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2RII Serial #209719-15999 Service Manual

1. 8 6 Pushout Panel Will Not Slide Forward 8 6 Carrier and Packer Panel Stop Short of Home Position After Each Cycle 8 6 Pushout Panel Returns When Pushout Cylinder is Retracted 8 7 Pushout Cylinder Will Not Extend to Push QUEE 8 7 Load Will Not Push Out 8 7 Packer Panel Drifts Open While Packing Load Into 8 8 Cycle Time is Too 8 8 Tailgate Will Not Raise 8 8 Container Won t Lift 8 9 Winch Motor 8 9 Container Raises Very Slowly 8 9 Description of Hydraulic System 8 11 SECTION 9 SERVICE AND REPAIR 9 1 Description of Operating Cylinders 9 1 Test for Leaking Packer Panel Cylinders 9 2 Test for Leaking Carrier Panel Cylinders 9 4 Removal of Packer Panel Cylinders 9 7 Removal of Carrier Panel Cylinders 9 9 Disassembly of Operating Cylinders 9 11 Inspection and Replacement of Operating Cylinders 9 11 Reassembly and Installation of Operating Cylinders 9 12 Description of the Packer Panel 9 12 Bearing Replacement 9 12 Roller Replacement Shimming 9 13 Description of Tailgate L
2. LOSUITIO Ed d Edu S Y WE d dos Compaction Mule Container Container Handling Systems Terms You Need to Know Container Attachment lale TP Container Lifting Cylinder CLC Container Push Basic Attach SECTION 3 OPERATION Description of Operating Controls Location Of Operating Controls Compaction Cycle Operation Operating Procedures Pre operating Walk around Inspection Walk around Inspection Checklist Start Up Operating Instructions Positioning Pushout Panel TABLE OF CONTENTS SECTION 3 OPERATION continued Loading the Hopper 3 13 Attaching a Container to the Packer 3 13 Using a Winch or Container Lift Cylinder 3 14 Using a Container Push Bar 3 15 Packing the cmn atm e 3 15 Pushout Panel Operation During Packing PCM 3 16 3 16 Disconnecting the Container 3 16 Unloading at Dumpsite
3. 3 17 Lifting the Tailgate 3 17 Ejecting the 3 18 Lowering the 3 18 Shut 3 19 SECTION 4 GENERAL REPAIR PRACTICES Preparation for 4 1 Replacement 4 1 Service Bulletins 4 1 Safety 4 2 Prior to Performing Any Service or Repair 4 2 Safety During Service and Repair 4 2 Welding lt 4 2 4 2 Oxy Acetylene Torches 4 3 Removal Disassembly Repair 4 3 Reassembly and Installation 4 4 Electrical Testing 4 4 Checking for Voltage 4 4 Checking Continuity 0 4 4 WANG PT 4 4 Lifting Instructions 4 4 Capacity of Lifting Device Required for Removal 4 5 Sling Strap Specifications 4 5 Chain and Hardware Specifications 4 5 Capscrew Marking and Torque Values 4 6 SECTION 5 SPECIFICATIONS Body Dimension Illustration 5 1 Lubricants 5 2 Hydraulic 5 5 2 an 2 201 5id 202666524 2504
4. PACKER PANEL LEVER OBSERVE FLUID FLOW PACKER PANEL CYLINDERS OPERATIONAL STATUS Truck Running PTO Engaged 2 Shift the carrier panel lever outward to fully extend the carrier panel cylinders home position OPERATIONAL STATUS Truck Off PTO Disengaged 3 Disconnect and cap the lines that connect to the rod end of one cylinder 4 Shift the carrier panel lever outward to apply hydraulic pressure to the case end of the carrier cylinders Hold the lever 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 excessive piston seal leak If the cylinder does not leak excessively continue test OPERATIONAL STATUS Truck Off PTO Disengaged 5 f the cylinder does not leak reconnect hydraulic lines to the rod end of cylinder Repeat steps 3 5 for other cylinder SECTION 9 SERVICE AND REPAIR CARRIER PANEL LEVER Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components A el QD qm ally I 2 D 7 LEVER us Z 657 7 CARRIER PANEL OBSERVE FLUID FLOW 9 5 SECTION 9 SERVICE AND REPAIR 6 Shift the carrier panel lever inward to retract the carrier panel cylinder A CAUTION CARRIER PANE LEVER Loosen the hydraulic fittings slowly to releas
5. 5 Clean inspect and replace the guide and piston rings 7 as necessary When installing new rings the ends should be positioned on opposite sides of the tube to prevent leakage 6 After the tubes have been installed back into the case the retaining rings 6 should be installed packings 4 replaced and the head nuts 3 rein stalled 9 41 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PUSHOUT PANEL PUSHOUT PANEL Refuse is compacted against and ejected from the body by the Pushout Panel Two methods of controlling the movement of the pushout panel are available Telescopic and Clamp The telescopic system uses one multi stage cylinder while the clamp system uses two cylinders and a pushout bar In the clamp system the clamping mechanism is locat ed near the bottom of the pushout panel in the trough area In the telescopic system the telescopic cylinder is attached to the pushout panel approximately half way up the pushout panel During its movement through the body the pushout panel rides in a trough The panel rides on replaceable plastic and fiber wear blocks that control its movement in the trough and reduce friction In the clamp system one of the wear blocks is adjustable and is called the friction brake The front outside edges of the pushout WEAR BLOCKS panel ride on pushout shoes of the same material PUSHOUT SHOES FRONT WEAR BLOCK REPLACEMENT The wear blocks should be replaced before there
6. Latches will secure straight containe nnion pivot bars which meet ANSI Z245 6 container dimensions shown below 77 1 2 in 78 in i 72inmax 11 4 in 1 3 4 in The container attachment on this compactor as originally mounted is compatible with ANSI 2245 6 containers CONTAINER DUMP CONTROL NOTE Both container latch arms must be in place and latched before raising container A DANGER K Stand clear when container dumping mechanism is in motion ENGINE SPEED UP 281 PACKING OPERATION INSTRUCTIONS INWARD MOVE CONTROL OUTWARD FOR CARRIER DOWN FOR CARRIER UP NTROL INWARD e CO FOR PACKER OPEN MOVE CONTROL OUTW FOR PACKER CLOSE ote 1 en loading hopper n i Note 2 When body is full operate packer contri ii Be sure all persons are clear of hopper opening before operating controls SECTION 1 SAFETY PRECAUTIONS 12 000 LB CAPACITY 3 0 000 LB CAPACITY HCW 4722 KIA To prevent possible serious injury or death do not use this refuse collection vehicle to tow other equipment It is not intended designed or equipped for towing NOTE Both container latch arms must be in place and latched before raising container 5 SECTION 1 SAFETY PRECAUTIONS WT ENGINE VEE BEACON LIGHT PACKER SPEED UP 9 4 9 2 CARRIER CARRIER CARRIER Q 46 o d z o chassis unles engine CAUTI 0 N Serious pump dam
7. Truck Running PTO Engaged 1 Move the pushout lever to position the pushout panel approximately midway in the body 2 Weld a lifting eye to the roof of the body OPERATIONAL STATUS Truck Off PTO Disengaged 3 Attach a sling connected to a lifting device capable of lifting 750 165 to the telescopic cylinder 4 Remove the capscrews and bearing block halves connecting the pushout panel to the cylinder 5 Move the pushout lever to slowly retract the tele scopic cylinder until it is completely retracted OPERATIONAL STATUS Truck Off PTO Disengaged 6 Using the lifting device lower the telescopic cylin der until it is resting on the floor of the body 7 Disconnect the hydraulic line to the cylinder port Cap the hydraulic lines and the cylinder to prevent contamination of the hydraulic system 8 Remove the cylinder end case pin SECTION 9 SERVICE AND REPAIR PUSHOUT LEVER aro PUSHOUT LEVER ni NOTE For more information about lifting devices and slings refer to Sec 4 General Repair 9 Attach a sling connected to a suitable lifting device with a minimum lifting capacity of 750 Ibs 341 kg 10 Operate the lifting device slowly and guide the cylinder out of the body through the side access door Take care during removal to avoid damaging the surrounding components or hydraulic lines 9 39 SECTION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER PACK
