 2 Loosen the six capscrews retaining the filter hous ing cover 1 3 Using the handle rotate the housing cover clock wise until the large holes line up with each cap screw 4 Remove housing cover 5 Carefully remove the filter element 2 from the housing taking care not to shake or tap the ele ment 6 Using a solvent clean out the dual spring by pass opening located on the inner housing cover 7 Remove and replace the o ring 3 located on the inside of the housing cover Lubricate the new o ring and inside cover flange with a multi purpose grease 8 Lubricate the two o rings part number N72130 that are provided with the new filter element Install these in the grooves located in the openings at each end of the new filter element CLEANING HYDRAULIC STRAINER MONTHLY Close gate valve 11 Remove cover 7 and o ring 8 Unscrew strainer 9 Clean strainer 9 thoroughly in a suitable cleaning solvent Inspect for damage Replace if necessary Reinstall strainer 9 Replace the o ring 8 with a new one Install the o ring 8 carefully and secure the cover 7 to the strainer housing 10 with attaching hard ware 8 Open gate valve 11 UON N O O1 FLUSHING HYDRAULIC SYSTEM YEARLY 1 Retract all cylinders 2 Drain all fluid from the hydraulic tank into a suitable container by removing drain plug 12 Wipe out the bottom of the
72. aves furniture and any other items loaded into the body that take up relatively large amounts of space will reduce the compaction ratio 2 Moisture content of refuse Wet refuse will pack tighter than dry and consequently a wet load will weigh more than a dry load Wet refuse loaded into the body will increase the compaction rate 3 Operation of the equipment As with the operation of any type of heavy equipment one machine can yield different results with different operators Operating a front loader is a skill Placement of items in the hopper and not overloading the hopper are all learned skills that will affect the compaction rate of a unit 4 Preventive maintenance A properly maintained unit will achieve higher compaction rates than one that is poorly maintained The condition of the hydraulic system pump main relief setting and the condition of the cylinders will all have an effect on unit performance and compaction Some chassis components will also affect compaction The engine speed during packing fluid level in an auto matic transmission and the condition of the clutch assembly in a standard transmission chassis may also affect compaction LEACH SECTION 8 TROUBLESHOOTING j An electrical wiring diagram is included in Section 9 SERVICE AND REPAIR under ELECTRICAL SYS TEM Problems in the hydraulic system may be found by per forming the PRESSURE CHECKS found in Section 7 CHECK OUT
73. bling the auto mode RV1 provides a continu ous air signal through SV2 out port I ALCM to the air actuator on the main control valve extending the telescopic cylinders As the packing ejection panel extends from the home position the air supply to RV2 and PS2 through port is discontinued The packer panel home light is turned off and the packer panel par tially extended light is turned on SOL1 is energized to allow continuous air flow from RV4 When the auto pack button is released the air logic system automatically shifts to packing ejection panel retract mode SIDE DOOR OPEN WITH PACKING EJECTION PANEL HOME NOTE When the side door is closed the auto reset valve must be depressed to shift the ALCM back into the auto pack mode Operator Action None PNEUMATIC SYSTEM When the side door is opened a continuous air signal from the side door switch is sent through port F on the ALCM to PS1 turning on the side door open light and through SV1 to pilot port A on RV3 The same air sig nal continues through port E to the pilot port B on the auto reset valve cutting off the air supply to RV3 Air supplied from the side door switch to the auto pack extend and retract palm buttons is also cut off NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times LEACH SECTION 10 PNEUMATIC CONTROLS LIFT ARMS MOVING UP NO
74. body Pack previously dumped material before emptying container Leak in the hydraulic system Check system for leaking components or lines Tighten or replace Defective control valve Repair or replace control valve See Section 9 Service and Repair Defective or worn pump Repair or replace pump See Section 9 Service and Repair Leaking or by passing cylinder Repack or replace cylinder See Section 9 Service and Repair Sliding top door pressure low Check the sliding top door pressure See Section 7 Check out Air toggle switch defective Replace the air toggle switch LIFT ARMS DRIFTING DOWN Worn spool in main control valve Replace the valve section See Section 9 Service and Repair Lift arm cylinder by passing Repack or replace cylinder See Section 9 Service and Repair Piston backed off rod Tighten repair or replace cylinder See Section 9 Service and Repair Check valve in lift arm cylinders sticking Repair or replace the lift arm cylinders See Section 9 Service and Repair Binding actuator on the main control valve Replace the actuator SECTION 8 TROUBLESHOOTING DESCRIPTION OF HYDRAULIC SYSTEM The following is a description with flow diagrams of what happens in the hydraulic system during the load ing packing and unloading operations of the unit Operator action is presented and then a description of the hydraul
75. bs Operate the hoist to snug the lifting slings without applying strain on the cylinder 3 Remove the capscrew from the rod end cylinder pin 4 Make sure the cylinder weight is securely support ed and carefully remove the pivot pin Check for pivot pin and pin hub wear Operational Status CAPSCREW Truck Running PTO Engaged 5 Slowly move the lift arm control to completely retract the cylinder Operational Status Truck Off Keys Removed 6 Disconnect both the case end and rod end hoses Immediately cap and plug the hoses and cylinder ports to keep fluid in and dirt out 7 Remove the capscrew and pin from the case end 8 Slide the cylinder from the pivot hub Check for pivot hub and cylinder hub wear Whenever disassembling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly loosen the fittings 10 DISASSEMBLY OF LIFT ARM CYLINDER 1 Clean the mounting hardware and outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder components during disassembly 2 Secure the case end of the cylinder to a work bench or floor mount and the rod end to an over head lifting device with a minimum lifting capacity of 500 Ibs to ease the disassembly of parts 3 Remove the plugs from the ports and drain the fluid 4 Remove the setscrew and nylon plug from the head gland cap 5 Rotate the head gland
76. cks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage Anew rod wiper rod seal o rings and piston seals must be installed any time the cylinder is disas sembled Pay particular attention to the way the parts are positioned before disassembly Parts that must be replaced together are available in the form of a kit from your local authorized Leach Distributor PISTON PISTON ROD 5 Slowly operate the hoist to carefully pull the piston rod assembly out of the case 6 Unscrew the piston nut from the rod and remove the piston Remove and discard the piston seal and o ring 7 Slide the head gland off the rod and discard the head gland o ring backup ring rod seal and rod wiper PISTON SEAL O RING 572 PISTON NUT CYLINDER CASE REASSEMBLY AND INSTALLATION OF FORK TILT CYLINDERS Coat all seals and o rings with clean fresh hydraulic fluid before reassembly Reassemble and install the cylinder in the approximate reverse order of disassem bly When installing the piston to the rod torque the piston nut to 284 312 Ft Lbs NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 12 may be nec essary to properly reassemble the cylinder LEACH ADJUSTABLE FORK ASSEMBLY DESCRIPTION OF ADJUSTABLE FORK ASSEMBLY T
77. clearance as originally mounted 35845 35845 Commercial HYDRAULIC FLUID ONLY SPEED UP 106113 70979 LU 06114 106112 106113 106114 100895 LEACH 1 6 SECTION 1 SAFETY PRECAUTIONS CONSOLE CONTROL MAIN REMOTE MAIN e REMOTE 107256 BREAKER FUSE ID WARNING WARNING BAT Overhead clearance hazard Check overhead clearance before actuating any controls 15 A FRONT PUMP TEST 10 A B UP amp REAR DOOR Keep access door closed 85 210275 Commercial 10 A TOP DOOR CLOSED when ejector panel is in motion 10 A LIFT ARMS L OUT Use only the side access door 10 A ARMS ABOVE BODY to enter or exit the body Do not open access door unless f omm LIFT ARMS DOWN eall pressure against ejector 10 A PACK amp SIDE DOOR panel has been relieved 10 FRONT PUMP RELAY eengine is stopped and key removed ADANGER arms activated FORKS DOWN 10 AID amp CLEAR LITE 10 REAR WORK LIGHT from the cab 210021 eStand clear of 40A REAR DOOR arms at all times 10 A UTL amp CONT LIGHT 10A BEACON OR STROBE 108091 108091 4 DANGER e Stand clear of lift arms at all times Do not stand or cross under raised lift arms or container LIFT ARMS UP 108406 210267 DANGER Ensure top door is completely open before
78. container AWARNING WEEKLY Clean the brealher weekly with suitable thoroughly belore D ing brealher thal not be H CHECK REPLACE RETURN Fork and lift arm cylinders a LINE FILTER ELEMENT ful ly retra cted 2 Cur eu line filler is a M me du amp S cur among the hydraulic Its Stick to a strict maintenance Time Lapse Recommendations for Element Replacement 1 Aller the first 20 hours of hydraulic pump aparalion d hours of hydraulic pump mp 2 ours of hydraulic pui ner if so indicaled by me fitter he condilion of Ihe Hier element must be checked weekly by fooking al the visual indicator on the filter housing j 815 sm 17 18 AWARNING ACAUTION ACAUTION axe c you know salety n freezing climates all grease and ail E m ec s 3 st re at least xtended operation of unit whhout proper filtra i He ave co rating el tenes tion wil result in reduced service lile of nydraulic 5yslem components The unit must he In the following ejecti retracled rear door CLEANING HYDRAULIC closed and latched hit arms up fork uki fevel shou TANK STRAINER MONTHLY the narma ELT DO NOT FILL BEYOND THIS LINE m zn REF E Grease weekly 6 bee on Every 40 hrs of operation with EPI SERVICE grease or equivalent thy sing wi Fork weldment pivot 2 B Open the gate valve PTO drive shaft Fork til
79. container during the dumping process A CAUTION LIFT ARMS DOWN Do not exceed 55 degrees from vertical when dumping the container LOWERING THE CONTAINER 1 Raise the empty container to a vertical position using the fork tilt of the joy stick A CAUTION Lowering a container before tilting the forks to a vertical position could result in damage to the container truck cab or front loader EC 2 Lower the container As the lift arms go below the body height the ARMS ABOVE BODY indicator light should go out A CAUTION If ARMS ABOVE BODY indicator light stays on or comes on DO NOT MOVE THE UNIT 3 he forks must be level so the container can be set flat on the ground A CAUTION On units equipped with the hinged top door the top door must be closed before moving the vehicle Use the overhead mirror provid ed to ensure that the top door is closed 4 Back the unit away from the container A CAUTION Make sure the roadway is clear before trav eling in reverse 5 Stop the truck and position the arms and forks to the travel position 3 10 TRAVEL POSITIONS To determine the appropriate travel position for the forks and lift arms it should be determined whether the unit will be used in a residential or commercial applica tion Units which DO NOT have a container affixed to the forks and arms should be transported with the lift arms fully lowered and the forks fitted i
80. d be sure the old weld is completely cleaned out 2 When repairing a cracked weld the old weld should be completely removed before rewelding 3 When adding a part or attachment be sure the metal is clean before welding the part is properly located and the weld will not cause damage to adjacent parts 4 Use the following rods rod AWS number for welding Body except tailgate hinge area E6010 E6011 E6013 Tailgate hinge area TT E11018 E7018 Tailgate nananana E6010 E6011 E6013 TOD e a era Ea E6010 E6011 Packing ejection panel E11018 E7018 5 Use the following wire for welding all locations ER70 S LIFTING INSTRUCTIONS Because of the size and weight of the major components found on the Leach Millennium it is necessary to use suit able lifting devices for removal The following components require lifting devices for removal cylinders lift arms top door packing ejection panel and the tailgate CAPACITY OF LIFTING DEVICE REQUIRED FOR REMOVAL Se e E E ee Gee EE E EEE 1000 Ibs TOD OOO aae edie e ae oe E E E Coen E Ges oes E pee E a 4 1500 Ibs Ci AS EEEREN ee es we ae oe aoe we 54 4000 Ibs Packing ejection panel
81. d seals are available as a repair kit from your local authorized Leach Distributor REASSEMBLY AND INSTALLATION OF SLIDING TOP DOOR CYLINDER Coat all seals and o rings with clean fresh hydraulic fluid before reassembly Reassemble and install the sliding top door cylinder in the approximate reverse order of disassembly When installing the piston to the rod torque the piston nut to 80 88 Ft Lbs NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering the cylinder PISTON SEAL PISTON PISTON NUT SECTION 9 SERVICE AND REPAIR DESCRIPTION OF SLIDING TOP DOOR INSPECTION AND REPLACEMENT OF The top door consists of one fabricated assembly to SLIDING TOP DOOR close the top of the body The top door is controlled by a cylinder and opens and closes by operator action 1 Inspect the top door for cracked welds or breaks from the chassis cab Repair any defective area following all the safety precautions pertaining to welding described in Section 4 GENERAL REPAIR PRACTICES REMOVAL OF SLIDING TOP DOOR 2 Inspect the top door bearing slides for excessive wear and replace if necessary 3 Install the top door in the approximate reverse Operational Status order ol remove Truck Off Keys Removed 1 Disconnect the rod end of the top door cylinder as described earlier in this section NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about
82. d near the 5 spool con trol valve and in the lift arm circuit The purpose of the valves is to divert hydraulic fluid flow to the top door section of the 5 spool control valve until the top door is completely open CHECKING THE UPPER SEQUENCE VALVE PRESSURE Operational Status Truck Off Keys Removed 1 Connect a pressure gauge to the test nipple on the elbow located on the first section of the 5 spool control valve as shown in this section 2 Start the unit and engage the PTO 3 Starting with the lift arms in their lowest position move the lift arm control to raise the lift arms While the arms are moving up the pressure will increase to 1850 PSI NOTE Make sure that the lift arm air limit switch on the lift arm pivot tube is not contacted while per forming the test IF NOT Operational Status Truck Off Keys Removed Adjust the sequence valve 1 Remove the caps and loosen the locknut on the sequence cartridge 2 Turn the adjustment screw in clockwise to raise the pressure out counter clockwise to lower the pressure NOTE The sequence valve connected to port A top port controls the upward movement of the lift arms The sequence valve connected to port lower port controls the downward move ment of the lift arms SEQUENCE VALVES 1850 PSI CHECKING THE LOWER SEQUENCE VALVE PRESSURE Operational Status Truck Off Keys Removed 1 Connect a pressure gauge to the test nipple on th