8. DISASSEMBLY OF HYDRAULIC PUMP 307451 01 1 After removal thoroughly clean the pump Scribe the rear housing 1 and the front housing 9 so they are marked for reassembly Carefully place the pump body in a vise and remove capscrews 10 and washers 11 4 Remove pressure balance 2 and pressure plate 6 5 Remove keys 5 from the gears 4 Remove gears 4 pressure plate 3 and pressure balance 2 3 Lift the front housing 9 from the rear housing 1 and remove o ring 8 Be sure dowels 7 do not fall out NOTE Care should be taken not to bend or damage the pressure plates 6 Clean and dry all parts Inspect parts carefully for A WARNING Be sure to wear eye protection OQO 2 4 SS REPLACING SEALS IN FRONT HOUSING 1 Remove the front housing 9 as described in steps 1 3 of the disassembly instructions 2 Remove both outer seals 12 snap rings 13 and both inner seals 12 3 Clean seal bores 4 Install both inner seals 12 and both snap rings 13 Seal lips are to be installed towards inside of pump 5 Pack grease into both seal bores to cover the inner seals 6 Install both outer seals 12 Pack grease into both seal bores to cover the seals Seal lips are to be installed towards inside of pump 9 53 SECTION 9 SERVICE AND REPAIR REASSEMBLY OF HYDRAULIC PUMP 307451 01 1 Place the rear housing 1 with the opening up an
9. by training and experience in the safe operation HYDRAU LI FLU D Training includes complete knowledge of your employer s work rules all governmental regulations and manufacturer s operator and safety manuals relative to this machines safe use Cath SUBJECTS HIMSELF AND OTHERS TO i e Stand clear when tailgate is in motion amp during Keep access door closed 7 77 unloading cycle when ejector panel is in motion Use only the side access door i e Do not stand or A WARN l N G to enter or exit the body U s cross under raised Do not open access door unless 7 ve siopped at any ever tailgate Stand facing truck side Use both hands on LI gral andles all pressure against ejector Riding step shall not be used when i T Speeds are expected to exceed 10 mph or when Falling hazard iniri tered ced FOR CARRIER OMM 5 E R CARRIER UR distance traveled without stopping wil iced 2 A one mile Do not operate vehicle at speeds key removed oue CON AOL OUTWARD Vehicle is moving backward in excess of 10 mph for distances OR PASEL E OPEN Da not mount or dismount riding step when M vehicle is in motion over 2 tenths mile or In reverse Do not ride on loading sill or on gear when rider or riders are on Note 2 container attachment riding steps 2RII PACKING OPERATION INSTRUCTIONS LOADING INSTRUCTIONS FOR CLAMP PUSHOUT SYSTEM
10. paction mechanism The packer panel is hinged to the carrier panel and is controlled by the operating cylin ders Rollers supporting the two panels move along a track inside the tailgate The packer panel sweeps forward through the hopper picking up the refuse and together with the carrier panel moves the refuse forward into the body where it is compacted against the pushout panel BEARING REPLACEMENT OPERATIONAL STATUS PACKER PANEL LEVER Truck Running PTO Engaged 1 Move the packer panel lever outward to fully extend the packer panel cylinders and put the panel into the home position 2 Raise the tailgate for access to the bearing through bolts Support the tailgate with stands prior to loosening through bolts INSIDE BEARING HOUSING 9 12 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged Remove the nuts 2 and through bolts 1 Hemove the bearing assembly 3 Inspect the bearing surface for excessive or uneven wear scoring or other damage Heplace a worn bearing assembly Install the bearing housing over the packer panel tube and secure to the carrier panel channel with through bolts shims and nuts Torque to 900 ft lbs 1221Nm then tack weld the nuts to the bolts 8 Install the grease fitting and lubricate as described in LUBRICATION CHART Sec 6 PRE VENTIVE MAINTENANCE ud Check that the packer panel torque tube is straight Eve
11. stitute parts may affect the operation and performance of the unit and will void the warranty Insure maximum reliability and protect your investment insist on Leach Signature original factory replacement parts SERVICE BULLETINS In addition to the information provided in this Service Manual Service Bulletins are issued when needed to cover interim changes or to provide supplementary information necessary for maintaining the refuse unit in a proper safe operating condition Check with your authorized Leach dealer accordingly anyone who uses a service procedure or tool which is not recommended by Leach Company must first thoroughly satisfy himself that neither his nor the operator s safety will be jeopar dized by the service methods selected Any person who modifies their equipment must do so in accor dance with American National Standards Institute 2245 1 1992 It is important to note that deviating from these procedures could cause damage to the unit or render it unsafe However please remember that these procedures are not all inclusive 4 1 SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR 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 5 ignition key 3 Place an OSHA approved chock block in front of and behind the front tire 4 f steel supports are to
12. tion to proper preventive maintenance as described in this section will ensure and extend trouble free operation of the unit Particular attention to correct lubrication of the unit and maintenance of the return filler are probably the two most vital areas of preventive maintenance required The objective of preventive maintenance is to anticipate and prevent am operational difficulties before they require MATIN NS extended shut down 9 7 M 25 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 bul letins from Leach Company concerning updated maintenance information Keep those bulletins with this manual and make notes at the appropriate places in the manual referencing the updated infor mation IBI C s WT ME e 11 Service Dept P Verve E C M 6 1 SECTION 6 PREVENTIVE MAINTENANCE INSTRUCTIONS Grease weekly every 40 hrs of operation with MOBILUX EPI SERVICE grease or equivalent Oil weekly every 40 hrs of operation with SAE 10 or equivalent ILLUS LUBE POINT QTY Control levers Clamp cylinder
13. Avoid contact with piping hoses or cylinders to prevent burns Never use hands to check for leaks Hydraulic fluid escaping under pressure may cause injury FIRE PROTECTION 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 around when working with flammable mate rials such as fuel tanks or storage batteries 3 Never have an open flame as a light source 4 Never load ashes or other materials which might 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 activate the packer con trols SHUTDOWN 1 Put all controls in neutral 2 Set parking brake 3 Disengage PTO 4 Shut off engine 5 Shut off solenoid dashboard switch 6 Remove key 7 Lock vehicle SECTION 1 SAFETY PRECAUTIONS In case of injury seek proper medical treatment immediately Rubbish scrap paper and litter are highly com bustible Such material should be stored in metal containers entirely clear of sparks and flames 1 5 SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL CARRIER CARRIER CARRIER PACKER PACKER PACKER R KIBE CONTAINER FALLING SWINGING
14. Container attachment 9 Bump bar Lid guard CONTAINER PUSH BAR CPB 1 Control lever 2 Push bar 3 Lift pad 4 Container dumping cylinder 5 Bump bar 6 Container attachment 2 6 BASIC OPERATION All Leach container handling systems have three 3 basic steps for operation ATTACH The first step in container handling is to attach the con tainer to the rear loader by securing it with the latch arms of the container attachment ATTACH CONTAINER DUMP A container handling system is used to raise the con tainer and empty the refuse into the hopper of the rear loader DISCONNECT When the container is empty it is lowered to the ground the latch arms released and the truck is moved forward SECTION 2 INTRODUCTION DISCONNECT 2 7 SECTION 2 INTRODUCTION 2 8 SECTION 3 OPERATION GENERAL This section will provide all of the instructions necessary to operate the 2Hll Packmaster However prior to attempting any operation of the unit make sure you are familiar with all of the safety information contained in Section 1 SAFETY PRECAUTIONS DESCRIPTION OF OPERATING CONTROLS The following information is for descriptive purpos es only It is not to be misconstrued as operating instructions For operating instructions refer to OPERATING PROCEDURES later in this section There are only a few controls required for the complete and eff