83. ded and then retracted should take 26 to 30 seconds in the auto pack mode IF NOT 2 Adjust the engine RPM to achieve the correct cycle time If correct cycle time cannot be achieved refer to Section 8 TROUBLESHOOTING CHECK SLIDING TOP DOOR CYCLE TIME Operational Status Truck Running PTO Engaged 1 Move the top door control while maintaining the engine at the RPM shown on the dash decal A complete cycle the cylinder fully extended and then retracted should take 18 to 24 seconds TOP DOOR OPEN INDICATOR LIGHT GREEN TOP DOOR PARTIALLY OPEN INDICATOR LIGHT YELLOW INDICATOR LIGHT RED SECTION 7 CHECK OUT LIET ARMS FORK TILT UP 26 30 SECONDS DOWN if AWA 18 24 SECONDS TOP DOOR CLOSE SLIDING TOP DOOR TOGGLE SWITCH TOP DOOR OPEN CABLE CONTROL SLIDING TOP DOOR LOCKOUT SWITCH 7 3 SECTION 7 CHECK OUT CHECK TAILGATE CYCLE TIME Operational Status Truck Running PTO Engaged complete cycle the cylinders fully extending and then retracting should take approximately 20 sec onds CHECK PRESSURES The pressure checks provided below will indicate the operating condition of the hydraulic system Detailed adjustment procedures are provided later in this section and are referenced at the appropriate chec
84. der components and mounting parts 2 Secure the case end of the cylinder to a work for damage and wear and replace as required bench or floor mount and the rod end to an over Parts that must be replaced together o rings and head lifting device with a minimum lifting capacity seals are available as a repair kit from your local of 500 Ibs to ease the disassembly of parts authorized Leach Distributor 3 Remove the plugs from the cylinder ports and drain the fluid 4 Rotate the head gland and unscrew it from the cylinder case Slowly operate the hoist to carefully REASSEMBLY AND INSTALLATION OF pull the piston rod assembly out of the case TAILGATE CYLINDER 5 Unscrew the piston nut from the rod and remove and discard the rod o ring and piston seal Coat all seals and o rings with clean fresh hydraulic 6 Slide the head gland off the rod and discard the o fluid before reassembly Reassemble and install the tail ring wiper seal and rod seal gate cylinder in the approximate reverse order of disas sembly When installing the piston to the rod torque the piston nut to 215 x10 Ft Lbs NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering the cylinder PISTON SEAL PISTON PISTON ROD WIPER SEAL CYLINDER CASE DESCRIPTION TAILGATE The tailgate assembly is the structure which closes the rear of the body It is raised to allow ejection of refuse fro
85. ders can be controlled by feathering the joystick control handle The joystick control is a self centering valve Movement of the lift arm cylin ders may be stopped by releasing the joystick control handle 10 4 SLIDING TOP DOOR OPEN NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the top door toggle switch upward to the top door open position PNEUMATIC SYSTEM When the top door toggle switch is moved upward to the top door open position chassis supply air flows in from the red line through the top door valve and flows through a green line to the air actuator on the top door work section of the 5 spool hydraulic control valve NOTE The top door toggle switch is a spring centered valve Movement of the top door may be stopped by releasing the top door toggle switch SLIDING DOOR CLOSED NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the top door toggle switch down ward to the top door close position PNEUMATIC SYSTEM When the top door toggle is moved downward to the top door close position chassis supply air flows in from the red line through the top door valve and flows through a green line to the air actuator on the top door work sec tion of the 5 spoo
86. ditive content C If the sample shows distinct rings the fluid should be changed D If a distinct dark spot remains in the middle but a lighter colored fluid migrates outward in the blotter paper the fluid is about to dump or already has sludge or other by products into the system The time for replacement of this fluid has already passed Kits are available from your fluid supplier to test for acid content in much the same way you would test the con dition of swimming pool water A shift in acid content may indicate a breakdown in the fluid KEEP ACCURATE DATED RECORDS OF ALL PER TINENT INFORMATION GAINED FROM THESE LEACH The Check Out Section is provided as a preventive maintenance tool to ensure that the Leach Millennium front loading refuse unit is operating at peak efficiency which in turn leads to higher payloads and less down time due to malfunctions The items listed in this section should be checked weekly or every 40 hours of opera tion which occurs first Pressure checks are used to check the condition of the cylinder seals and valve components The pressures should be checked only after the hydraulic fluid reser voir is filled to the correct capacity and the hydraulic fluid has reached a minimum operating temperature of 100 Fahrenheit 37 Celsius A 0 5000 PSI 0 345 BAR gauge can be attached to the quick connect cou pling on the five spool valve inlet located at the right passenger side
87. draulic pump opera tion 3 Thereafter every 250 hours of hydraulic pump operation or sooner if so indicated by the filter replacement indicator CLEAN TANK BREATHER WEEKLY Clean the air breather 6 every week Replace the breather yearly or when it cannot be cleaned ade quately LUBRICATION POINTS WEEKLY Weekly or every 40 hours of operation lubricate the unit as shown on the LUBRICATION CHART in this section SECTION 6 PREVENTIVE MAINTENANCE REPLACEMENT OF FILTER ELEMENT For units with cast aluminum filter housing iden tifiable by the solid cast aluminum cover secured with four capscrews 1 Clean the filter housing area completely to avoid contamination 2 Loosen the four capscrews retaining the filter hous ing cover 1 approximately six revolutions 3 While pushing downward on the housing cover rotate the cover clockwise until the cover retaining flanges clear the retaining capcrews The filter bypass spring locator produces mild tension against the filter housing cover Use caution when removing cover release spring tension slowly 4 Remove the bypass valve and spring locator from the filter element 2 5 Carefully remove the filter element 2 from the housing taking care not to shake or tap the ele ment 6 Remove and discard the filter housing cover o ring 3 from the top of the filter housing 4 and clean the o ring groove 7 Lubricate the two o rings part number 934371 that
88. dumping targe containers in 106260 4 DANGER lt FORK REAR TILT ARM DOOR DOOR FRONT LOADER CONTROLS FORK TILT LIFT ARM TOP DOOR REAR DOOR 204718 Stand clear when 204742 AUTO PACK duini e Tailgate latch is STOP 1 unloading cycle activated from cab not stand or Stand clear of 108476 cross under raised tailgate latch at all times 38979 210268 CAUTION Serious pump damage wili result if vehicle is operated at highway speed with pump engaged Move unit with pump engaged only as required to perform its function as a refuse collection compaction vehicle at speeds less than 10 mph tailgate CONTAINER STROBE BEACON WORK LIGHT LIGHT LIGHT ON ON ON 101767 106496 108325 108408 108323 108326 101767 NOTICE POWER A TAKE OFF OPERATION MECHANICALLY SHIFTED 0 5 Maximum capacity of container lifting system is 8000 LBS 204161 204161 100930 1 7 SECTION 1 SAFETY PRECAUTIONS SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW CAB GUARD TOP DOOR BODY LIFT ARM ce ae i H AMA iPr HYDRAULIC LIFT ARM TANK CYLINDER HOPPER TAILGATE LIFT CYLINDER giis SEED TAILGATE PACKING EJECTION PANEL LOC a ag lt lt 2
89. e elbow located on the first section of the 5 spool control valve as shown in this section 2 Start the unit and engage the PTO 3 Starting with the lift arms in their highest position move the lift arm control to lower the lift arms while the arms are moving down the pressure will increase to 1850 PSI NOTE Make sure that the lift arm air limit switch on the lift arm pivot tube is not contacted while per forming the test IF NOT Operational Status Truck Off Keys Removed Adjust the sequence valve 1 Remove the cap and loosen the locknut on the sequence cartridge 2 Turn the adjustment screw in clockwise to raise the pressure out counter clockwise to lower the pressure NOTE The sequence valve connected to port top port controls the upward movement of the lift arms The sequence valve connected to port lower port controls the downward move ment of the lift arms LEACH SECTION 7 CHECK OUT CHECK PACKING EJECTION PANEL WEAR BLOCKS Operational Status Truck Off Keys Removed WEAR 1 Visually inspect all packing ejection panel wear BLOCKS blocks for excessive wear These items must be replaced before there is metal to metal contact 2 Shim or replace worn parts as described in Section 9 SERVICE AND REPAIR under packing ejection panel Y PACKING EJECTION PANEL CHECK AIR REGULATOR PRESSURE WITH AIR CONTROLS Operational Status Truck Running PT
90. e Section 2 SAFETY PRECAUTIONS Never enter under the raised refuse body unless both body props are in position LEACH SECTION 3 OPERATION BODY TILT SWITCH RUBBER HOOK BODY PROP BODY TILT CYLINDER 3 15 SECTION 3 OPERATION SECTION 4 GENERAL REPAIR PRACTICES Proper service and repair is important for the safe reliable operation of all mechanical prod ucts The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as rec ommended It is important to note that deviating from these procedures could cause damage to the unit or PREPARATION FOR SERVICE Proper preparation is very important for efficient and safe service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and reduce the incidence of misplaced tools and parts If the portion of the unit to be repaired is excessively dirty it should be cleaned before work starts Cleaning will occasionally uncover trouble sources Tools instruments and parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a needless delay Special tools required for a job are listed in Section 12 SERVICE TOOLS REPLACEMENT
91. e unit Before attempting any repair of the unit become thor oughly familiar with the OPERATION instructions Section 3 and GENERAL REPAIR PRACTICES Section 4 Also before performing any work on the unit know and OBSERVE all SAFETY PRECAUTIONS listed in Section 2 There are some procedures in this section that will require that the truck is running In these instances the operational status will be indicated Otherwise make sure that the truck is shut off and the keys are removed The pressure of the hydraulic system and resulting movement of the unit s parts can cause serious injury or death MAIN COMPONENT LOCATION Fork tilt cylinders Fork assembly Lift arm cylinders Lift arm assembly Tailgate cylinders Tailgate Top door cylinder Sliding top door Hinged top door Packing ejection cylinders Packing ejection panel Main control valve Controls Hinged top door sequence valve front mounted ee E 17 pnm Y RONM ADOOMNDOAWND ok Ol SEQUENCE VALVES 1850 PSI SECTION 9 SERVICE AND REPAIR TEST FOR BYPASSING CYLINDERS NOTE Before testing any cylinders make sure main relief pressure is set at 3000 PSI as described under Main Relief Pressure Check Section 7 CHECK OUT Operational Status PTO Engaged Truck Running 1 Move the control to fully
92. e welds for cracks 4 Make sure that the tailgate latch hooks are secure ly locked 5 Check the lift arm bearing area to ensure that no metal contact is present between the pivot tube and bearing holder Never under any circumstances enter the body if the truck is running Always make sure the truck engine is off and the keys are in your pocket before entering the body 6 Look around the packing ejection panel Clean out any refuse caught in this area that could hamper the smooth movement of the panel Be careful when cleaning around the telescopic cylin ders Avoid hitting the exposed cylinder rods with shov els or debris LEACH SECTION 3 OPERATION LIT ur ril 900 oXYy 2 mil 2p TAILGATE LATCHES 3 5 SECTION 3 OPERATION 7 Make sure that the side access door is closed and locked securely A CAUTION The access door must be closed for the INDICATOR LIGHT packing ejection panel to be moved If the access door is opened the packing function stops and the controls will not work The door must be closed and latched and the reset activated before the operation can resume Check Indicator Light Console for proper illumination of door ajar light when ruck engine i i truck engine side access door is open Ne
93. each Distributor REASSEMBLY OF JOYSTICK ASSEMBLY 1 Coat all seals and o rings with Dow Corning 44 or equivalent pneumatic grease Reassemble in the approximate reverse order of disassembly 2 When the joystick is reassembled and installed the ball socket can be adjusted for sensitivity Pull the dust boot up and loosen the jam nut on the ball socket assembly Turn the actuator nut clockwise to increase sensitivity counter clockwise to decrease sensitivity LEACH SECTION 10 PNEUMATIC CONTROLS CONNECTOR v LOCK NUT T ACTUATOR NUT BODY CASTING 10 7 SECTION 10 PNEUMATIC CONTROLS ALCM LAYOUT PLUG WHEN LIFT ARM LOCKOUT IS NOT USED LIFT ARM LOCKOUT 9 20785 01 v5 SECTION 10 PNEUMATIC CONTROLS ALCM SCHEMATIC PRESSURE TO DIRECTIONAL VALVE FROM JOYSTICK PACKER LOCKOUT AnM LOCKOUT PLUG WHEN LIFT PACK ARM LOCKOUT IS NOT USED E a 4EXTERNAL AIR SUPPLY y REQUIRED FOR LIFT 1 ao ARM LOCKOUT Hy ait CUNT LOUPE SAMT a a AUTO PAK ES CONTROL 252 N O DEN DP H TEN 0 MID AUTO PACK RET LIMIT HOME MODE 1 2 LV1 L PB3 770 HELE JAIR SUPPLY TO LIMIT VALVES ALCM PORT AIR HOSE COLOR VOCATION DESIGNATION Yellow Emergency
94. ed PSI fluid should exit port T 1 Remove the power on demand valve from the front IF NOT of the body Plug all hoses and tubes on the body 5 Loosen the locknut on the relief cartridge located to prevent contamination next to port EF Turn the adjustment clockwise to increase pressure or counter clockwise to 2 Plug all of the ports on the power on demand decrease pressure valve EXCEPT ports IN and using the prop er size metal o ring plugs IF 3100 PSI CANNOT BE ACHIEVED 6 Replace the power on demand relief cartridge 3 Connect a porta power with a gauge capable of reading 0 5000 PSI to port IN 7 Reinstall the power on demand valve on the unit 7 9 SECTION 7 CHECK OUT ADJUSTING THE ADJUSTABLE FORK VALVE The adjustable fork valve directs hydraulic fluid to the adjustable fork cylinder by operating a lever which is attached to the valve It can direct the hydraulic fluid to either the case end or the rod end of the cylinder depending on which way the operator chooses to adjust the fork This valve is located inside the cab of the truck within reach of the operator This valve incorporates a relief cartridge to guard against excessive pressure build up in the adjustable fork cylinder CHECKING THE RELIEF PRESSURE Operational Status Truck Off Keys Removed 1 Remove the line at the case end of the adjustable fork cylinder Plug the cylinder port 2 Install 0 2000 PSI gauge
95. en at a pressure of 900 PSI KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Oylinder Exhaust LEACH 8 13 SECTION 8 TROUBLESHOOTING SLIDING TOP DOOR CLOSES Operator Action The operator moves the top door control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the case end of the top door cylinder As the cylinder extends return flow from the rod end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinder is fully extended the port relief will open and allow the pressure to build to 600 PSI KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder 8 14 Exhaust SECTION 8 TROUBLESHOOTING HINGED TOP DOOR OPENS Operator Action The operator continues to hold the lift arm control in the lift arm up position Top door opening movement is automatic HYDRAULIC SYSTEM The operator action shifts the control valve directing fluid to the rod end of the lift arm cylinder through a sequence valve The lift arms raise and contact a nor mally
96. erating and weath er conditions See Section 6 PREVENTIVE MAIN TENANCE for additional information about servic ing the hydraulic tank CHECK ELECTRICAL SYSTEM 1 Check the warning lights in the cab by pushing the test button All the lights should illuminate when test button is activated 1 Top Door Open 5 Side Door Open 2 Top Door Partial 6 Tailgate Ajar Closed 7 Packer Panel Home 3 Top Door Closed 8 Packer Panel Part Ext 4 Arms Above Body 9 Pump On NOTE The automatic illumination of the warning lights will be tested while checking the unit s hydraulic operations 2 Check all clearance lights stop lights tail lights and turn signals 7 2 If the unit being worked on has a hinged top door it is important to refer later in this sec tion for specific instructions CHECK DUMPING CYCLE TIME Operational Status Truck Running PTO Engaged 1 Move the lift arm control to fully raise the arms then immediately lower the lift arms A complete cycle should take 13 to 15 seconds Do not tilt forks NOTE See Section 10 for units equipped with the hinged top door IF NOT 2 Adjust the engine RPM to achieve the correct cycle time Change the dash decal to show the new rec ommended RPM CHECK PACKING CYCLE TIME Operational Status Truck Running PTO Engaged 1 Move the packing control while maintaining the engine at the RPM shown on the dash decal A complete cycle the cylinders fully exten
97. eservoir and the front tandem axle Check that there is no liquid in the clear separator and drain if necessary Check the gauge at full system pressure it should read 105 PSI Pressure protection valve Located on the air supply reservoir this valve will disable the Leach pneumatic system if system pressure drops below 70 PSI Check for proper operation Air lines and fittings These the multi colored poly lines used throughout the system Check for any kinks plugs or breaks Check the lines at the fittings for leaks and secure connections Pay particular attention to the air lines black leading to the air actuator on the main control valve These are secured by push lock type con nectors Make sure they are completely inserted into the connectors and the push locks are holding them in place Proximity switches Located on each tailgate latch mechanism 2 they control the auto pack full eject lockout Check for proper operation and adjustment See Section 11 ELECTRICAL 10 5 SECTION 10 PNEUMATIC CONTROLS ALCM DIAGNOSTIC PROCEDURES Before attempting to diagnose the ALCM valve array perform the BASIC CHECKS listed in this section Once those have been eliminated check the ALCM auto pack board for any external cracks or splits that might cause a loss of air pressure If the ALCM auto pack board is free of any external leaks remove the four 4 capscrews that fasten the ALCM to the main service panel and view t
98. extend the cylinders FULLY EXTENDED Operational Status Truck Off Keys Removed 2 Disconnect and cap the hydraulic line which con nects to the rod end of one 1 cylinder at a time Operational Status Truck Running PTO Engaged OBSERVE FLUID FLOW 3 Move the control to apply hydraulic pressure to the case end of the cylinder s Hold and observe the fluid flow from the open port on the rod end The flow of hydraulic fluid should be no more than 2 fluid Ounces per minute A flow greater than 2 ounces indicates an excessively leaking piston seal If the cylinder does not leak excessively con tinue the test RECONNECT HOSE Operational Status Truck Off Keys Removed 4 Reconnect the hydraulic line to the rod end of the Operational Status cylinder y Truck Running PTO Engaged 7 Move the control to apply hydraulic pressure to the rod end of the cylinder s Hold and observe the Operational Status fluid flow from the port on the case end of the cylin der The flow of hydraulic fluid should be no more PTO Engaged than 2 fluid ounces per minute A flow greater than 2 ounces indicates an excessively leaking piston seal Disassemble the cylinder and replace the seal as described later in this section If the cylinder Operational Status does not leak excessively continue the test Truck Off 6 Disconnect and cap the hydraulic line which con nects to the case end of one 1 cyli
99. ft arms raised and the packing ejection panel at the rear of the body before attempting to tilt the body RAISING Operational Status Truck Off Keys Removed Before operating the body tilt the lift arms must be in the raised position the packing ejection panel must be at the rear of the body and the rubber hooks located on each body prop must be loosened When the body tilt switch is moved to the raise position the self contained hydraulic pump and reservoir is activated allowing fluid flow to the case end of the body tilt cylinders As the cylinders extend the body props move with the body As they approach the maximum extended length of the cylinders the props will automatically engage a notch on the cylinder brackets When both props are posi tioned into the notched area of the bracket feather the switch to the lower position which will allow the cylin ders to slightly retract and cause the body props to sup port the body LOWERING Operational Status Truck Off Keys Removed Before lowering the body connect the rubber hooks on each side of the body to the body props then slightly raise the body to release the body props Lower the body so that the body props clear the cylinder bracket Stop lowering the body and loosen the rubber hooks from both body props Continue to lower the body until the body contacts the chassis frame rails the entire length Reconnect the rubber hooks NOTE Before operating the body tilt se
100. gle switch located on the ser vice panel controls the movement of the sliding top door Moving the toggle switch up will open the top door Pushing the toggle switch down will close the top door HINGED TOP DOOR If the unit is equipped with the hinged top door the opening and closing of the door is automatic and func tions each time the lift arms are raised or lowered On units equipped with a hinged top door a lockout switch is located on the service panel which allows the lift arms to be raised and the top door to remain closed if selected TAILGATE OPEN WITH CABLE CONTROL AUTO PACK The tailgate is opened by moving the tailgate control lever to the open position Moving the tailgate control lever to the tailgate closed position will close and latch he tail EE TAILGATE TOGGLE SWITCH The tailgate toggle switch located between a guard on the main service panel controls the movement of the tailgate Moving the toggle switch up will raise the tail gate Pushing the toggle switch down will lower the tail gate TEST BUTTON Depressing this button located in the center of the bot tom row of the indicator light console will cause all of the indicator lights on the control console to illuminate If any of the indicator lights fail to illuminate remove the unit from service 3 4 TOP DOOR PARTIALLY OPEN INDICATOR LIGHT YELLOW TOP DOOR OPEN INDICATOR LIGHT GREEN INDICATOR LI
101. he Leach distributor for exchange The labor to replace or repair the part shall be the responsibility of the customer There is no warranty on expendable items wear components or used paris Leach Company reserves the right to redesign and or discontinue the manufacture of parts compo nents and assemblies at any time FOREWORD The Leach Company has been a leader in the refuse industry for over 100 years The Leach Millennium is the industry standard for both quality and performance We at the Leach Company are justifiably proud of the quality engineering material and workmanship that goes into each and every packer we produce This commitment to quality extends to the best parts service and dis tributor organization in the industry One area of great importance to us at the Leach Company is your safety This unit was built in accordance with the American National Standards Institute ANSI standard for Mobile Refuse Collection and Compaction Equipment Safety Requirements ANSI Z245 1 1992 Before operating this unit please read and understand the safety precautions found in Section 1 of the Service and Operators manual They are important and are provided to assist you in the safe operation of the unit This manual was produced with the intention of providing clear concise instructions for the prop er operation and servicing of your refuse packer It was produced with the latest information avail able at the time of publication
102. he adjustable fork assembly connects with a contain er for loading and dumping of refuse The adjustable fork assembly allows for 16 of travel on the right fork to adapt to varying container sizes The electric over hydraulic switch which controls activation of the hydraulic circuit should remain in the off position and only be turned on to adjust fork width The need for removal of the fork assembly is rare and is generally limited to replacement of the entire assembly REMOVAL OF ADJUSTABLE FORK ASSEMBLY Operational Status Truck Off Keys Removed 1 Disconnect the rod end cylinder pin of both tilt cylin ders as described earlier in this section NOTE See Section 4 GENERAL REPAIR PRAC TICES for detailed information about the cor rect use of slings and lifting chains 2 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 1600 Ibs to the fork assembly Operate the lifting device no more than necessary to support the weight of the fork assembly 3 Remove the capscrews and pivot pin 4 Operate the lifting device to free the fork assembly from the lift arms 5 Position the fork assembly on supports to facilitate inspection Supports must be capable of holding 1600 Ibs Pivot SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF ADJUSTABLE FORK ASSEMBLY 1 Inspect all portions of the fork assembly Check pivot holes and pivot pin bushings for enlargement or
103. he bottom of the board Visually check for any internal cracks or splits between the visible air passages in the ALCM auto pack board Also look for any plugged or restricted passages If the ALCM auto pack board appears to be satisfacto ry proceed with the following diagnostic procedures following the steps by the particular malfunction you are experiencing NOTE Use the pneumatic schematics in this section to aid in the location of various components The shuttle and relay valves on the ALCM are equipped with buttons on each end to manually shift the individ ual valve The relay valves have a silver button on one end and a blue button on the other end The shuttle valves have white buttons on both ends When referring to top or bottom the top of the valves are facing the packer and if applicable the lift arm lock out module s Packing ejection panel in home position auto pack will not engage Push and hold the blue button on RV2 If no response push the top button on SV2 Packing ejection panel will not stop at the auto pack limit Push and hold the blue button on RV1 Packing ejection panel at the auto pack limit position auto retract will not engage Push and hold the blue button on RV1 If no response push and hold the silver button on RV4 packer lockout module If no response push and hold the blue button on RV3 If no response push and hold the bottom button on SV3 Packing ejection panel finishes auto pack
104. he suction hose Replace the o rings on the pump Tighten or repair any leaks in the hydraulic system Check and repair cable or air control See Section 9 Service and Repair Check system for leaking components or lines Tighten or replace Repair or replace pump See Section 9 Service and Repair Repair or replace control valve See Section 9 Service and Repair Repair repack or replace fork cylinders See Section 9 Service and Repair Check main relief pressure and adjust See Section 7 Check out Check the fork tilt relief pressure See Section 7 Check out Check main relief pressure and adjust See Section 7 Check out Repair or replace pump See Section 9 Service and Repair Repair repack or replace cylinder See Section 9 Service and Repair Check packing relief pressure See Section 7 Check out Clean areas between the packing ejection panel and the body SECTION 8 TROUBLESHOOTING POSSIBLE CAUSE REMEDY PACKING EJECTION TELESCOPIC CYLINDER EXTENDS SLOWLY 1 Cylinder is by passing hydraulic fluid internally Replace worn piston seals Replace cylinder See Section 9 Service and Repair 2 Pump is worn or defective Repair or replace the pump See Section 9 Service and Repair 3 Dump valve sticking Clean or replace the dump valve Cable or air actuator does not open control valve Check and repair cable or air ac
105. hese transceivers may match the wavelength of the proximity switch field This can cause the switch to function when the radio system is transmitting Through proper adjustment and electri cal connections this can be avoided When installing a new proximity switch follow the instructions below to assure correct performance of the electrical system 1 Center the actuator to and in front of the sensing face of the switch 2 Adjust the distance between the actuator and the sensing face to 0 140 3 5 mm 3 Connect any unused wire to the red wire on the switch constant power mx F _ 5 2 5 gue t mae x 42 2 de ILE 3 M di de Q m PE i 3 55 2 ides 2 so 4 X 5 e 5 amp 5 E 1 B 5 a mY xo lt gt 475 a e E J gt J 1222223 5 p ge ee ee NINES LH m D DII NI 5 al m 22 22292242225 11 4 SI wv s 2 AN 2 4 4 2 52422 2 22 5 44 y e si 3 PJ 3 Bi i E I ic E 5 DER T M J 5 5 5 5 5 S 5 a 5 e e l a e _ aM a o O e 5
106. hichever comes first with SAE 10 or equivalent NOTE In below freezing climates all grease and oils should have a cold test rating of at least 20 F 6 3 SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM 6 4 HYDRAULIC SYSTEM SERVICE Proper maintenance of the hydraulic components is of vital importance to the service life of the system and the operation of the unit as a whole CHECKING FLUID LEVEL DAILY Place all cylinders in the retract position When check ing the fluid level in the hydraulic tank also note any frequent or sudden loss of fluid This may indicate leak age which must be traced and corrected to avert equipment failure and possible damage to other com ponents If low fill the hydraulic tank to the NORMAL FILL LEVEL with hydraulic fluid as specified in Section 5 SPECIFICATIONS according to operating and weather conditions The condition of the filter element 2 must be checked daily by looking at the visual indicator on the filter Refer to item 5 on the tank illustration CHECK REPLACE RETURN LINE FILTER ELEMENT The return line filter 2 is a vital component of the hydraulic system Without proper filtration problems are bound to occur among the hydraulic system compo nents Stick to a strict maintenance schedule for this item Time Lapse Recommendations for Element Replacement 1 After the first 20 hours of hydraulic pump operation 2 After the next 50 hours of hy
107. ic flow and the interaction of system compo nents i e valves and cylinders follows Before pro 0000 o PN ceeding to the flow diagram refer to the illustration and NY COSS become familiar with the system component nomencla mm ture SYSTEM COMPONENT NOMENCLATURE NOTE Units equipped with a front mounted pump also have a 2GPM flow control valve located at the inlet to the 5 spool control valve assembly Since the front mounted pump requires some fluid flow to lubricate and cool the continuously running pump this flow must be continuously returned to tank KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders q Tailgate Cylinders S 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder 8 8 TILT FORKS UP Operator Action The operator moves the tilt control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the rod end of the tilt cylinders As the cylinders retract return flow from the case end of the cylinder is directed through the control valve and then return line filter to the tank When the cylinders are fully retracted the main relief will open at 3000 PSI and direct the rod end flow to the tank KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders
108. ilable Check the specific unit being operated to determine the control type LEACH SECTION 3 OPERATION SERVICE PANEL AUTO PACK AIR CONTROL CONTROL CONSOLE INDICATOR LIGHT CONSOLE WITH AUTO PACK SERVICE PANEL SECTION 3 OPERATION PTO PUMP CONTROL The PTO Power Take Off is engaged to put the hydraulic pump in operation The exact location of the control will vary depending on the type of PTO Pump truck cab style and control panel location The PTO Pump may be engaged by the use of a lever rock er switch or push pull cable Be sure to read all the safety decals associated with the PTO before attempt ing operation When the pump is engaged an indicator light will illuminate PUMP SWITCH On units equipped with a front mounted pump the con trol switch is turned on to engage the pump and off to disengage the pump ENGINE SPEED UP Engine speed hydraulic flow rate is controlled by the operator depressing the accelerator A decal located on the dash gives the maximum rec ommended engine revolutions per minute RPM to be used when operating the Front Loader DO NOT EXCEED THE POSTED RPM NOTE Engine speed will vary between PTOS chassis and pump arrangements FORK TILT CONTROL When the joystick or cable control is moved to the tilt down position the forks will tilt down Movement
109. ing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders SECTION 8 TROUBLESHOOTING Pump Pressure Top Door Cylinder Exhaust LEACH SECTION 8 TROUBLESHOOTING LOWER LIFT ARMS Operator Action The operator moves the lift arm control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the case end of the lift arm cylinders As the cylinders extend return flow from the case end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinders are fully extended the pressure will increase to a port relief setting of 2000 PSI KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Cylinder Exhaust 8 12 SECTION 8 TROUBLESHOOTING SLIDING TOP DOOR OPENS Operator Action The operator moves the top door control HYDRAULIC SYSTEM The operator action shifts the control valve directing the pump flow to the rod end of the top door cylinder As the cylinder retracts return flow from the case end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinder is fully retracted the port relief will op
110. ion even when the auto reset control valve to retract the cylinders palm button is depressed KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Oylinder Exhaust LEACH 8 19 SECTION 8 TROUBLESHOOTING PACKING AUTO PACK Operator Action None KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder 8 20 HYDRAULIC SYSTEM When the pneumatic switch at the auto pack area is contacted the main control valve is shifted directing fluid flow to the rod end of the packing ejection cylin ders As the cylinders retract flow from the case end is directed through the dump valve directly to the tank When the cylinders have completely retracted a sec ond pneumatic switch is contacted which shifts the air logic and main control valve to neutral Pressure Exhaust SECTION 8 TROUBLESHOOTING EJECTION Operator Action The operator depresses the auto pack palm button and holds it HYDRAULIC SYSTEM The operator action shifts the control valve directing fluid flow to the case end of the packing ejection cylin ders extending the packing ejection cylinders to the rear
111. istances at highway speeds 3 The Top Door Partially Open indicator light instructs the operator that the top door is not fully open for loading or closed for travel 4 If the unit is equipped with the hinged top door the opening and closing of the door is automatic and functions each time the lift arms are raised or low ered A top door lockout switch is standard on hinged top door units The lockout switch will allow the lift arms to be raised without lifting the top door for servicing the chassis engine On units with the sliding top door the oper ator must fully open the door prior to lifting the container Damage to the container or the front loader may result if the container is dumped onto a closed or partially opened door 3 8 CONTAINER SLEEVES TOP DOOR PARTIALLY OPEN INDICATOR LIGHT YELLOW TOP DOOR OPEN INDICATOR LIGHT GREEN RED SLIDING TOP DOOR TOGGLE SWITCH TOP DOOR OPEN CABLE CONTROL SLIDING TOP DOOR LOCKOUT SWITCH LIFTING THE CONTAINER Check to ensure that there is adequate overhead clearance to raise the lift arms and top door for dumping the container Prior to lifting any container ensure the ejector panel is in the home position Check the indicator light console to ensure the Packer Home Light is illuminated Under no circumstances should a container be raised on the lift arms if the Packer Panel Part Ext light is illuminated 1 Raise
112. kout proce dure Prior to performing pressure checks Operational Status Truck Off Keys Removed 1 Connect a pressure gauge to the test nipple locat ed on the elbow on the inlet of the 5 spool control valve assembly 2 Start the unit and engage the PTO Pump 3 Perform the following checks in order CHECK MAIN RELIEF PRESSURE Operational Status PTO Engaged Truck Running 1 Move the tilt control to fully retract or extend the fork cylinders 2 Hold and read the gauge The pressure should be 3000 PSI NOTE Maintain the engine RPM at the posted speed IF NOT Operational Status Truck Off Keys Removed 3 Adjust the main relief pressure TO ADJUST THE PRESSURE loosen the locknut on the main relief cartridge located on the first section of the 5 spool control valve assembly Turn the adjustment clockwise to increase pressure and counter clockwise to decrease pressure n 4 20 SECONDS 1000 3000 2601 INLET CONTROL VALVE IF 3000 PSI CANNOT BE ACHIEVED 4 Check the cylinders for bypass see Section 9 SERVICE AND REPAIR 5 Replace the main relief valve cartridge see Section 9 SERVICE AND REPAIR 6 Replace the hydraulic pump see Section 9 SER VICE AND REPAIR LEACH CHECK THE LIFT ARM PRESSURE 1 Install a pressure gauge as described earlier in CHECK PRESSURES Operational Status Truck Running PTO Engaged 2 Move the lift arm control to fully
113. l hydraulic control valve NOTE The top door toggle switch is a spring centered valve Movement of the top door may be stopped by releasing the top door toggle switch LEACH TAILGATE OPEN NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the tailgate toggle switch upward to the tailgate open position PNEUMATIC SYSTEM When the tailgate toggle switch is moved upward to the tailgate open position chassis supply air flows in from the red line through the tailgate valve and flows through a yellow line to the air actuator on the tailgate work section of the 5 spool hydraulic control valve NOTE The tailgate toggle switch is a spring centered valve Movement of the tailgate may be stopped by releasing the tailgate toggle switch TAILGATE CLOSE NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the tailgate toggle switch down ward to the tailgate close position PNEUMATIC SYSTEM When the tailgate toggle switch is moved downward to the tailgate close position chassis supply air flows in from the red line through the tailgate valve and flows through a yellow line to the air actuator on the tailgate work section of the 5 spool hydraulic control valve NOTE The tailgate
114. lift arm cylin ders may be stopped by releasing the joystick control handle 10 3 SECTION 10 PNEUMATIC CONTROLS FORKS MOVING UP NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the joystick control handle to the forks up position PNEUMATIC SYSTEM When the joystick control handle is moved chassis supply air flows in from the red line through the joystick valve and flows through an orange line to the air actua tor on the fork work section of the 5 spool hydraulic con trol valve NOTE The operational speed of the lift arm cylinders can be controlled by feathering the joystick control handle The joystick control is a self centering valve Movement of the lift arm cylin ders may be stopped by releasing the joystick control handle FORKS MOVING DOWN NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator moves the joystick control handle to the forks down position PNEUMATIC SYSTEM When the joystick control handle is moved chassis supply air flows in from the red line through the joystick valve and flows through a orange line to the air actua tor on the fork work section of the 5 spool hydraulic con trol valve NOTE The operational speed of the lift arm cylin
115. ly clean the wear block mounting areas Install the new wear blocks in the approximate reverse order of the wear block removal Apply a liberal amount of an anti seize compound to the wear block mounting capscrews and torque to 39 foot pounds 5 4 Newton meters 9 26 DESCRIPTION CAB GUARD CYLINDER One 1 single acting hydraulic cylinder raises the cab guard to provide clearance so that the chassis cab may be tipped The rod end is pinned to the cab guard and the cylinder case end ear is pinned to the front of the body TEST Bras LEAKING CAB GUARD CYLIN Since o is single acting a breather is located on the rod end Any fluid leaking from the breather is an indication of a leaking piston seal REMOVAL OF CAB GUARD CYLINDER Operational Status Truck Off Keys Removed To remove the cylinder relieve the pressure from the case end port and remove the hose Unpin the rod and case ends of the cylinder and carefully remove the cylinder DISASSEMBLY OF CAB GUARD CYLINDER 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder compo nents during disassembly 2 Secure the case end of the cylinder to a work bench or floor mount and the rod end to an over head lifting device with a minimum lifting capacity of 500 pounds to ease the disassembly 3 Remove the plug from the cylinder port and drain the fluid 4 Remove the head gland re
116. m the body Its movement is controlled by the tailgate cylinders and it is locked shut by the latch hooks REMOVAL OF TAILGATE Operational Status 1 Truck Running PTO Engaged Extend the tailgate lift cylinders enough to disen gage the latch hooks Operational Status Truck Off Keys Removed 2 3 Disconnect the rod end of the tailgate cylinders as described earlier in this section Attach chains to a suitable lifting device with a min imum lifting capacity of 4000 Ibs to the tailgate as shown Operate the lifting device no more than nec essary to support the weight of the tailgate assem bly Remove capscrews retainers and hinge pins Note the location and amount of shims used on each hinge Save these shims for reassembly Position the door assembly on the ground or on supports as needed to facilitate inspection and or repair Supports must be capable of holding 4 000 Ibs Do not work under a raised tailgate Install support stands as shown SECTION 9 SERVICE AND REPAIR LIFTING CHAINS TAILGATE INSPECTION AND REPLACEMENT OF TAILGATE 1 Inspect all metal parts pivots and hinge points for damage or fatigue Check hardware holes and piv ots for enlargement breaks in metal or welding cracks Repair following all safety precautions per taining to welding described in Section 4 GENERAL REPAIR PRACTICES Inspect the hinge pins Replace if they are wor
117. n cracked or fatigued Inspect the tailgate seal condi tion and replace if necessary Install the tailgate in the approximate reverse order of removal taking special care to locate the hinge shims in the same amount and location as they were removed 9 15 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF SLIDING TOP DOOR CYLINDER One 1 double acting hydraulic cylinder opens and closes the top door during the loading operation The rod end is pinned to the top door while the cylinder case end is pinned to the body structure NOTE See the description of the optional hinged top door later in this section OF SLIDING TOP DOOR CYLINDE Operational Status Truck Running PTO Engaged 1 Lift arms must be at their lowest position and the top door must be fully open Operational Status Truck Off Keys Removed NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains 2 Secure nylon sling around the cylinder and attach to a suitable lifting device with a capacity of at least 500 pounds Operate the hoist to make the lifting sling snug Remove the capscrew from the cylinder rod end Disconnect both the case end and the rod end hoses Immediately cap or plug the hoses and cylinder ports to keep fluid in and dirt out 5 Make sure the cylinder is securely supported by the hoist and carefully remove the capscrew A
118. n the vertical position Units WHICH HAVE a container affixed to the forks and arms such as a residential application will commonly travel with the lift arms fully raised with the container in the hopper of the body It must be realized that with this positioning of the arms the container will become the highest point of the unit and must not exceed thirteen feet six inches 13 6 When transporting the unit with a container in the hopper the overall height of unit and container must not exceed thirteen feet six inches 13 6 Units with hinged top doors SHOULD NOT carry containers in the hopper of the body while the unit is moving COMPACTION While packing a unit it is very important to remember that the compaction may vary with the following condi tions 1 Type of refuse Tree branches dry leaves furni ture and any other items loaded into the body that take up relatively large amounts of space will reduce the compaction ratio 2 Moisture content of refuse Wet refuse will pack tighter than dry and consequently a wet load will weigh more than a dry load Wet refuse loaded into the body will increase the compaction rate 3 Operation of the equipment As with the opera tion of any type of heavy equipment one machine can yield different results with different operators Operating a front loader is a skill Placement of items and not over loading the hopper are learned skills that will affect the compaction ra
119. nal adjustments on the regulators yourself If you suspect a leak in the system perform a bub ble test with Ivory soap DO NOT USE ANY OTHER BRAND OF SOAP BECAUSE OF THE DANGER OF OXYGEN COMBINING WITH IT AND EXPLODING When preparing to use the torch make certain that the regulator valves are all the way out to the off position before the main tank valves are opened to protect the regulators from the sudden impact of tank pressure When opening the tank valves stand alongside of the regulators out of the way in case they blow out Backfiring or machine gunning at the torch is very dangerous and can lead to a major explosion Welding or cutting should be done in a location well away from flammable materials LEACH REMOVAL DISASSEMBLY AND REPAIR 1 Cleanliness is very important dirt is the number one cause of wear in bearings bushings and espe cially in hydraulic components 2 Inspect hydraulic components for leaks before cleaning The dirt build up on the component can aid in tracing fluid leaks 3 Clean hydraulic connections before removal to pre vent dirt from entering the component 4 Loosen hydraulic fittings slowly 5 Cap hydraulic fittings immediately after removal to prevent dirt from entering the component or line and to prevent fluid from leaking 6 Clean the component in non flammable solvent before disassembly 7 Inspect the component after cleaning for signs of wear
120. nder at a time 8 Reconnect the hydraulic lines to the cylinder Truck Running 5 Move the control to fully retract the cylinder s Keys Removed Repeat steps 6 through 8 for the other cylinder LEACH N FORK TILT CYLINDERS DESCRIPTION OF FORK TILT CYLINDERS Two double acting hydraulic cylinders tilt the container handling forks during loading and dumping operations The rod end is pinned to a pivot ear on the fork assem bly while the cylinder case weldment pivot ear is pinned to the lift arm assembly REMOVAL OF FORK TILT CYLINDERS Operational Status Truck Running PTO Engaged 1 Lift arms must be at their lowest position Move the tilt control to extend the tilt cylinders 2 The container forks must be supported prior to dis connecting the tilt cylinders Operational Status Truck Off Keys Removed NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains 3 Secure nylon sling around the cylinder and attach to a suitable lifting device with a capacity of at least 500 Ibs Operate the hoist to tighten the lifting sling 4 Remove the capscrew and retainer from the cylin der rod end cylinder pin 5 Carefully remove the cylinder pin Check for pin and pin hub wear Operational Status Truck Running PTO Engaged 6 Slowly move the tilt control to completely retract the cylinder Operational Status Truck Off