15. Replace the cartridge with a new one if defective See Sec 7 CHECK OUT to check the sequence valve pressure 4 Replace o rings 5 f a valve cartridge is not readily available for replacement plug or cap the threaded orifice to prevent contamination until one is available NOTE Do not operate packer without cartridge installed INSPECTION AND REPLACEMENT OF SEQUENCE CARTRIDGE 1 Inspect all parts for damage of excessive wear replace defective parts 2 Replace all o rings every time a cartridge is removed DISASSEMBLY OF PILOT CHECK NOTE The pilot check portion of the 210384 SPC valve is not rebuildable and must be replaced as an assem bly 1 Clean the area around the pilot plug with solvent to prevent contamination 2 Remove the pilot cap 1 by using the special plug wrench See Sec 10 Service Tools 3 Remove the internal components as shown 2 INSPECTION AND REPLACEMENT OF PILOT CHECK 1 Inspect all parts for damage or excessive wear 2 Replace all o rings 3 every time the pilot check is disassembled If any part of the pilot check is worn the complete assembly must be replaced SECTION 9 SERVICE AND REPAIR SPC VALVE P N 300551 SEQUENCE CARTRIDGE SPC VALVE P N 210384 SPC VALVE P N 300551 9 23 SECTION 9 SERVICE AND REPAIR REASSEMBLY AND INSTALLATION OF PILOT CHECK 1 When replacing the complete assembly or just the o rings always check the
16. Truck Off PTO Disengaged 1 Loosen and release swing away the tailgate clamps 9 15 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged 2 Depress the speed up button and move the tailgate lift lever to raise the tailgate and hold 3 Second person observe the breather in both cylinders for fluid leakage A slight leak that soon stops is not critical A steady leak requires new piston seals ily E REMOVAL OF TAILGATE LIFT CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 With the tailgate closed attach a sling connected to a suitable lifting device with a capacity of 500 los 227 kg to the tailgate lift cylinder NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Disconnect the hydraulic line 1 at the cylinder port in the piston rod and cap the line 3 Remove the restriction pin 2 and plug the cylinder port 4 Remove the capscrew 3 washer 4 and cover 5 from the cylinder end 5 Remove capscrew 6 lockwashers 7 cover 8 and pin 9 from the rod end 9 16 DISASSEMBLY TAILGATE LIFT CYLINDER 1 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 227 kg to ease the disassembly of parts 2 Clean the mounting hardware and out
17. Truck Off PTO Disengaged c Remove the button plug from the end of the Main Control Valve bonnet using a screwdriver then shift the Main Control Valve linkage to the detented power position and release leaving the valve spool in the detented position OPERATIONAL STATUS PTO Engaged Truck Running d While observing the pressure gauge slowly increase the main relief valve setting The pres sure indicator will increase until the knockout pressure setting is reached and the Main Control Valve spool returns to neutral SECTION 7 CHECK OUT 1000 30007 S J 0 4000 PSI GAUGE PACKER PANEL SECTION 4 CARRIER PANEL LEY SECTION CAR ADJUSTING SCREW LESS THAN 1000 PSI CARRIER LEVER e The knockout pressures should be set at 1200 PSI 83 BAR for the packer panel section and 1800 PSI 125 BAR for the carrier panel sec tion If the knockout pressure setting requires adjustment it may be changed by turning the knockout pressure adjustment screw located inside the bonnet clockwise to increase the knockout pressure setting or counter clockwise to decrease the setting Once the proper knockout setting has been attained reinstall the button plug to seal the Main Control Valve f Return the main relief valve pressure setting to its specified value as described previously 7 5 SECTION 7 CHECK OUT CHECK RESISTANCE CARTRIDGE PRESSURE OPERATIONAL STATUS
18. Truck Running PTO Engaged LINE TO TELESCOPIC CYLINDER 1 At the 2 spool valve disconnect the line going to the extend port of the telescopic cylinder 2 Into this port on the 2 spool valve install the blank ing plug part no 16112 3 Attach a gauge 0 2000 PSI and port a power to the blanking plug 4 Operate the port a power and observe the pres sure obtained on the gauge The pressure should be 1600 PSI 111 BAR RESISTANCE 5 If it is necessary to adjust the pressure loosen the CARTRIDGE locking nut on the cartridge and turn the adjusting screw clockwise to increase pressure and counter clockwise to decrease pressure 6 Once the correct pressure setting has been obtained secure the carriage adjustment by tight ening the lock nut 1600 PSI 7 Remove the port a power and blanking plug Reinstall the line to the telescopic cylinder a D y E 0 E Zh LOCKING ADJUSTING NUT SCREW LEACH 7 6 SECTION 7 CHECK OUT CHECK SEQUENCE VALVE PRESSURE PUSHOUT Truck Running PTO Engaged i 3 1 Depress the speed up button 2 Move the pushout control lever to extend the pushout cylinder 3 Read the gauge just as the pushout cylinder begins extending Pressure should be 1200 PSI 83 BAR IF NOT SPEED UP OPERATIONAL STATUS BUTTON Truck Off PTO Disengaged 4 Correct pressure by a Removing nut b Loosening jam nut c Adjusting setscrew in t
19. 7 Check Out Cycle packer 6 or 7 times to bleed air out of system SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING TELESCOPIC CYLINDER POSSIBLE CAUSE REMEDY 1 Excessive fluid flow being forced through the 1a Release speed up button main relief in the 2 spool valve 1b Only partially pull feather the 2 spool valve control handle LOAD WILL NOT PUSH OUT 1 Less than full pressure in telescopic cylinder 1a Perform test for leaking cylinder and repair 1b Adjust main relief pressure See Sec 9 Service and Repair 2 The operator is trying to push the load out 2 Move the unit forward to finish unloading against a pile of refuse dirt or bank of a hill PUSHOUT PANEL SLIDES FORWARD TOO FAST WHILE PACKING REFUSE 1 Cylinder bypassing 1 Perform test for leaking cylinder 2 Resistance setting too low 2 Adjust resistance cartridge PUSHOUT PANEL WILL NOT SLIDE FORWARD AUTOMATICALLY 1 Resistance setting too high 1 Reduce resistance setting 2 Packer panel not applying full force to move 2a Check pressures pushout panel forward 2b Check pump CARRIER AND PACKER PANEL STOP SHORT OF HOME POSITION AFTER EACH CYCLE POSSIBLE CAUSE REMEDY 1 Unit full 1 Empty unit 2 Resistance too high 2 Reduce resistance setting 3 Packer panel does not deliver full force 3 See Section 8 Troubleshooting SECTION 8 TROUBLESHOOTING CLAMP SYST
20. Clamp mechanism PTO shaft Tailgate lift cylinder top and bottom Tailgate clamps 7 Operating cylinders top pivots 0O 0008 E Oo Not Shown Telescopic cylinder pivot pins 6 2 KM 1 In below freezing climates all grease and fluids should have a cold test rating of at least 20 F ILLUS LUBE POINT QTY NOTE NOTE The packer panel must be in the home position to lubricate the following lube points 8 Operating valve 4 1 control lever e 9 Inside amp outside 3 bearing housing e 10 Carrier panel cylinder 1 end e 11 Packer panel cylinder 2 roller ends e 12 Rollers 4 3 amp 4 E 13 Optional control 2 lever LEACH SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART 74 gyt ES 4 AN 3 582 WS INS SP fogy 5 RE 2955 BX X NN A Fa 8598 c PENNA 0 zc 89 2 Nd S S88 4 SNS 98 5 SpA o gt ZO8L5 IN GAS ge gge e A 2 0 SS O o 2 7 2 y4 00 298 935 Ho 0 Dp N o00C y oS olg gt os vy 2 25 2 i we eSSOOL SG eros teacor 3 aid lt H Q o PREVENTIVE MAINTENANCE PX 4 pum N N S En E BE j CB Qe o 30 6 4 HYDRAULIC SYSTEM SERVICE See accompanying Hydraulic System illustration Proper maintenance of the hydraul
21. Linkage binding or restrictive CARRIER PANEL VALVE SECTION WILL NOT SHIFT TO NEUTRAL 1 Perform test for leaking cylinder See Sec 9 Service and Repair 2 Perform pressure check as described in Sec 7 Check out 3 Inspect and free linkage as necessary 1 Carrier cylinder seal leaking 2 Pressure too high 3 Linkage binding or restrictive PACKER PANEL DOES NOT DELIVER FULL FORCE TO PACK LOAD INTO BODY POSSIBLE CAUSE REMEDY Perform checkout procedures through pres sure checks See Sec 7 Check out Add fluid to correct level See Sec 6 Preventive Maintenance Service system as described in Sec 6 Preventive Maintenance Hydraulic pressure incorrect Hydraulic fluid in tank is low Tank strainer screen is dirty this condition will starve pump and cause noise in the system Wrong type of hydraulic fluid in system Main relief section of 2 spool directional valve opens too soon Hydraulic pump is defective and will not deliver full pressure Operating cylinder piston seal is leaking Operating valve pressures are too low Air in hydraulic lines Drain and refill with correct type of hydraulic fluid See Sec 5 Specifications Adjust main relief setting on 2 spool valve See Sec 9 Service and Repair Replace pump See Sec 9 Service and Hepair Perform test for leaking cylinder See Sec 9 Service and Repair Perform pressure checks See Sec