121. nder with the pilot check with relief valve still connected Whenever disassembling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly crack or loosen the fittings TOP DOOR CYLINDER SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF HINGED TOP DOOR CYLINDERS 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt and foreign matter from contaminating the cylinder compo nents during disassembly 2 With the cylinder secured to a workbench or floor mount remove the pilot check with relief valve and plug all ports on the valve to prevent contamination Attach the rod end of the cylinder to an overhead lifting device with a minimum capacity of 500 pounds to ease the disassembly 3 Drain the hydraulic fluid from the cylinder 4 Rotate the head gland and unscrew it from the cylinder case Slowly operate the hoist to carefully pull the piston rod assembly out of the case 5 Unscrew the piston nut from the rod and remove the piston assembly Remove the discard the rod o ring and backup ring piston seal and wear rings 6 Slide the head gland off the rod Remove and dis card the wear ring buffer ring U cup and rod wiper ring On some cylinders the removal of a retainer ring may be necessary to remove the rod wiper ring 7 Remove all of the plugs and orifices from the case of the cylinder and note their location Clean the pl
122. nnectors on the actuator Air logic control module ALCM malfunctioning Repair or replace the ALCM See Section10 Pneumatic Controls for diagnostic procedures INDICATOR LIGHTS ON CONTROL CONSOLE WILL NOT LIGHT 1 Indicator will not light 1a Replace bulb 1b Tighten or reconnect wire 2 Defective pressure switch 2 Replace switch 3 Air line to pressure switch kinked 3 Replace or un kink the air line SECTION 8 TROUBLESHOOTING POSSIBLE CAUSE REMEDY LIFT ARMS TAILGATE FORK TILT OR TOP DOOR WILL NOT MOVE 1 Kinked air line Replace or straighten air line NOTE AIR LINE AIR LINE Blue Lift Arms Green Top Door Orange Fork Tilt Yellow Tailgate Defective air actuator Replace air actuator Kinked air inlet Replace Red air line or un kink Defective joystick Replace joystick Defective top door or tailgate toggle switch Replace toggle switch Air lines to the actuator on the main control valve Reconnect the air lines ensure that they are loose or disconnected fully engaged into the push lock connectors on the actuator Air regulator defective Replace the air regulator HINGED TOP DOOR ERRATIC WHILE OPENING OR CLOSING Incorrect pressure setting of sequence valves 1 Check pressure and reset sequence valves Worn pump hydraulic pressure not constant 2 Repair or replace pump Cartridge in sequence valve sticking 3 Clean or replace sequence val
123. nt loader The valve also houses the main system relief valve for the unit The valve is connected through an adjustable cable assembly to levers in the cab of the chassis or is operated by the air actuators in the air control system REMOVAL OF THE 5 SPOOL CONTROL VALVE ASSEMBLY 1 2 Remove the cotter pin and clevis pin connecting the valve spools to the cable yokes If equipped with air controls remove air lines from pneumatic actuators at valve assembly Shut off the gate valve near the hydraulic tank Disconnect the hydraulic lines connected to the main control valve Remove the three 3 mounting capscrews Remove the valve assembly 5 SPOOL VALVE ASSEMBLY 9 28 DISASSEMBLY 5 SPOOL CONTROL VALVE ASSEMBLY 1 Remove the tie rods and separate the valve sec tions NOTE If only one valve section needs to be removed from the unit the tie rods may be removed and the single section withdrawn from the assem bly TIE RODS SPOOL SECTIONS LEACH SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF SPOOL SECTIONS 1 2 Prior to disassembly of the spool section clean paint dirt burrs etc from the end of the spool Remove the spool end cap The spool can now be withdrawn with the centering spring assembly still in place Withdraw the spool carefully to avoid dam aging seals NOTE For cleaning or inspection this is probably as far as you will need to go If furthe
124. of the control to the tilt up position will tilt the forks up DUAL OPERATING CONTROLS AIR On units utilizing dual controls a toggle switch located at the rear of the Auto Pack Board will select either the right or left work station The operation of each of these work stations is identical When switching from one side to the other on the work stations the indicator light panel should be in an unobstructed view by the operator FORK TILT DOWN CABLE CONTROL WITH AUTO PACK 3 2 CAUTION LEACH CO STRONGLY RECOMMENDS ENGINE BE KEPT BELOW RPM WHEN PTO 15 ENGAGED AIR CONTROL FORK TILT UP AUTO PACK ___ BOARD FORK TILT UP TOGGLE SWITCH LEFT RIGHT WORK STATION LEACH AUTO PACK BOARD LIFT ARM CONTROL When the joystick or cable control is moved to the lift arm down position the lift arms will lower Movement of the joystick or cable control to the lift arm up position will raise the lift arms LIFT ARM DOWN LIFT ARM DOWN LIFT ARM UP AUTO PACK BUTTON Depressing the green palm button will cause the pack ing ejection panel to move rearward until reaching the auto pack section of the body then the packing ejection panel will reverse and retract to the front of the body and automatically stop EMERGENCY STOP BUTTON Depressing the red palm button at any time will
125. of the body ejecting the load KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve gt Dump Valve Fork Tilt Cylinders Pressure Top Door Cylinder Exhaust LEACH 8 21 SECTION 8 TROUBLESHOOTING EJECTION HYDRAULIC SYSTEM The operator action releasing the auto pack palm but Operator Action ton allows the pneumatic switch which was contacted at The operator releases the auto pack palm button after auto pack location to again reshift the air logic and ejecting the load hydraulic valve The control valve now directs fluid flow to the rod end of the packing ejection cylinders retract ing the cylinders As the cylinders retract flow from the case end is directed through the dump valve directly to the tank When the cylinders have completely retracted the home limit pneumatic switch is contacted which shifts the air logic and main control valve to neutral KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve E Dump Valve Fork Tilt Cylinders Pump Pressure Top Door Cylinder Exhaust Sequence Valve h 8 22 SECTION 9 SERVICE AND REPAIR GENERAL This section contains all the instructions necessary for the repair and replacement of the main components of th
126. ollowing maintenance 1 INSPECTION Perform the Pre operating Walk Around Inspection described in Section 3 OPERATION Never go under the vehicle with the engine running Death or serious injury could result a When checking for hydraulic leaks pay particular attention to hose fittings and connections at the cylinders and valves A build up of hydraulic fluid and dirt indicates a small leak that can probably be corrected by tightening the fitting or connection b Check the visual indicator to determine the condi tion of the return line element c Check all major moving parts for smoothness and ease of operation LEACH SECTION 6 PREVENTIVE MAINTENANCE S MENGE lt Za 10 LF Prey 2 CLEANING Hose the entire unit inside and out with clean water Make sure no refuse is lodged in the body trough or behind the packing ejection panel LUBRICATION Frequent inspection of grease points will indicate when lubrication is needed SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART hh um ll FE sue NW MED e PEE NSS SEES 24 NVA _ PES NEN etus ut uae ur EMT nosci 9 8 SECTION 6 PREVENTIVE MAINTENANCE ILLUSTRATION LUBE POI
127. open pneumatic switch which shifts the spool in the hinged top door section of the control valve When the valve is shifted fluid is directed through the valve to the rod end of the top door cylinders When the top door cylinders are completely retracted the pressure builds to 1850 PSI and the sequence valve is shifted and the lift arm cylinders will continue to retract and raise the lift arms N SN 2 iy WSS F FZ eU KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders SS Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder Sequence Valve LEACH Pressure Exhaust 8 15 door movement is automatic KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 8 16 SECTION 8 TROUBLESHOOTING HINGED TOP DOOR CLOSES HYDRAULIC SYSTEM The operator action shifts the control valve directing fluid to the case end of the lift arm cylinders through a sequence valve The lift arms lower and release a nor mally open pneumatic switch which has pneumatically kept the hinged top door spool section of the control valve shifted Once released a spring shifts the valve allowing the top door to close When the top door cylin der completely extends AND
128. operator in mind However as with any industrial machinery especially those that are large and apply forces through hydraulic pressures the ultimate responsibility for safety rests with you the operator An alert conscientious attitude and observance of all known safe operating practices are the best ways to prevent accidents Before operating the unit it is the operator s responsibil ity to be thoroughly familiar with the instructions con tained in the Operators Manual DANGER WARNING AND CAUTION DECALS oee the accompanying pages for illustrations of all safety decals 1 These decals must be obeyed at all times 2 These decals must be in place at all times Report any damaged or missing decals to the proper authority at once 3 Replacement decals can be ordered free of charge from your local authorized Leach Distributor DANGER WARNING CAUTION and NOTE notations appear throughout this manual The word DANGER precedes information pertain ing to specific immediate hazards which if disre garded WILL result in SEVERE PERSONAL injury or death of the user or others The word WARNING precedes information pertain ing to hazards or unsafe practices which if disre garded COULD result in personal injury or death of the user or others PRIOR TO START UP 1 Never operate machinery while wearing jewelry or loose clothing which may catch on moving parts Wear proper safety equipment as specified by your emplo
129. or external damage 8 When disassembling a component note the posi tion of each part as it is removed to aid in reassem bly REASSEMBLY AND INSTALLATION Assemble parts in the same position as removed Align parts accurately before mating Inspect o ring and seal grooves for sharp edges nicks or burrs before installing new sealing parts Lubricate all new sealing parts with clean fresh hydraulic fluid before installation 5 Use care not to damage new sealing parts on reassembly NOTE See Section 9 SERVICE AND REPAIR for specific repair instructions oma ELECTRICAL TESTING The electrical system used on the unit consists of vari ous lights switches and wiring Testing the components and wiring can be accomplished by two simple checks CHECKING FOR VOLTAGE and CHECKING CONTI NUITY CHECKING FOR VOLTAGE A test light is used to check for the presence of elec tricity in a live circuit Connect the test light clip to a good ground and the probe at the point where the pres ence of voltage is to be checked If voltage is present the light will be on if no voltage is present the light will be off LEACH SECTION 4 GENERAL REPAIR PRACTICES 9 During disassembly note the condition of each part as it is removed to aid in diagnosing problems and to help prevent them in the future 10 Clean and inspect disassembled parts for wear cracks dirt etc 11 After cleaning and inspection reu
130. ot holes and pivot pin bushings for enlargement or fatigue 2 Replacement of fork assembly components is not recommended Replace the entire assembly if damage is found 9 8 ROD END CYLINDER PIN INSTALLATION OF FORK ASSEMBLY Install the fork assembly in the approximate reverse LEACH SECTION 9 SERVICE AND REPAIR LIFT ARM CYLINDERS Two double acting hydraulic cylinders raise and lower the lift arm assembly during loading The cylinder rod is connected to the lift arm and the cylinder case end con nects to the body 5 Ren N DESCRIPTION OF LIFT ARM CYLINDERS The lift arm cylinders are a cushion type During cylin der retraction hydraulic fluid is forced out of the case end port by the travel of the piston much the same as any double acting cylinder However the case end port is located at a point where the piston will actually pass over the port The piston is designed with a seal at each end and a recess between There are also passages machined into the piston connecting the case end face of the pis ton and recesses between the piston seals As the first piston seal passes the case end port during retraction the cylinder rod continues to retract Hydraulic fluid now flows through the machined pas sages of the piston into the recess between the piston seals and out of the case end port to the tank An ori fice is installed where the machined passage exi
131. ould result in improper actuation in the future and should be corrected 7 ZAS Z3 LZ XL 4 T Z N 27 yes ON cA ILE eA e TIEN E DESCRIPTION QTY 1 1 6 6 1 1 1 1 1 1 1 1 Adapter Housing Assembly Screw 1 4 20 Washer Bolt 3 8 16 Spring Retainer Centering Spring Washer Spacer Bonnet Piston Seal Rod Seal SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF MAIN RELIEF SECTION 1 Remove the main relief cartridge from the valve REASSEMBLY OF VALVE SECTIONS AND s CONTROL VALVE ASSEMBLY Do not attempt to disassemble the main relief cartridge It is not field serviceable and must be replaced TIE RODS Before assembly coat all seals and o rings with clean fresh hydraulic fluid unless noted otherwise in these instructions Reassemble and install the parts in the approximate reverse order of disas sembly When assembling the individual sections torque the port relief cartridges and port plugs to 20 x2 Ft Lbs Torque the load check plug to 17 x1 Ft Lbs Torque the seal retainer dust boot bolts to 10 x1 Ft Lbs When assembling the section to each other DO NOT LUBRICATE THE SEALS They must be completely free of oil grease and dirt as well as the section surfaces Tighten the tie rod bolts evenly to prevent any dis tortion of the sections Torque the tie
132. pedal this will stop the transmission gears from turning The PTO control lever is then moved meshing the PTO and transmission gears When the transmis sion is shifted to neutral the PTO and pump start turn ing When engaged an indicator light will illuminate HOT SHIFT OR DRY VALVE A hot shift PTO or dry valve on front mounted pumps may be engaged independent of the transmission oper ation When engaged an indicator light will illuminate SECTION 3 OPERATION INDICATOR LIGHT CONSOLE PTO PUMP SWITCH INDICATOR LIGHT CONSOLE aL SHIFT INTO DRIVE WHILE DEPRESSING THE BRAKE PEDAL p as go 3 7 SECTION 3 OPERATION LOADING Lower the forks until they are parallel with the contain er sleeves It may be necessary to raise or lower the lift arms to align the forks NOTE The travel speed of the forks is determined by the distance the control lever is moved and the engine speed Be sure that the forks are completely through the sleeves before attempting to raise the container OPENING THE TOP DOOR 1 The sliding top door must be fully open before rais ing the container A green indicator light will illumi nate when the door reaches the full open position 2 When the sliding top door is fully closed the top door closed light will illuminate The top door should be closed when the unit is full or for travel ing long d
133. pontaneously ignite in the presence of oil and grease The hoses torch handles and regu lators must be kept free of petroleum products 3 Before using the equipment inspect it for cleanli ness and for leaks 4 2 10 If steel supports are to be used to support the tail gate place them as shown in Section 9 SERVICE AND REPAIR under TAILGATE REPAIR When working on the unit always use the service tools listed in Section 12 SERVICE TOOLS if so directed by the instructions in Section 9 SERVICE AND REPAIR Whenever dismantling any hydraulic or pneumatic line valve or cylinder be sure to turn off the flow relieve the pressure and slowly loosen the fittings Pump removal due to the weight and location of the pump it is advisable to place a floor jack beneath the pump and apply a slight pressure so that when the bolts are removed the pump is sup ported When it becomes necessary to raise the tailgate for maintenance or repair do not enter the area beneath the tailgate unless the proper bracing has first been applied All bracing and supports must be able to support 4000 Ibs Never enter the body when the load is under com paction pressure Hoses cannot be safely repaired When they show signs of deterioration they should be replaced Return regulators periodically to the distributor for inspection Store gas bottles upright and out of the sun Do not attempt to repair or make inter
134. r disassembly is required the centering spring assembly can be removed by removing the bolt INSPECTION OF VALVE SECTION Jd Use solvent to thoroughly clean all parts Inspect the valve body spool bore for any slight burrs The bore must be smooth Remove burrs with crocus cloth Inspect all other parts for wear and damage Replace as necessary Before reinstalling a spool be sure it is absolutely clean Also again inspect the spool bore to be sure no dirt has entered 9 29 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PNEUMATIC ACTUATORS The pneumatic actuator is installed on one end of the valve spool in place of the standard positioner A man ual lever can be used on the opposite end as an over ride to the actuator if required The pneumatic actuator is preassembled Disassemble only as needed to proceed with the installation below ACTUATOR INSTALLATION 1 Remove the existing positioner from control valve Do not remove the spool seal or seal plate 2 Remove any oil film from both the internal and external threads of the adapter ITEM 1 Apply supplied thread locking compound medium strength anaerobic adhesive Loctite 242 or equiv alent to both the internal and external threads of the adapter Install the adapter on the spool and tighten to 11 14 ft Ib torque 3 Mount housing assembly ITEM 2 on to the valve using 2 each of the provided screws ITEM 3 and washers ITEM 4 and tighten
135. retract cycle will not disengage at the home position Push and hold the silver button on RV2 If no response push and hold the silver button on RV3 If no response push and hold the bottom button on SV2 Packing ejection panel full ejects will not auto retract Push and hold the blue button on RV3 If no response push and hold the silver button on RV4 packer lockout module If no response push and hold the blue button 10 6 on RV1 If no response push and hold the bottom but ton on SV3 Packing ejection panel is able to full eject with the tail gate closed Push and hold the silver button on RV4 packer lockout module If no response check SOL1 packer lockout module for malfunction See Section 11 ELECTRICAL Packing ejection panel will not extend beyond auto pack limit with the tailgate open full eject Push and hold the blue button on RV4 packer lockout module If no response push and hold the silver button on RV2 If no response push and hold the silver button on RV3 If no response check SOL1 packer lockout module for malfunction See Section 11 ELECTRICAL Emergency stop button valve engaged will not stop the auto pack cycle Push and hold the bottom button on SV1 If no response push and hold the silver button on Auto pack cycle be engaged with the side door open Push hold the top button on SV1 If no response push and hold the silver button on RV3 Auto pack cycle cannot be resumed
136. ropriate The International Standards Organization assigns specification numbers so that a con sumer receives the same product from various suppliers AGMA NO Gravity API Flash F Pour Point F Viscosity SSU 100 F SSU 210 F cSt 40 C cSt 100 C Viscosity Index ASTM Oxidation Test Hours to 2 0 Neut No ASTM Rust Test amp B Foam Test Vickers Vane Pump Test Dielectric Strength ASTM 877 EC 180 F 33 375 20 112 40 21 4 1 98 2500 Pass Pass Pass 25Kv 40 37 3 10 31 380 20 158 44 30 5 5 2 99 2500 Pass Pass Pass 25Kv 40 37 3 15 2500 Pass Pass Pass 25Kv 40 37 3 15 Do not use engine oil automatic transmission fluid ATF or add diesel fuel or kerosene to the hydraulic fluid Service life of all hydraulic system components may be adversely affected HYDRAULIC FLUID To serve its purpose and give long and satisfactory service hydraulic fluid must possess desirable physical and chemical characteristics Stability over a wide range of temperatures and under agitation is very important Premium hydraulic fluids should be used in Leach hydraulic systems In addition to the above characteristics select ed additives should be added to provide additional resistance to wear corrosion oxidation decomposition and foam ing All additive blending should be done by the lubricant supplier so that they are compatible with each other A reputable lubrican
137. run engine DEATH OR SERIOUS INJURY 4 if tank valve is required to be closed or if oil CLOSED 108322 210027 210027 tank is not at proper fill level WARNING DO NOT ENTER UNLESS 35210 Ail pressure against ejector panel has been relieved Engine is stopped and key removed 9 32711 Rotating drive shaft Do not approach drive shaft unless engine is stopped and key removed OFF ae mere Rotating power take off shaft hazard WARNING Do not enter under chassis unless engine is stopped and key removed e HEADLIGHT INTERFERENCE HAZARD e POSITION ARM FOR PROPER HEADLIGHT ILLUMINATION WHICH e Is below top of body Will not obstruct view Ensure top doors remain closed 32755 41894 DANGER Tailgate is activated OF Fs A DANGER from cab 108324 Ensure proper clearance height e Stand clear of al all times tailgate at all times EE e travel only with lift arms below listed clearance height and with top door and tailgate at lowest level 104122 18 104122 210266 SECTION 1 SAFETY PRECAUTIONS OVERHEAD CLEARANCE Millennium Front Loader This vehicle with top door and tailgate in lowest m LUBRICATION position requires the following clearance height as LEAC H A y CHART originally mounted Required height does not allow dE ai E for additional clearance for carry
138. s deactivated the air pressure is removed from the top door section of the 5 spool control valve allowing the spool to shift back allowing fluid to flow to the case end of the hinged top door cylinders allowing the door to close Adjusting the switch is accomplished by loosening the actuator band on the lift arm pivot tube and rotating the band to contact the air limit switch at the point preferred to start the hinged top door opening during lift arm up motion 9 20 TOP DOOR CYLINDER AIR LIMIT SWITCH LEACH DESCRIPTION OF HINGED TOP DOOR The hinged top door consists of one fabricated assem bly to close the top of the body The top door is con trolled by two 2 hydraulic cylinders which pull the top door rearward and upward to open the hopper and push the top door forward and downward to close the hopper The opening and closing of the hinged top door occurs automatically with the raising and lowering of the lift arms REMOVAL OF HINGED TOP DOOR Operational Status Truck Off Keys Removed 1 Remove the wind screens from both sides of the top door 2 Disconnect the rod ends of the top door cylinders and secure them away from the top door 3 Attach chains slings to a suitable lifting device with a minimum capacity of 1500 Ibs 700 kg to the top door Operate the lifting device no more than nec essary to support the weight of the top door 4 Locate and remove the hinge pin retainer bolts from both hinge pins
139. s the packing ejection panel moves rearward refuse is pushed out 4 Once the load is ejected release the Auto Pack palm button the packing ejection panel will return to the home position Disengage the PTO Pump and pull the truck forward enough for the tailgate to clear the ejected refuse when lowered Never enter under a raised tailgate 5 Engage the PTO Pump The operator moves the tailgate toggle switch downward to lower and latch NEM Sm Monona the tailgate The tailgate ajar indicator light backup ne ns UNLOAD LA STAND CLEAR WHEN TAILGATE lights and beacon will go out and the back up alarm cross will quit Sounding as the hooks are latched secure ly 6 Operator releases the tailgate toggle switch 7 Disengage the PTO prior to driving out of the unloading site SHUTDOWN Put all the controls in neutral Set the parking brake Disengage the PTO Shut off the engine Remove the key Drain the water from the air tank Lock the vehicle NOTE Purging of the air system will ensure that mois ture does not enter the control systems of the chassis or refuse body control system NEC eet M 25 3 14 BODY TILT GENERAL The body tilt lifts the refuse body from the chassis frame rails to provide maintenance access OPERATION A CAUTION The body must be completely empty the li
140. sable hydraulic parts should be immediately coated with clean fresh hydraulic fluid to prevent rust formation If these parts are not going to be reinstalled immedi ately they should be wrapped in a clean lint free cloth or paper to prevent nicks or scratches 12 When repacking a cylinder or resealing a valve replace all seals and o rings that are disturbed dur ing the repair The price of a few seals is very little compared to a return repair job 6 Use correct torque values when reassembling and installing Components See CAPSCREW MARK ING AND TORQUE VALUES later in this section 7 Always check the hydraulic fluid level in the hydraulic tank after performing any service or repair of the hydraulic system 8 Always lubricate components with grease fittings after they have been repaired and reinstalled 9 Use only Leach Signature replacement parts CHECKING CONTINUITY A continuity tester is used to check the ability of a con ductor to allow current to pass A continuity tester uses a self contained power source and should never be used on a live circuit Connect the clip to one side of the component to be tested and touch the probe to the other side If the component has the potential to pass current has continuity the light will be on if the com ponent is not able to pass current there is no continu ity and the light will be off 4 3 SECTION 4 GENERAL REPAIR PRACTICES WELDING 1 When rewelding an old wel
141. sary to manually clean debris use a long pole and DO NOT stand under the tailgate Know the height of the unit at all times Be sure to allow sufficient clearance from overhead restric tions Do not attempt to load refuse into the hopper after the packing cycle has begun The packing ejection panel must be in the home position and stopped before loading the hopper Ensure that persons are clear of the container before raising or lowering Always have the lift arms in the travel position while transporting Always ensure that all persons are clear of the equipment before actuating the lift arm or pack ing ejection controls The operator should warn persons not to stand or cross under a raised tailgate or container LEACH SECTION 1 SAFETY PRECAUTIONS GENERAL MAINTENANCE HYDRAULICS 1 Hydraulic fluid operates under high temperatures Avoid contact with piping hoses or cylinders to pre vent burns 2 Never use hands to check for leaks Hydraulic fluid escaping under pressure may Cause injury 3 In case of injury seek proper medical treatment immediately FIRE PROTECTION 1 Keep a fire extinguisher accessible at all times as recommended by the Bureau of Motor Carrier Safety 2 Never use lighted smoking materials open flame or sparks when working with flammable materials such as fuel tanks or storage batteries 3 Never use an open flame as a light source 4 Never load ashes or other materials which migh
142. stop the packing ejection panel NOTE Any time the emergency stop palm button is depressed the auto reset button must be engaged before the auto pack system will acti vate AUTO RESET BUTTON This button located on the Auto Pack board is used to reset the air logic after depressing the red emergency stop button The Auto Pack palm button or retract palm button must be depressed pack green or retract black after depression of the auto reset button LIFT ARM UP SECTION 3 OPERATION LIFT ARM DOWN QAN D CABLE CONTROL WITH AUTO PACK AIR CONTROL EE LIFT ARMS DOWN IU M Tem cse AUTO PACK BUTTON RETRACT BUTTON EMERGENCY STOP BUTTON AUTO RESET BUTTON AUTO PACK BUTTON AUTO RESET BUTTON RETRACT BUTTON EMERGENCY STOP BUTTON SECTION 3 OPERATION TOP DOOR OPEN WITH CABLE CONTROL AUTO PACK The sliding top door is opened by moving the top door control lever to the open position Continue to hold the lever until the door is fully opened A green indicator light will illuminate when the door is fully open Close the top door by moving the top door control lever to the closed position until the yellow top door partial open light goes out the red top door closed light illu minates and the top door is fully closed SLIDING TOP DOOR SWITCH AIR CONTROL The sliding top door tog
143. systems operating up to 3000 PSI The action of tightening the assembly s nut draws the flared surfaces of the fittings together creating a positive seal Fittings that are properly tightened and supported should not become loose on their own Two methods are available to determine if a fitting is properly tightened 1 The torque method 2 The flats method TORQUE METHOD Fitting Size Thread Size Torque Value ft lbs FLATS METHOD The flats method for tightening JIC fittings can be used when a torque wrench is not available or because of fit ting location a torque wrench cannot be used 1 The swivel nut should be hand tightened to the mating fitting Hand tight is the point where the swivel fitting no longer threads on to the mating part when a moderate amount of force is applied with your fingers While the swivel nut is being tightened the tube or hose should be wiggled to ensure the flare surfaces align prop erly 2 When the swivel nut is hand tight make a line on one of its flats and extend the line to the adjacent flat on the mating part See illustration below Using the correct size wrench rotate the swivel nut clockwise the proper number of flats Refer to the table for suggested amount of flats rotation SECTION 4 GENERAL REPAIR PRACTICES SUGGESTED AMOUNTS OF FLATS ROTATION HOSE TUBE Fitting size Thread Size flats rotation flats rotation TORQUE SPECIFICATIONS FOR FLAT FACE FLARE FITTING
144. t PACKING SET SETSCREW 9 23 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PACKING EJECTION PANEL The packing ejection panel is a moveable component which is used to compact refuse and eject it from the body This plate slides on eight shoes and is moved rearward and forward by the packing ejection cylinders REMOVAL OF PACKING EJECTION PANEL Operational Status Truck Running PTO Engaged 1 Raise tailgate to the full up position 2 Extend the packing ejection cylinders to move the packing ejection panel to its rearmost position in the body Operational Status Truck Off Keys Removed Do not work under a raised tailgate unless the tailgate is supported by stands or an overhead hoist capable of holding at least 4 000 16 3 Disconnect the rod end of the packing ejection cylinders and support cylinders as described earli er in this section 4 Weld an eye to the center of the plate and attach a chain to prevent the plate from tipping over upon removal 5 The packing ejection panel can now be removed by sliding it from the body The method of removal will depend upon equipment available Whatever method is used the equipment must be capable of lifting a minimum of 4 000 Ibs and the plate should be secured safely to the removing device INSPECTION AND REPLACEMENT OF PACKING EJECTION PANEL 1 Inspect all portions of the packing ejection panel assembly for bent components or broken welds 2 Inspect the bo