22. Main Line Pressure 7 4 Check Packer and Carrier Panel Shifting Pressure 7 5 Check Resistance Cartridge Pressure 7 6 Check Sequence Valve Pressure 7 7 Check Friction Brake Clamp 7 8 Check Clamp Mechanism 7 8 Check Pushout Shoes and Wear Blocks 7 9 Power Off 7 9 SECTION 8 TROUBLESHOOTING 8 1 Sons PP 8 1 Dieseling in Hydraulic Systems 8 2 Operation is 8 3 Pump Noise is 8 3 Engine Will Not Speed Up When Carrier Panel Lever or Speed UP Button is Engaged 8 4 Engine Speed Will Not Return to Normal When Packing Cycle is Completed or Speed Up Button is Released 8 4 SECTION 8 TROUBLESHOOTING continued Packer Panel Valve Section Shifts too Soon 8 4 Carrier Panel Valve Section Shifts to Neutral too Soon 8 5 Packer Panel Valve Section Will Not Shift 8 5 Carrier Panel Valve Section Will Not Shift To Neutral 8 5 Packer Panel Does Not Deliver Full Force to in House Hydraulic Fluid Testing 8 5 Loud Squealing Noise When Manually Retracting Telescopic Cylinder 8 6 Load Will Not Push Out 8 6 Pushout Panel Slides Forward Too Fast While Packing Refuse
23. NEG RD BK mill ETTET 1 SPEED UP P S L S TURN LT RUN FUSE BE CLEARANCE LT YW RD RD BK LT SOLENOID BTA YW RD US ET S qo BE WE BE WE OE i TAILGATE NEUTRAL SW Ar SOLENOID COLOR CODE KEY RED RD BROWN BN WHITE WEJ GREEN GN YELLOW YW BLUE BE GREEN WHITE GN WE YELLOW BLACK YW BK PINK PK RED WHITE RD WE ORANGE 0E BLUE WHITE BE WE RED BLACK RD BK PINK BLACK PK BK PINK BLUE PK BE TAN BLACK WHITE BK WE ORANGE WHITE OE WE WE SPEED UP SWITCH WE BE WE TOP REAR OF BODY JUNCTION BOX pa RD WE PK HARNESS WIRE LIGHT BAR RD T oat 0E RD WE BE WE E 2 e Cou CAE HARNESS WIRE cr HE L S TAILGATE 1 BE BN WEJ 9 59 BN YW CD RIGHT TURN RIGHT STOP amp TAIL RIGHT TURN ar aa z BACK UP LIGHT d RIGHT STOP amp TAIL RD LICENSE PLATE BN LIGHT PM WE 63 BACK UP ALARM WE YW LEFT STOP amp TAIL RD WE w BACK UP UTILITY LIGHT pou LEFT TURN LEFT TURN LEFT STOP amp TAIL E F R BUZZER MARKER LIGHT BN SECTION 10 SERVICE TOOLS GENERAL The service tools shown will be required for some service and repair procedures These tools are available from your local authorized Leach distributor The actual use of each tool is descr
24. PANEL The correct method of operation is thoroughly described in the 2RII Operator s Manual Our policy is not to describe the many different ways in which a unit might be incorrectly operated however in an attempt to provide maintenance personnel with clues that may assist in the diagnosing of a reoccurring carrier packer panel concern that might be operator induced we offer the following Skimming is a result of the operator interrupting the movement of the packer panel and stopping the pack er panel before it rotates perpendicular 90 to the car rier plate When the packer panel is not allowed to fully rotate and the carrier is then moved toward the home position a shear load is induced to the lower channel of the carrier panel The carrier panel lower channel is designed for compression or tension not shear loads If the lower channel on the carrier panel cracks or the center bearing straps consistently break suspect that the unit is being skimmed REMOVAL OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove top sheet supports for better accessibility 2 Remove the packer panel as previously described 3 Remove the operating cylinders as previously described 4 Remove the tubing to the operating valve Cap the lines and plug the ports in the valve to prevent con tamination 5 Remove the carrier panel 9 50 Short cycling is when the carrier panel is stopped before it completely
25. Pry out the rod wiper 7 rod seal 8 and o ring 9 With the cylinder securely anchored to a bench Remove compression spring 10 Unscrew the piston rod 11 from the piston disc Remove the wear ring 14 and piston seal 15 Clean the outside of the cylinder with solvent to prevent dirt from entering the cylinder during disas sembly pression Care should be used when disassembling by loosen ing nuts carefully and therefore relieving spring tension safely lockwashers 5 pull out the piston rod assembly 12 and remove the rod o ring 13 9 37 SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CLAMP CYLINDER 1 Check the bore of the cylinder thoroughly for cracks rust scoring or excessive wear 2 Check all other parts for damage 3 The rod wiper 1 head o ring 2 rod seal 3 wear ring 4 piston o ring 5 and piston seal 6 are supplied as a repair kit and must be replaced any time the cylinder is disassembled NOTE If the cylinder is not to be installed immediately keep the parts sealed to prevent dirt from entering the cylinder REASSEMBLY AND INSTALLATION OF CLAMP CYLINDER 1 Reassemble and install the clamp cylinder in the approximate reverse order of disassembly 2 During reassembly pour one cup of hydraulic fluid into the vented end of the cylinder to help prevent rust 9 38 REMOVAL OF TELESCOPIC CYLINDER OPERATIONAL STATUS
26. Secure cable to lifting device Container overload Reduce weight of material in container Container frozen to the ground Do not use lifting device to break container loose from the ground Control linkage is not moving the directional valve Repair the linkage Lifting motor or cylinder s by passing hydraulic Repair or replace the defective component fluid Shear pin or key broken between winch shaft Replace the key or pin and drum WINCH MOTOR LEAKING 1 Shaft seal damaged 1 Replace shaft seal 2 Motor worn internally 2 Replace motor CONTAINER RAISES VERY SLOWLY 1 Winch motor by passing 1 Repair or replace motor 2 Rear loader hydraulic system not providing 2 Check and repair rear loader hydraulic sufficient flow rate or pressure for container system following procedures in service handling systems manual SECTION 8 TROUBLESHOOTING SECTION 8 TROUBLESHOOTING CLAMP SYSTEM DESCRIPTION OF HYDRAULIC SYS TEM The following is a description with flow diagrams of what happens in the hydraulic system of a clamp type system during the loading packing and unloading oper ations of the unit Operator action is presented and then a description of the hydraulic flow and the interaction of system compo nents i e valves and cylinders follows Before pro ceeding to the flow diagram refer to the illustration and become familiar with the system component nomencla ture S
27. are clear of hopper opening before operating controls STROBE LIGHT WARNING A WARNING TAILGATE Do not transport container Do not operate OPEN O meenanism vehicle in excess Transporting a container could result in personal of 20 mph from the injury or property damage stand up position WARNING Stand facing truck side Use both hands on grab handles Riding step shall not be used when Speeds are expected to exceed 10 mph or when distance traveled without stopping will exceed 2 tenths of one mile Vehicle is moving backward Do not mount or dismount riding step when vehicle is in motion Do not ride on loading sill or on container attachment SECTION 1 SAFETY PRECAUTIONS BY ENGINE This unit conforms to all American SPEED UP HYDRAULIC National Standards Institute safety requirements Z 245 1 in effect on FLU D ONLY the date of manufacture LEACH DRIVER SIGNAL DO NOT FILL BEYOND THIS LINE FILTER ELEMENT CHANGE To ensure oil cleanliness and longer wr I EJECTION machine life change the element at LEACH COMPANY intervals of 20hrs 50hrs and at rs NN EJECTION 250hr intervals thereafter SAFE RANGE XXXXXXXX ALL CYLS RETRACTED CAUTION NON A WARNING oe em ing YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS Failure to do so may result in personal injury fou are
28. being careful not to overtighten 10 Replace the plastic plug 2 and setscrew 3 9 40 SECTION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER DISASSEMBLY ROD END 4 5 1 Prior to disassembling the cylinder first make four clips from thin steel These clips should be approx imately 020 thick 72 wide and 4 long Bend each clip at a right angle about 1 from the end so it can hang over the edge of the tube 2 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to prevent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up 3 Remove the setscrew 1 plastic plug 2 and head nut 3 Insert a long thin screwdriver under the end of the retaining ring 6 prying it out of the groove Using another screwdriver place it behind the retaining ring and work your way around the cylin der prying the ring out of the groove as you go When you are opposite the starting point hang one of the clips on the edge of the tube so that the long end of the clip is between the ring and the groove in the cylinder Continue to use the screwdrivers as ory bars and hang the remaining clips The clips CASE END should be equally spaced around the retaining ring 4 Using an appropriate lifting device raise the tube completely out of the cylinder The retaining ring 6 will come out with the tube