145. t be smoldering These materials could ignite refuse in the packer body HOUSEKEEPING Good housekeeping habits are a major factor in acci dent prevention 1 Keep handrails and steps clean and free of grease or debris 2 Do not store brooms or other equipment where they could inadvertently be dislodged or create a hazard CLEANLINESS 1 Rubbish scrap paper and litter are highly com bustible Such material should be stored in metal containers entirely clear of sparks and flame SHUTDOWN 1 Put all the controls in neutral 2 Set the parking brake 3 Disengage the PTO 4 Shut off the engine 5 Remove the key 6 Drain the water from the air tank BAD AT 7 Lock the vehicle 2221 a LEACH SECTION 1 SAFETY PRECAUTIONS _ 90090000888 6 G9 2 69 69 G9 a G2 69 G9 Go 9080900809 as c gt mA udi ho L 2 2 4 WU x E e Wit HI NN LI M S a p ee rra c pi e Qt EEEN ot 2 amp wc 2 alte ag tae ot uak 412 oe hes arse aat il MO ote ee 3 N DECAL LOCATED ON LEFT AND RIGHT SIDE UNIT SECTION 1 SAFETY PRECAUTIONS INTERMEDIATE ile POSITION LOWER OR TRAVEL SS RAISED
146. t cylinder rod end Fork tilt cylinder case end 1 Hl AM i Lin cylinder rod end s i Lift cylinder case end bien FLUSHING HYDRAULIC SYSTEM YEARLY 1 Drain alt fluid from the hydraulic tank into a iner by removing the deain plug gnelic ring and wipe out the 5 des above i lank with tresh as Rear door cylinder case end in Section 5 SpecMications of the Rear door latch pivot Ing and Rear door cylinder rod end SAFE RANGE 17 106544 miae 9 Packing Ejection cylinders rod uid a Packing Ejection cylinders case end the NORMALI sight XXXXXXXX RETRACTED ALL CYLS RETRAC XX XXXXXXXX 304697 JOYSTICK CONTROL ADD HYDRAULIC FLUID This unit conforms to all American National Standards institute safety LEFT e RIGHT _ 106110 requirements Z 245 1 in effect on 106110 the date of manufacture 40643 104154 LEACH 104154 LIFT ARMS DOWN LIFT ARM amp FORK CONTROL LIFT ARM DOWN FILTER ELEMENT CHANGE ensure cleanliness and longer machine life change the element at intervals of 20hrs 50hrs and at 250hr intervals thereafter FORKS UP LIFT ARMS 100890 UP m a3 100890 a3 106497 UP n 590 204160 OVERHEAD CLEARANCE This vehicle with top door tailgate and lift arms lowest travel position requires of overhead
147. t on the relief cartridge located next to port EF Turn the adjustment clockwise to increase pressure or counter clockwise to decrease pressure IF 3100 PSI CANNOT BE ACHIEVED 6 Replace the power on demand relief cartridge 7 Reinstall the power on demand valve on the unit LEACH SECTION 7 CHECK OUT ADJUSTABLE FORK SYSTEM ADJUSTING THE POWER ON DEMAND VALVE The power on demand valve is designed to provide hydraulic fluid to the adjustable fork valve at a fixed flow rate of 3 5 GPM When the adjustable fork system is RELIEF not in use hydraulic fluid is allowed to travel to the main CARTRIDGE system of the Leach Millennium The power on demand valve is located on the right front of the body next to the five 5 spool valve It is electrically activated by a toggle switch located in the cab When activated the hydraulic fluid will be directed to the adjustable fork valve which is also located in the cab By movement of the lever on this valve the dis tance between the forks can be adjusted to accommo date various sizes of containers Along with diverting the hydraulic fluid to the adjustable fork valve the power on demand valve also incorpo rates a relief cartridge to guard against any unforeseen pressure build up in the system CHECKING THE RELIEF PRESSURE Operational Status 4 Operate the porta power As the pressure rises watch port T When the pressure reaches 3100 Truck Off Keys Remov
148. t supplier backed up by a reputable oil company is great assurance of obtaining high quality prod ucts and generally speaking higher quality is worth the higher initial cost LEACH 5 1 SECTION 5 SPECIFICATIONS 5 2 GENERAL The Leach Millennium has been designed for long peri ods of efficient uninterrupted operation Careful atten tion to proper preventive maintenance as described in this section will ensure and extend trouble free opera tion of the unit Particular attention to correct lubrication of the unit and maintenance of the return line filter are probably the two most vital areas of preventive mainte nance required The objective of preventive mainte nance is to anticipate and prevent operational difficul ties before they require extended shut down for costly repairs OPERATING AND MAINTENANCE RECORDS Prepare and adhere to a maintenance schedule Keep detailed records of all maintenance performed Regularly inspect operating and maintenance records for deviations from normal operating conditions Analyze the records for indications of potential trouble NOTE Occasionally distributors will receive service bulletins from Leach Company concerning updated maintenance information Keep those bulletins with this manual and make notes at the appropriate places in the manual referenc ing the updated information PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE Each day perform the f
149. taining ring Use a drill with an internal grinding wheel to remove any burrs and or rust from the internal groove on the cylinder case Slowly operate the hoist to carefully pull the piston rod assembly out of the cylinder case 5 Unscrew the piston nut from the rod and remove and discard the rod o ring and piston seal 6 Slide the head gland off the rod and discard the o ring wiper seal and rod seal INSPECTION AND REPLACEMENT OF CAB GUARD CYLINDER 1 Thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear 2 Check all cylinder components and mounting parts for damage and wear and replace as required Parts that must be replaced together o rings and seals are available as a repair kit from your local authorized Leach Distributor LEACH SECTION 9 SERVICE AND REPAIR CAB GUARD CYLINDER BREATHER CYLINDER CASE 4 SETSCREW WIPER SEAL SEAL PISTON SEAL PISTON NUT PISTON RETAINING RING HEAD GLAND REASSEMBLY AND INSTALLATION OF CAB GUARD CYLINDER Heassemble and install the cab guard cylinder in the approximate reverse order of disassembly NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering the cylinder 9 27 SECTION 9 SERVICE AND REPAIR DE SCRIPTION OF 5 SPOOL CONTROL VALVE ASSEMBLY The 5 spool control valve assembly directs fluid to the various hydraulic components of the fro
150. tal surfaces to remove and prevent the formation of rust 2 INSPECTION a In addition to the body mounting hardware which is checked daily inspect all other accessi ble mounting hardware and fittings for tightness Refer to the CAPSCREW MARKING AND TORQUE VALUES CHART provided in Section 4 GENERAL REPAIR PRACTICES b Check electrical wiring and insulation for frays breaks and loose connections 3 LUBRICATION Refer to the LUBRICATION CHART in this section and service those items which require weekly lubri cation 4 HYDRAULIC SYSTEM a The return line filter element is vital to the ser vice life of the hydraulic system Refer to HYDRAULIC SYSTEM SERVICE later in this section for more detailed information about this important item b Check the breather cap on the hydraulic tank Clean it weekly and replace it if it can not be cleaned out thoroughly or is missing 5 CHECK OUT PROCEDURES Each week perform the CHECK OUT PROCE DURES listed in Section 7 of this manual MONTHLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a month remove and clean the hydraulic tank fluid strainer as described in HYDRAULIC SYS TEM SERVICE in this section YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a year drain flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SER VICE in this section b Once a year replace the hydraulic tank air breather LEACH SECTION 6 PREVENTIVE MAINTENANC
151. te top door lift arm position and if so equipped to activate the automatic pins on the triangle attachment These switches can be wired either in the normally open or the normally closed positions These switches have no moving components and func tion by passing an actuator through an electronically generated field opening or closing the circuit as need ed CHECKING THE PROXIMITY SWITCH On the side of the switch there is an L E D embedded into the plastic housing which will glow red when the switch is activated If a faulty switch is suspected look on the side of the switch when the actuator is in front of the sensing face The L E D light should be glowing through the plastic case Cleanliness of these switches is crucial Refuse gather ing around the switch may send a false signal Also dirt or grime gathering on the face of the switch may inhib it the switch from functioning SECTION 11 ELECTRICAL REPAIR Repair of the electrical system is limited to the replace ment of burned out light bulbs and other defective parts or wiring INSPECTION 1 Operate all light switches and pushbutton controls to ensure that they are operating normally 2 Check all wiring for breaks frayed or worn insula tion and loose terminal connections ADJUSTMENT OF THE PROXIMITY SWITCH Due to a growing amount of companies utilizing radio transceivers to dispatch and track their trucks in the field it is possible that some of t
152. te of a unit LEACH SECTION 3 OPERATION Compaction rates of a unit will depend on the season the type of trash the weather and the operation and maintenance of a unit If the unit packs relatively con sistent loads and has been properly maintained accord ing to the Service manual then it is safe to assume that it is getting maximum compaction for your particular conditions SECTION 3 OPERATION AUTO PACK 1 To maximize load density the packing ejection panel should be moved rearward after each con tainer is dumped Depress the green auto pack button to start the cycle The operator must main tain a constant engine RPM as shown on the dash decal This will ensure that the packing force is suf ficient to both compact the load as well as to auto matically shift the auto pack to neutral when com paction is completed The packing ejection panel will automatically extend reverse retract and stop To continue the cycle if the red emergency stop pushbutton has been depressed it will be neces sary to push the auto reset pushbutton Immediately after depressing the auto reset button the packing ejection panel will resume motion in the direction of either pack or retract depending on which button pack green retract was depressed prior to depressing the Emergency Stop button Disengage the PTO Pump before driving the unit Note position of ejector panel
153. the Front Loader s loading functions This assembly con sists of the control levers in the cab and connecting cables to the front of the main control valve assembly CABLE CONTROL YOKE WITH AUTO PACK REMOVAL DISASSEMBLY OF CONTROL LOCK NUT LINK Operational Status Truck Off Keys Removed 1 To remove the control cables remove the cotter pin and clevis pin from the clevis Loosen the locknut and remove the clevis 2 After removing the clevis from the cable end slide the cable through the bracket being careful not to damage the threads on the cable end BRACKET CABLE ed AND ADJUSTMENT Install the cables in the approximate reverse order of removal 2 Position the cable into the bracket and tighten the locknut Put the nut onto the threaded end of the cable turn the clevis onto the end of the cable Reinstall the cotter pin and clevis pin 9 32 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF LEACH HYDRAULIC PUMP The pump that serves the complete hydraulic system is a gear type driven via a yoke and driveshaft arrange ment coupled to the engine crankshaft REMOVAL OF HYDRAULIC PUMP Operational Status Truck Off Keys Removed PUMP 1 Close the gate valve near the hydraulic fluid tank 2 Remove the hose clamp 3 Remove the pump suction line and allow the fluid to drain NOTE The pump suction line tube and hose will also be filled with hydraulic fluid The pump and line may be drained into an absol
154. the pump flow to the rod end of the tailgate cylinder As the cylinder retracts return flow from the case end of the cylinder is directed through the control valve and then the return line filter to the tank When the cylinder is fully retracted the port relief will open at 3000 PSI KEY Lift Arm Cylinders Hydraulic Tank Packing Ejection Cylinders Tailgate Cylinders 5 Spool Control Valve Dump Valve Fork Tilt Cylinders Pump Top Door Cylinder 8 18 Exhaust mL N 5 Y Y A TUN mil P a SECTION 8 TROUBLESHOOTING PACKING AUTO PACK NOTE Operator Action Once the body s capacity is full the The operator depresses and releases the auto pack packing ejection cylinders will no longer con palm button tact the pneumatic switch for auto pack At this point the pressure will raise to 3000 PSI and HYDRAULIC SYSTEM the Emergency stop button must be de The operator action sets the air logic and shifts the pressed Now the retract button should be main control valve directing fluid flow to the case end depressed and held until the packer home light of the packing ejection cylinders extending the pack illuminates At this point you can continue to ing ejection cylinders to the auto pack position At this pack out the hopper but keep in mind auto point a pneumatic switch is contacted shifting the main pack will not funct
155. through SV3 out port J on the ALCM to the air actuator on the main control valve automatically retracting the telescopic cylinders PACKING EJECTION PANEL RETURNS TO HOME POSITION NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action None PNEUMATIC SYSTEM Packing ejection panel returns to home position actu ating the home position limit valve which sends an air signal through port on ALCM through RV2 to pilot port A on RV3 This terminates the continuous air sup ply from RV3 to RV1 and resets RV2 for the next pack ing cycle The air signal from the home position limit valve also goes to PS2 turning the packing ejection panel home position light on EJECTION NOTE Chassis supply air is available to the E stop side door switch auto reset packer home and packer retract limit valves at all times Operator Action The operator holds down the green packing ejection button before the midway point of the auto pack func tion and continues to depress the packing ejection but ton until the packing ejection panel reaches the extreme rear of the refuse body PNEUMATIC SYSTEM Depress and hold the green auto pack palm button A continuous air signal is sent through port A1 on the ALOM to pilot port B on RV4 and pilot port A on RV1 RV4 shifts sending an air signal to pilot port B on RV3 ena
156. to the line that was removed from the case end of the cylinder Operational Status 3 Locate the switch in the cab marked FORK ADJUSTMENT Move it to the ON position 4 Locate the adjustable fork control lever and move it inward Raise the engine speed to the specified RPM on the decal located on the dashboard 5 The gauge should read 1500 PSI IF NOT 6 Remove the cover from the adjustable fork valve Locate the relief cartridge which is next to the eye of the spool where the lever attaches to the spool 7 Loosen the locknut on the relief cartridge Turn the adjustment clockwise to increase pressure or counter clockwise to decrease pressure IF 1500 PSI CANNOT BE ACHIEVED 8 Replace the adjustable fork valve relief cartridge 9 Repeat steps 3 through 7 10 Install the cover on the adjustable fork valve 2000 N 1004 3000 a 1 2 5 2 11 Connect the hydraulic line to the case end of the adjustable fork cylinder 1500 PSI RELIEF CARTRIDGE LEACH CHECKING THE PILOT CHECK RELIEF VALVES HINGED TOP DOOR The two 2 pilot check relief valves are located on the hinged top door cylinders one each and are directly connected to the case end of the cylinder The purpose of the valves is to lock the hydraulic fluid in the case end of the cylinder when the door is closed ensuring that the door will remain closed When the cylinder recei