29. broken or Repair or replace engine mounts as required missing ENGINE SPEED WILL NOT RETURN TO NORMAL WHEN PACKING CYCLE IS COMPLETED OR SPEED UP BUTTON IS RELEASED 1 Short circuit in electrical system Check for and repair short in system as described in Electrical Section See Sec 9 Service and Repair 2 Carrier panel lever speed up switch is defective Repair replace or adjust as required 3 Solenoid mounting loose broken or incorrect Be sure solenoid mounting is correct and Secure 4 Truck engine mounts loose worn broken or Repair or replace engine mounts as required missing PACKER PANEL VALVE SECTION SHIFTS TOO SOON 1 Object in hopper that the packer panel cannot Recycle unit Rearrange or remove refuse if move necessary 2 Cycle time too fast Adjust speed up cable length 3 Packer panel valve section pressure too low Perform pressure checks as described in Sec 7 Check out SECTION 8 TROUBLESHOOTING CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON 1 Perform pressure check as described in Sec 7 Check out PACKER PANEL VALVE SECTION WILL NOT SHIFT Perform test for leaking cylinder See Sec 9 Service and Repair Perform pressure check as described in Sec 7 Check out Inspect and free linkage as necessary 1 Carrier panel valve section pressure too low 1 Packer panel cylinder seal leaking 2 Packer panel valve section pressure too high 3
30. but also pro vides a perfect situation for air separation In addition the flow regulator bypass at the pump output is returned back to the pump input this recirculates the fluid air and allows for the separation of even more air In cases where the seals in 2RIl packer cylinders appear to be burnt or melted consider the possibility of air ingestion The following suggestions may help in eliminating this problem 1 Ensure that the pump suction connections are tight It is possible for a suction hose connection to allow air in without leaking any fluid out 2 The pump shaft seal can allow air into the system Replace if the seal is suspect 3 Check for air ingestion around the packings on the gate valve stem Tighten the packing nut if suspect 4 Excessive system flow rate cycle time too fast can agitate the hydraulic fluid Set the cycle time according to specifications 5 Do not thin hydraulic fluid with diesel fuel lowers the flash point Weather permitting use a higher flash point fluid After making any repairs on the hydraulic system bleed the system at reduced engine speed and pressure to remove any trapped air Depending on the size of the component e g cylinder hose it may be necessary to cycle the unit several times Of course the larger the air pocket the more cycles are needed To avoid potential problems thoroughly bleed all hydraulic systems and ensure that all inlet connections are tight and not i
31. components for sharp edges for burrs 2 Coat all parts with hydraulic fluid before inserting them into the valve body 3 Reassemble the components in the reverse order of disassembly 4 Connect all hydraulic lines in approximate reverse order of disassembly OPERATING VALVE OPERATING The operating valve is located on the tailgate above the packer and carrier panels It controls the operation of the packer and carrier panels through the entire pack ing cycle It may have either 3 or 4 individual valve sec tions depending on the installation of options The standard valve will have 3 sections with one section unused if there are no container handling options installed 9 24 REMOVAL OF THE MAIN CONTROL VALVE Place the packer and carrier panels in the inter rupted cycle position 2 Move the packer panel control lever outward to sweep the packer panel through the hopper toward the home position Stop the movement of the panel move the control lever to the neutral position when the panel becomes vertical straight up and down 3 Turn off the engine remove the keys 4 Disconnect the shift linkage 5 Disconnect and cap all hydraulic lines and hoses 6 Plug all open ports on the valve to prevent contam ination NOTE The operating valve assembly and bracket weigh approximately 100 Ibs Use appropriate lifting pro cedures and techniques when handling this assem bly 7 Remove the capscrews w
32. every forty 40 hours of operation for cracked or fatigued welds loose or broken fasteners worn bear OR ings pin hubs or pins The four 4 torque tube bearing SA straps should be lubricated a minimum of every forty Me h XO 40 hours of operation ES SE BEARING STRAP PACKER PANEL TORQUE TUBE MONTHLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM LIFTING HOOK a Once a month remove and clean the hydraulic tank fluid strainer as described in HYDRAULIC SYS TEM SERVICE in this section A thorough inspection of any container lifting hook should be completed once a month consisting of check ing for distortion cracks nicks wear latch engagement and secure end connections Maximum distortion allowable is an 8 percent increase in the throat dimen sion or a 10 degree twist in the hook Cracks nicks and wear must not exceed 10 percent of any dimension b Each month check the tailgate lift cylinder air breather If plugged replace it with a new breather THROAT OPENING Visually inspect before each use for obvious damage BACK YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a year drain flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SERVICE in this section b Once a year replace the hydraulic tank air breather c Once a year replace the fibrous tailgate lift cylinders air breathers 6 10 GENERAL The 2RIl Packmaster has been designed to provide long peri
33. replacement parts NOTE See Section 9 SERVICE AND REPAIR for specific repair instructions ELECTRICAL TESTING The electrical system used on the unit consists of vari ous lights switches and wiring Testing the compo nents and wiring can be accomplished by two simple checks CHECKING FOR VOLTAGE and CHECKING CONTINUITY CHECKING FOR VOLTAGE A test light is used to check for the presence of electric ity in a live circuit Connect the test light clip to a good ground and the probe at the point where the presence 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 WELDING 1 Completely clean out an old weld before rewelding 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 alive 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 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 t
34. sole noid ON OFF switch a relay and solenoid air cylin der A speed up push button and speed up switch connected to the operating control linkage on the Operating Valve The function of the speed up sys tem is to speed up the engine and provide more power to the hydraulic pump during operation of the various hydraulic cylinders TAILGATE OPEN LIGHT 3 This warning light located in the cab will illuminate if the tailgate is ajar Having the tailgate ajar will also sound the backup alarm and illuminate the backup NN CAUTION lights TAILGATE AWARNING Operation of the unit with an illuminated or defective warning system can result in person al injury and or equipment damage 3 3 SECTION 3 OPERATION ENGINE SPEED UP PUSH BUTTON 4 When depressed this push button switch will cause the engine to speed up and supply more power to the hydraulic system Located on the lower front left side of the body it is depressed by the operator when operat ing either the pushout lever or tailgate lift lever NOTE Additional speed up control buttons may be installed with optional winches and container attachments FRONT CONTROL VALVE The front control valve is located behind the access door on the front left hand side of the body The control levers for this valve extend out through a cutout in the door This valve controls the ejection pushout panel and the lifting of the tailgate PUSHOUT LEVE
35. sole and exclusive warranty of the Leach Company THE COMPANY MAKES NO WARRANTY AS TO MERCHANTABILITY FITNESS FOR USE LEGAL ITY 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 DAMAGES OF ANY KIND OR NATURE OTHER THAN ITS LIMITED WARRANTY OF REPLACE MENT 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 warranty will be void and no effect if a Company products are modified other than as done at its fac tory or as authorized to be done by the factory in writing or b Parts or assemblies of any other man ufacturer 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 the Leach distributor for exchange The labor to replace or repair the part shall be the resp
36. the cylinder is back to the tank AEN PRESSURE pp RETURN OPERATING VALVE SS TAILGATE LIFT CYLINDER SPC VALVE HYDRAULIC 7 FLUID TANK gt TAILGATE PACKER LIFT CYLINDER CYLINDER PUSHOUT CYLINDER 8 13 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM CARRIER amp PACKER PANELS MOVE DOWN TO INTERRUPTED CYCLE POSITION OPERATOR ACTION None Operating valve shifts automatically HYDRAULIC SEQUENCE At the end of the packer panel cylinder stroke pressure builds to 1200 PSI 83 BAR causing the operating valve to shift diverting flow to the rod end of the carrier cylin ders The cylinders retract moving the carrier and pack er panels down to the interrupted cycle position trapped fluid keeps the packer panel cylinders retract ed At the end of the carrier cylinder retraction stroke pressure builds to 1500 PSI 104 BAR causing the oper ating valve to shift to neutral umm PRESSURE m RETURN TRAPPED FLUID D mo n py OPERATING VALVE E TAILGATE Z LIFT Y CYLINDER SPC VALVE HYDRAULIC lt FLUID TANK PACKER 22 TAILGATE CYLINDER LIFT CYL PUSHOUT CYLINDER 8 14 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM PACKER PLATE SWEEPS HOPPER OPERATOR ACTION Operator shifts the control levers outward to start com paction HYDRAULIC SEQUENCE F
37. with more than one container handling system 2 4 ARM LATCH PUSH BAR LIFTING CYLINDER SECTION 2 INTRODUCTION GENERAL TERMS YOU NEED TO KNOW The main purpose of a refuse body is to load compact Before going further become familiar with the contain transport and unload refuse To assist in loading of handling terms you will need to know refuse in containers various container handling sys tems are available to be mounted on Leach rear load ers A refuse container may be a mobile residential one 1 cubic yard container with casters or a ten 10 cubic yard stationary commercial container The equipment required to lift and empty these containers will vary according to the container s type and size HOOK 1 Throat Opening 2 Back 3 Heel 4 Hook Safety Latch 5 Point 6 Base CONTAINER 1 Trunnion bar 2 Hook point 3 Lid CONTAINER ATTACHMENT o lem 1 Loading sill 2 Arm 3 Latch 4 Guide ear S7 T E 2 5 SECTION 2 INTRODUCTION WINCH 1 Control lever 2 Engine speed up button 3 Hook 4 Hook safety latch 5 Cable 6 Winch assembly 7 Container attachment 8 Bump bar Lid guard CONTAINER LIFTING CYLINDER CLC 1 Control lever 2 Engine speed up button 3 Roller guide 4 Hook 5 Hook safety latch 6 Cable 7 Lifting cylinder assembly 8
38. 1 Remove the old track bar and make sure the track channel is smooth and clean 2 Weld a new track bar in place The surface of the track bar must be at 90 from the side of the tail gate so the roller will run true SECTION 9 SERVICE AND REPAIR CARRIER PANEL PACKER PANEL The Leach track bar is made out of special alloy bar steel Do not substitute a different steel It may cause damage to the tailgate WRONG RIGHT 9 51 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF LEACH 5 HYDRAULIC PUMP 307451 01 Ro arrangement It is usually mounted under the body near the front end curb side The Leach pump can accom modate PTO shafts that turn either clockwise or coun terclockwise rotation The locations for the suction and pressure hoses are clearly indicated by markings in the housing The pump which serves the complete hydraulic system CSS NS 5 9 I is a gear type coupled to the PTO shaft through a yoke J REMOVAL OF HYDRAULIC PUMP GATE VALVE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Shut the gate valve at the underside of 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 absolutely clean container and the fluid poured back into the tank 4 Disconnect the pressure hose at the pump an
39. 2 5 2 Total System 5 2 zx no vo Ge oes Grae a we 5 2 Leach Hydraulic Fluid Recommendation 5 2 Hydraulic 5 2 TABLE OF CONTENTS SECTION 6 PREVENTIVE MAINTENANCE 6 1 Operating and Maintenance Records 6 1 Lubrication 6 2 Hydraulic System 6 5 Checking Fluid Level Daily 6 5 Clean Tank Breather Weekly 6 5 Check Replace Return Line Filter 6 5 Replacement of Filter Element 6 5 Cleaning Hydraulic Strainer Monthly 6 5 Flushing Hydraulic System Yearly 6 6 Hydraulic System 6 7 Contamination 6 7 Commercial Hydraulic Fluid Testing 6 7 In House Fluid Testing 6 7 Preventive Maintenance Requirements 6 8 Daily Preventive Maintenance 6 8 Weekly Preventive Maintenance 6 9 Yearly Preventive Maintenance 6 10 SECTION 7 CHECK OUT 7 1 Check Hydraulic Tank Fluid Level 7 1 Check Engine Solenoid Switch 7 2 Check Engine Speed Up Switches 7 2 Check Packing Cycle Time 7 3 Check 7 3 Check
40. 7 500 Ibs 3402 kg to the tailgate as shown Operate the lifting device no more than necessary to support the weight of the tailgate 9 18 SECTION 9 SERVICE AND REPAIR 5 Remove cap screw 1 and locknut 2 to remove retainer 3 and hinge pin 4 6 Opperate the lifting device and or move the truck forward to free the tailgate from the body 7 Position the tailgate on the supports as needed to facilitate repairs The supports must be capable of supporting 7 500 Ibs 3402 kg INSPECTION OF TAILGATE 1 Inspect all the sheet metal for bends dents or tears Check the hardware holes for enlargement or breaks in the metal Check threaded holes for stripped or otherwise damaged threads Check the tailgate seal for any sign of deterioration Check handles for looseness 2 Replace any defective or worn part Follow all safe ty precautions pertaining to welding described in Sec 1 SAFETY 3 See Sec 4 GENERAL REPAIR INSTRUCTIONS for information pertaining to welding repairs REASSEMBLY AND INSTALLATION OF TAILGATE Reassemble and install the tailgate in the approximate reverse order of disassem bly and removal 9 19 SECTION 9 SERVICE AND REPAIR FRONT CONTROL VALVE The front control valve is located behind the access door in the front left hand side of the body It is manu ally activated and controls the raising and lowering of the tailgate and the operation of the pushout panel This v
41. CYLINDER 8 22 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PANEL SWEEPS BACK OVER LOAD OPERATOR ACTION The operator moves the control levers inward to start the compaction cycle HYDRAULIC SEQUENCE Operator action causes the operating valve to shift diverting flow to the rod end of the packer panel cylin ders The packer panel cylinders retract causing the packer panel to sweep rearward over the load Return fluid flow from the cylinder is back to the tank NENNEN PRESSURE 9999999999 RETURN TAILGATE OPERATING 222 LIFT VALVE CYLINDER act HYDRAULIC FLUID TANK TELESCOPIC CYLINDER a TAILGATE LIFT CYLINDER PACKER CYLINDER 8 23 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM CARRIER amp PACKER PANELS MOVE DOWN TO INTERRUPTED CYCLE POSITION OPERATOR ACTION None Operating valve shifts automatically HYDRAULIC SEQUENCE At the end of the packer panel cylinder stroke pressure builds to 1200 PSI 83 BAR causing the operating valve to shift diverting flow to the rod end of the carrier cylin ders The cylinders retract moving the carrier and pack er panels down to the interrupted cycle position trapped fluid keeps the packer panel cylinders retract ed At the end of the carrier cylinder retraction stroke pressure builds to 1800 PSI 125 BAR causing the oper ating valve to shift to neutral MEE PRESSURE 0000 RETURN TRAPPED FL