157. ts the LIFT ARM recess of the piston to reduce the flow of the hydraulic CYLINDER fluid This slows the rate of the cylinder rod retraction cushioning approximately the last two 2 inches of trav el To allow full flow during cylinder rod extension a sec ond passage is machined into the piston between the case end face and the recess between the piston seals A check valve is installed in this passage on the piston face side and is retained by the piston nut LIFT ARM When the cylinder is extended full flow of hydraulic fluid is allowed to pass through this check valve into the cylinder case extending the cylinder rod at the full rate of extension Upon retraction of the cylinder rod the check valve is closed off allowing hydraulic fluid to only pass through the orificed passage 9 9 SECTION 9 SERVICE AND REPAIR REMOVAL OF LIFT ARM CYLINDERS Operational Status PTO Engaged Truck Running 1 Move the lift arm to place the lift arms at their low SLING ARM est position CYLINDER NOTE fo The lift arm assembly must be supported prior to removal of the lift arm cylinders CAPSCREW uas Operational Status ton Truck Off Keys Removed NOTE CYLINDER PIN See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains 2 Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device with a capac ity of 500 I
158. ttom and top shoes for wear Shoes must be replaced before metal to metal contact occurs between the packing ejection panel shoe retainers and the body floor or the packing ejection panel weldment and the body floor PACKING EJECTION PANEL SHIM TOP SHOE BOLT RETAINER Ly p WEAR SHOE RETAINER CAPSCREW INSTALLATION OF PACKING EJECTION PANEL 1 Install the packing ejection panel in the approxi mate reverse order of removal 2 After installation the top shoes may be shimmed NOTE Equal amounts of shims should be installed on both sides in order to ensure straight move ment of the packing ejection panel LEACH DESCRIPTION OF PACKING EJECTION PANEL WEAR BLOCKS The packing ejection panel utilizes composite wear blocks for two functions to provide a wear surface between the body track channels and packing ejection panel and to inhibit refuse bypass into the forward side of the packing ejection panel The wear blocks should be replaced before there is metal to metal contact between the packing ejection panel and the body sides channels floor or trough They should be replaced in sets all track channel wear blocks at the same time all trough and floor wear blocks at the same time and all side wear blocks at the same time SHIM TOP SHOE BOLT RETAINER lt gt R S 7 E k La So WEAR SHOE RETAINER CAPSCREW SECTION 9 SERVIC
159. tuator See Section 9 Service and Repair Leaks in hydraulic system Check system for leaking components or lines Tighten or replace Defective or worn pump Repair or replace pump See Section 9 Service and Repair Defective control valve Repair or replace control valve See Section 9 Service and Repair Externally leaking or by passing lift arm cylinders Repair replace or repack cylinders See Section 9 Service and Repair Container load too heavy Remove part of container contents Packing ejection panel not at the front of the body Retract packing ejection cylinder to position panel at front of body Main relief valve out of adjustment Check pressures See Section 7 Check out Lift arm relief pressure low Check the lift arm pressure See Section 7 Check out Check valves inside the lift arm cylinders sticking Repair or replace the lift arm cylinders See Section 9 Service and Repair 1 Valve spool not shifting completely Adjust control cable or air actuator See Section 9 Service and Repair 2 Hydraulic fluid level low Check fluid level add if necessary See Section 7 Check out 3 Hydraulic strainer plugged Clean strainer See Section 6 Preventive Maintenance 4 Pump worn or defective Repair or replace pump See Section 9 Service and Repair SECTION 8 TROUBLESHOOTING POSSIBLE CAUSE REMEDY SLIDING TOP DOOR WILL NOT CLOSE Too much material in
160. ug the lifting sling without applying strain on the cylinder 3 Remove the capscrew and washer from the cylin der rod end NOTE See Section 4 GENERAL REPAIR PRAC TICES for more detailed information about the correct use of slings and lifting chains Whenever dismantling any hydraulic line valve or cylinder be sure to turn off the hydraulic flow relieve the pressure and slowly crack or loosen the fittings 4 Disconnect both the case and the rod end hoses Immediately cap or plug the hoses and cylinder ports to keep fluid in and dirt out 5 Make sure the cylinder is securely supported by the hoist and carefully remove the capscrew and pin from case end LEACH SECTION 9 SERVICE AND REPAIR LN TE r4 TAILGATE CYLINDERS e LATCH ARM n 4 REN RES se NEN 4 epe PR Den CAPSCREW 10009 ue SS CAPSCREW LATCHING ARM 9 13 SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF TAILGATE CYLINDER INSPECTION AND REPLACEMENT OF TAILGATE CYLINDER 1 Wash the mounting hardware and the outside of the cylinder assembly to prevent dirt and foreign 1 Thoroughly inspect the inside of the cylinder for matter from contaminating the cylinder compo cracks scoring or uneven wear nents during disassembly 2 Check all cylin
161. ugs and orifices and check them for dirt and wear 9 19 SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF HINGED TOP DOOR CYLINDERS 1 Thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear 2 Check all cylinder components and mounting parts for damage and wear and replace as required Parts that must be replaced together o rings and seals are available as a repair kit from your local authorized Leach Distributor REASSEMBLY AND INSTALLATION OF HINGED TOP DOOR CYLINDERS Coat all seals and o rings with clean fresh hydraulic fluid before reassembly Reassemble and install the hinged top door cylinder in the approximate reverse order of disassembly Pay particular attention to the proper relocation of all plugs and orifices in the cylinder case When installing the piston to the rod torque the piston nut to 25 Ft Lbs NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering the cylinder HINGED TOP DOOR ADJUSTMENTS ADJUSTMENT OF THE AIR LIMIT SWITCH ON THE LIFT ARM PIVOT TUBE Operational Status Truck Off Keys Removed The purpose of the air limit switch is as the lift arms move upward the switch is activated allowing air pres sure to shift the top door section of the 5 spool control valve which allows fluid to flow to the rod end open door of the hinged top door cylinders When the lift arms are being lowered and the switch i
162. ull Cycle 600PSI 41 5BAR YES 18 24 Seconds Full Cycle 1500 ves Consut Tipper Manufacture 7 YES NO Hinged Top Door Open Hinged Top Door Closed Adjustable Fork Residential Tipper Power On Demand 3100 PSI 214 BAR YES NO NO NO NO NO NO YES YES NO NO YES 2 YES 105 PSI 7 25 BAR NO Pneumatic Regulator SECTION 7 CHECK OUT GENERAL The Leach Millennium has been designed to provide long periods of trouble free operation Performing the check out procedures below at regular weekly inter vals will help to prevent unscheduled downtime Make sure you know and observe all safety precautions listed in Section 1 before per forming any of the following check out pro cedures Use extreme caution to avoid com ing near any moving parts Never enter the body of the unit when the truck is running Make sure the unit is in the correct opera tional mode as indicated by the OPERA TIONAL STATUS block presented at the beginning of each check NOTE Because of the location of some controls some checks will require two people CHECK HYDRAULIC TANK FLUID LEVEL 1 The unit must be in the following position a Packing ejection cylinders retracted b Tailgate closed and latched c Top door open d Lift arms up e Forks tilted up 2 The fluid level should be between the safe range marks on the sight gauge IF NOT 3 Add hydraulic fluid for normal op
163. using the indicator light console NOTE At any point during the auto pack or ejection cycle motion can be stopped by depressing the RED pushbutton located on the console To continue the cycle the AUTO RESET push button must be depressed Do not pack the load with the sliding top door closed AUTO PACK BUTTON AUTO RESET BUTTON SECTION 3 OPERATION UNLOADING WITH CABLE CONTROL WITH AUTO PACK Once the unit is full drive to an unloading site While unloading it is recommended that the sliding top door be open 1 Engage the PTO Pump 2 The operator moves the tailgate control lever to raise the tailgate As the hooks begin to release the dash warning light illuminates Continue to hold lever until the tailgate is fully raised TAILGATE AJAR Be sure the area behind and above the unit ao i TAILGATE is clear before raising the tailgate rm LEVER NOTE The backup alarm beacon light and tailgate ajar indicator light will come on AUTO PACK BUTTON 3 To eject the operator depresses and holds the auto pack pushbutton Engine RPM must be main tained at the designated speed to provide enough force to empty the unit As the packing ejection panel moves rearward refuse is pushed out 4 Once the load is ejected release the auto pack palm button and the packing ejection panel will return to the home position Disengage the PTO Pump and pull the truck forward
164. utely clean con tainer and the fluid poured back into the tank 4 Disconnect the pressure hose at the pump amp cap 5 Loosen the setscrew and free the yoke from the pump shaft by telescoping the drive shaft toward the engine 6 Remove the key from the pump shaft keyway 7 Remove the attaching hardware and pump assem bly from the mounting bracket NEW PUMP PREPARATION Before installing a new pump refer to Section 6 PRE VENTIVE MAINTENANCE and the following to prevent contamination of the new pump 1 Remove and clean the hydraulic tank strainer 2 Change the filter element 3 Drain and flush the hydraulic tank as described in Section 6 PREVENTIVE MAINTENANCE 4 Clean the magnetic plug INSTALLATION OF HYDRAULIC PUMP 1 Install the pump in the reverse order of removal MAKE SURE suction and pressure lines are installed correctly Tighten all mounting hardware and hose clamps 2 Be sure to re install any shaft guards that may have been removed TESTING A NEW PUMP After installing a new pump check for correct cycle time and main relief pressure as described in Section 7 SETSCREW CHECK OUT NS When replacing a hydraulic pump the pump cavity should be filled with hydraulic fluid prior to its engagement GATE VALVE YOKE LEACH 9 33 SECTION 9 SERVICE AND REPAIR HYDRAULIC SCHEMATIC SLIDING TOP DOOR FORK CYLINDER FORKS DOWN FORK 150 QD ROD 3 50 L FILTER 1 8
165. ver operate the Leach Millennium with any part of the control system removed Serious damage could result 9 Start the truck according to the manufacturers instructions and while it is warming up with the PTO Pump engaged and the parking brake applied continue the walk around inspection 10 Check all the operating indicator light console and running lights Make sure none are missing and that there are no burned out bulbs Check all the operating and running lights Make sure none are missing and that there are no burned out bulbs 11 Check the hydraulic tank sight gauge Add fluid if the level is below the indicated line See Section 5 SPECIFICATIONS of the service manual for the correct type of fluid to use To check the fluid level the packing ejection cylinders must be retracted the tailgate closed the lift arms up and forks tilted SIGHT GAUGE up in the travel position and the top door closed 12 Check the return line filter indicator 13 Again check for fluid leaks at the hydraulic cylin ders valves and fittings 14 Operate the controls to check each hydraulic circuit NOTE See operating instructions for specific opera tion of each control 15 After making sure that the area is clear of people and hazards back the unit up a few feet to ensure that the back up alarm and reverse lights are work ing properly Do not operate a unit that is in
166. ves Pilot check with relief valves on the top door 4 Clean or replace pilot check with relief valves cylinders sticking AIR PROBLEMS THAT WILL AFFECT HINGED TOP DOOR OPERATION The air limit switch on the lift arm pivot tube is out 1 Adjust air limit switch on lift arm pivot of adjustment and shifting the top door section of the main control valve at the wrong time Air tubing out of air limit switch at lift arm pivot Check air tubing and correct kinking of tube to main control valve top door section kinked reconnect partially or disconnected Air actuator on main control valve top door Replace air actuator on main control valve section leaking or sticking top door section Top door lockout switch defective Replace the top door lockout switch Air lines to the top door lockout switch kinked or Clean straighten or replace the air line plugged 1 Air limit switch at lift arm top door section not 1 Adjust or replace actuator arm or entire actuating limit valve 2 Main control valve top door section spool not Check air tubing from limit switch to actuator shifting or replace actuator 3 Refuse or material gathering on top door adding Clean top door excessive weight SECTION 8 TROUBLESHOOTING POSSIBLE CAUSE REMEDY OPERATION IS ERRATIC Inconsistent engine speed Maintain a constant RPM by use of the foot throttle Do not exceed posted RPM Hydraulic fluid too hot Check
167. ves pressure to the rod end to open the door a check valve is opened allowing the hydraulic fluid to exit the case end of the cylinders There is also a relief cartridge incorporated into the valve If for any reason the pressure exceeds 3600 PSI 250 bar in the case end of the cylinder assembly the relief cartridge will allow the excess pressure to escape to the hydraulic tank via the cylinder rod end tubing Relief Valve Cylinder SECTION 7 CHECK OUT CHECKING THE RELIEF PRESSURE HINGED TOP DOOR Operational Status Truck Off Keys Removed 1 Remove the pilot check relief valves from the case ends of the top door cylinders Plug all hydraulic lines and cylinder ports to protect from contamina tion 2 Locate and plug port V on the valve 3 Connect a porta power with a gauge capable of reading 5000 PSI 345 bar to the CYL port of the valve 4 Operate the porta power As the pressure rises watch the PILOT port of the valve When the pressure reaches 3600 3650 PSI 248 252 bar fluid should exit from the PILOT port of the valve 5 If the pressures are too high or too low replace the relief cartridge on the valve The relief cartridge is non adjustable and non serviceable gt Install the valves on the top door assembly SECTION 7 CHECK OUT HINGED TOP DOOR ADJUSTMENTS ADJUSTMENT OF THE HINGED TOP DOOR SEQUENCE VALVES The sequence valves are locate
168. yer 2 Never operate machinery while under the influence of intoxicants or narcotics Workers under the influ ence of intoxicants or narcotics present a hazard to themselves and others 3 Perform checks listed under Pre Operating Walk Around Inspection in Section 3 OPERATION LEACH SECTION 1 SAFETY PRECAUTIONS Publication of these precautions does not imply or in any way represent an all inclusive list It is the opera tors responsibility to be familiar with and ensure that operation is in accordance with safety requirements and codes including all applicable Occupational Safety and Health Act OSHA and American National Standards Institute ANSI regulations The word CAUTION precedes information pertain ing to potential hazards or unsafe practices which if disregarded MAY result in minor personal injury or damage to the equipment The word NOTE precedes information which is vital to the proper operation or maintenance of the equipment Never start or operate any malfunctioning equip ment a Be sure to immediately report any malfunctions to the proper authority b Power must be shut off ignition key removed and a sign attached to the steering wheel stat ing inoperative or malfunctioning equipment 4 Proper servicing requires specialized tools and pro cedures Service must be performed by authorized personnel only following procedures in the Leach Millennium Service Manual 5

Millennium Service Manual - Superior Truck Equipment Inc.

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