42. EM PUSHOUT PANEL RETURNS WHEN PUSHOUT CYLINDER IS RETRACTED CLAMP WILL NOT RELEASE POSSIBLE CAUSE REMEDY Refuse under pushout bar and or refuse jamming Clean out area around pushout bar amp clamp against pushout panel Clamp spring broken Replace spring clamp assembly See Sec 9 Service and Repair Pushout bar bent and binding on pushout panel Clamp Assembly Sec 9 Service and Repair Cracked or broken clamp block Replace clamp block See Clamp Assembly Sec 9 Service and Repair Operator holding speed up button Release speed up button PUSHOUT CYLINDER WILL NOT EXTEND TO PUSH OUT LOAD Sequence valve cartridge is defective Replace cartridge or adjust See Sec 9 Service and Repair Operator trying to push load out against pile of Unload unit as described in Sec 3 Operation refuse dirt or bank of hill Leaking piston seal in clamp cylinder Perform test for leaking cylinder and repair as required See Sec 9 Service and Repair Leaking piston seal in pushout cylinder Perform test for leaking cylinder and repair as required See Sec 9 Service and Repair Hydraulic tubing is damaged pinched shut Replace tubing Main relief pressure too low Check pressure See Sec 7 Check out LOAD WILL NOT PUSH OUT CLAMP SLIPS AND PUSHOUT BAR SLIDES THROUGH PUSHOUT PANEL Pushout bar has grease on it Clean bar and area around bar Pushout bar is worn
43. EMOVAL OF CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet to provide better accessibili ty Remove two capscrews 1 and lockwashers 2 securing the upper track hole cover 3 and remove the upper covers from each side of the tailgate OPERATIONAL STATUS Truck Running PTO Engaged ool CARRIER PANEL LEVER 2 Shift the carrier panel lever and cycle the unit until the roller assembly on the upper end of the carrier panel is in line with the open upper track hole OPERATIONAL STATUS Truck Off PTO Disengaged NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 3 Secure chains or a sling to the upper and lower end of the carrier panel Attach the other end to a suitable lifting device with a minimum lifting capac ity of 1 600 165 726 kg Adjust the hoist so that it will support the panel once the roller assembly and pivot pin are removed but not so tight that it changes the position of the carrier panel Zr 9 9 SECTION 9 SERVICE AND REPAIR 4 Once the carrier panel has been securely supported remove the roller assemblies 1 from each side of the tailgate through the open upper track holes Remove the split pin that retains the roller pivot 2 and remove the roller shaft bushings 5 Secure a nylon sling around the cylinder and attach to a lifting device with a lifti
44. ERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 6 Disconnect and cap the hydraulic line at the case end of the pushout cylinder OPERATIONAL STATUS Truck Running PTO Engaged CHECK FLOW 7 Move the pushout lever forward as if to retract the pushout bar and observe the fluid flow from the open cylinder port The flow of hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces indicates an excessive piston seal leak Disassemble the cylinder and replace the piston seal as described later in this section REMOVAL OF PUSHOUT CYLINDER OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the nylock socket head capscrew 1 and pushout bar holder 2 from the pushout cylinder piston rod 3 2 Disengage the bar from the lock in the head of the piston rod PUSHOUT LEVER 3 Move the pushout lever to fully retract the pushout cylinder 9 30 SECTION 9 SERVICE AND REPAIR CAPS OPERATIONAL STATUS Truck Off PTO Disengaged 4 Disconnect the two hoses fittings and elbow from the pushout cylinder Cap and plug the hoses and cylinder ports 5 Remove capscrews 1 lockwashers 2 and strap gt 3 plate 5 and locking plate 6 6 7 Remove cylinder end pin 7 6 Remove cap B screw 4 keeper d 8 Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device
45. GATE CLAMPS 3 9 SECTION 3 OPERATION Do not operate a unit that is in need of service or repair 16 Report any problems found during the pre opera tion walk around inspection to the maintenance supervisor for service or repair place a tag on the steering wheel using a non reusable fastener stating the unit is inoperative and remove the keys WALK AROUND INSPECTION CHECKLIST Lh Decals in place and readable 2 Look for any fluid leaks 3 Mounting hardware tight and in place 4 Tailgate clamps closed and tightened 5 Hydraulic fluid reservoir at correct level 6 All operating levers in neutral positions 7 Pushout panel area clear of debris 8 Engine warmed up according to manufacturer s instructions 9 All operating and running lights functioning 10 Engine speed up buttons operational 11 Packing cycle operates properly 12 Driver signal alarm can be heard 13 Back up alarm and tailgate ajar light are operable 14 Report any problems to proper personnel 3 10 SECTION 3 OPERATION START UP OPERATING INSTRUCTIONS 1 Inspect and start the truck as described in pre opera tional walk around inspection 2 Engage the Pump PTO control to start the hydraulic pump 3 Place the solenoid switch in the ON position SECTION 3 OPERATION POSITIONING PUSHOUT PANEL To load the unit the pushout panel must be positioned toward the rear of the body 1 Ch
46. ING REPLACEMENT 1 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to prevent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up 2 Remove the setscrew 1 and plastic plug 2 from the head nut 3 Remove the smallest head nut 3 using a strap or chain wrench If the tube turns with the head nut tighten the next head nut slightly 4 Repeat steps 2 and 3 to remove each head nut TELESCOPIC 5 Using a suitable lifting device attached to the rod CYLINDER eye 5 pull up on the tube The packing 4 should come out as the tube is raised If it does not clean off a section of the tube and wrap masking tape around it Lower the wrapped section of tube down into the packing and then lift the tube once again 6 When removing the packing from succeeding larg er stages replace the head nut 3 on the stage directly above the section you need access to Wrap a strap under the head nut and use it to lift the tube 7 Prior to installing new packing 4 clean the area thoroughly and lubricate the new packing set inside and out with an all purpose grease CASE END 8 Ifthe proper size packing driver is not available the packing may be installed by turning the head nut over placing it on the packing and using a rubber or plastic mallet tap the packing into place 9 Replace all of the head nuts 3
47. IPTION OF HYDRAULIC SYS TEM The following is a description with flow diagrams of what happens in the hydraulic system of a telescopic type system during the loading packing and unloading operations of the unit Operator action is presented and then a description of the hydraulic flow and the interaction of system compo nents i e valves and cylinders follows Before pro ceeding to the flow diagram refer to the illustration and become familiar with the system component nomencla ture SYSTEM COMPONENT NOMENCLATURE TAILGATE OPERATING LIFT VALVE CYLINDER HYDRAULIC TELESCOPIC CYLINDER TAILGATE LIFT CYLINDER PACKER CYLINDER 8 21 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM NEUTRAL with the packer panel in home position OPERATOR ACTION Operator starts the truck and engages the PTO and speed up system HYDRAULIC SEQUENCE Hydraulic fluid flows from the tank by gravity to the pump from there it is pumped to the front control valve Flow continues through the valve to and through the operating valve and then back to the tank During pack er operation if pressure increases to the main relief setting excess flow will be diverted from the front con trol valve back to tank ees PRESSURE 00000 RETURN TAILGATE OPERATING 222 LIFT VALVE es CYLINDER NI FRONT VALVE ac HYDRAULIC 3 FLUID TANK TELESCOPIC 7 CYLINDER TAILGATE PACKER CYLINDER LIFT
48. ISED 7 If the pressure is below the appropriate setting for your unit but is at least 1400 PSI 97 BAR loosen the lock nut on the relief cartridge and using an allen wrench turn the adjusting screw in rotate clockwise to reach the correct pressure If the pressure is above the appropriate setting loosen the lock nut on the relief cartridge and using an allen wrench turn the adjusting screw out rotate counter clockwise After readjusting retighten the lock nut Repeat steps 4 and 5 NS IF NOT 8 Perform TEST FOR LEAKING Tailgate CYLINDER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 4 and 5 and again check gauge for correct pressure TELESCOPIC 31 33 yd ACH 7 4 CHECK PACKER AND CARRIER PANEL SHIFTING PRESSURES There are two methods to determine accurate pressure settings OPERATIONAL STATUS Truck Running PTO Engaged 1 Use an electronic pressure gauge that maintains and records maximum system pressures 2 If an electronic gauge is unavailable and a mechan ical gauge must be used the following procedure is recommended a Install a 0 4000 PSI 0 276 BAR pressure gauge at the quick disconnect coupler on the two spool directional valve at front of the unit Check the main relief pressure as described in Section 7 Check Out of the Service Manual b Reduce the main relief setting to below 1 000 PSI 69 BAR OPERATIONAL STATUS
49. KER PANEL CYLINDERS Before testing any cylinder make sure the main system pressure is correct as described under MAIN LINE PRESSURE CHECK Sec 7 CHECK OUT PROCEDURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet over the operating cylinders for better accessibility during testing 2 Shift the packer panel lever outward to fully extend the packer panel cylinders NOTE Engine speed up only activates when carrier panel lever is activated PACKER PANEL LEVER Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components OPERATIONAL STATUS Truck Off PTO Disengaged 3 Disconnect and cap the lines to the rod end of one cylinder at a time 9 2 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged 4 Shift the packer panel lever outward to apply hydraulic pressure to the case end of the packer panel cylinders Hold the lever 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 excessive piston seal leak If the cylinder does not leak excessively continue test OPERATIONAL STATUS OBSERVE FLUID FLOW J Truck Off PTO Disengaged E 5 Reconnect the hydraulic lines to the end of cylin ders Repeat steps 3 5 for the other cylinder OPERATIONAL STATUS Truck
50. LEACH 2R ii Packmaster Service Manual Serial Number TO ORDER PARTS Contact your local Leach Signature Original Factory parts distributor Your Authorized Leach Distributor provide the following information Company name Date Your order number Routing instructions Quantity part number and description Model and serial number of unit Accept only Leach Signature Original Factory Parts 2 W gt SERIAL NUMBER Copyright Leach Company 2737 Harrison Street PO Box 2608 Oshkosh Wisconsin 54903 2608 December 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 purchase 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 performance of adjustments or the replacement of wear expendable components is not cov ered under warranty This limited warranty is the
51. LEAKING CLAMP PUSHOUT CYLINDER LEVER OPERATIONAL STATUS Truck Running PTO Engaged SPEED UP A 1 Depress speed up button Move and hold pushout BUTTON lever rearward to pressurize clamp cylinder 2 Watch for fluid leaking from the breather If there is leakage the piston seal must be replaced REMOVAL OF CLAMP CYLINDER OPERATIONAL STATUS Truck Off PTO Disengaged 1 With the unit empty and the clamp released remove the hydraulic hose 1 from the case end of the cylinder 2 and plug the cylinder fitting 2 Next remove the 2 capscrews 3 and 2 lockwash ers 4 from the rod end Now remove the keeper plate 5 and yoke pin 6 If necessary use a pin puller to pull the pin out 9 36 The cylinder weight is approximately 115 Ibs 53 kg It is advisable to attach a suitable lifting device to lift the cylinder To disconnect the cylinder case end remove the 2 CLAMP CYLINDER Remove the cylinder SECTION 9 SERVICE AND REPAIR capscrews 1 2 lockwashers 2 and keeper plate 3 To remove the clamp cylinder pivot pin 4 insert a x 3 capscrew into the end of the pin and use a pry bar to remove NOTE DISASSEMBLY OF CLAMP CYLINDER 1 2 Remove the set screw 1 and rod eye 2 4 CAUTION Cylinder is under spring com Remove the breather plug 8 and drain the fluid Unscrew the 4 nuts evenly 4 and remove the 4 Remove the cylinder cover 6
52. MPS SECTION 3 OPERATION DRIVER SIGNAL PUSH BUTTONS 8 These two push buttons one located on each side of the tailgate are connected a buzzer mounted under the dri t vers seat or under the dash in the chassis cab The oper f y ED V 2 ator depresses one of these push buttons to signal the dri is ready to be moved ver when the loading operation is completed and the truck DANN DRIVER SIGNAL PUSH BUTTONS SAS pi LZ e PACKER AND CARRIER PANEL OPERATIONAL LEVERS 9 10 CARRIER PANEL LEVER A Packer panel lever 9 The packer panel operational control lever is located e on the right curb side of the tailgate It is used by the I 9 operator to position the packer panel open or closed PACKER PANEL during the compaction cycle operation LEVER NOTE The engine speed up system does not engage only the packer panel lever is shifted The carrier panel lever must also be shifted to engage the COMPACTION CYCLE OPERATION engine speed up system Both the packer panel lever and the carrier panel lever B Carrier panel lever 10 are shifted simultaneously inward to open the packer The carrier panel operational control lever is located panel and lower the carrier panel to the interrupted on the right curb side of the tailgate Itis used by the cycle position Both levers are shifted outward to operator to position the carrier panel up or down dur
53. OPPER E EQ LOADING EDGE i T PS 1 Ni NN WISSSS V2 A 4 wo N PUSHOUT PANEL HYDRAULIC n TANK SECTION 2 INTRODUCTION The main purpose of the 2HII Packmaster is to safely and effi ciently 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 com ponents read the complete 2811 PACKMASTER SERVICE MANUAL Before going further look at the accompanying full page illustration of the 2RII Packmaster and become familiar with the terms you will need to know LOADING CARRIER PANEL Hefuse is first loaded into the hopper of the tailgate assembly The carrier and packer panels which sweep up and pack the refuse from the hopper will be in the home position PACKER PANEL HOME POSITION COMPACTION When the operator starts the packing cycle the carrier and packer panels move rearward over the load CARRIER amp PACKER PANELS MOVE OVER LOAD Next the carrier and packer panel automatically stop at the interrupted cycle position CARRIER PACKER PANEL 2 2 SECTION 2 INTRODUCTION The operator again activates the packing cycle The carrier and packer panels move forward and sweep the refuse from the hopper up into the body and pack it against the pushout panel Having completed a cycle the carrier and p
54. PSCREW HEAD MARKINGS Manufacturers marks may vary These are all SAE Grade 5 3 line OO 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 27 37 34 295 40 80 395 54 63 435 60 16 590 81 60 660 91 28 280 38 72 440 60 85 660 91 28 NOTES Always use the torque values listed above when specific torque values are not available The above is based on use of clean dry threads Reduce torque by 10 when engine oil is used as a lubricant Reduce torque by 20 if new plated capscrews are used 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 4 6 BODY DIMENSIONS 20 Cu yd AF After Frame 24 B Overall Length 249 CA To Centerline of rear Axle 150 CT To Centerline of Trunnion 50 Beam 125 Height Above Chassis Frame with 3 sill 101 Body Outside Width 96 Body Inside Width 90 hopper Depth 17 Interference point Above Chassis Frame 4 Top of Step Below Chassis Frame 19 Hopper Below Chassis Frame 23 Hopper Opening Width 80 Hopper Opening Height 56 Hopper Inside Width 80 Rear of Body to Rear
55. R 5 CLAMP SYSTEM The upper lever controls the movement of the pushout panel When the lever is moved rearward toward the tailgate a clamp cylinder clamps the pushout panel to the bar and the pushout cylinder is then extended When the lever is moved forward toward the cab the clamp holding the pushout panel to the bar is released and pushout cylinder is retracted TELESCOPIC SYSTEM 5 In the telescopic system the pushout panel is attached directly to the pushout cylinder No clamp is required Moving the control lever rearward toward the tailgate will move the pushout panel to the rear Moving the con trol lever forward toward the cab will move the pushout panel to the front TAILGATE CLAMPS 7 Tailgate clamps are located on each side of the tailgate at the bottom where the tailgate rests against the body They are used to secure the tailgate to the body during operation They must be manually loosened and swung away from the body before raising the tailgate Before attempting to loosen the tailgate clamps pressure against the tailgate must be relieved by opening the packer panel to the interrupted cycle stop position 3 4 PUSHOUT LEVER TAILGATE LIFT LEVER ENGINE SPEED UP BUTTON TAILGATE LIFT LEVER 6 The lower lever controls the tailgate Moving the lever rearward toward the tailgate will raise the tailgate Moving the lever forward toward the cab will lower the tailgate TAILGATE CLA
56. Replace pushout bar or install shims behind stationary block Unloading body on uphill grade Unload body on level or downhill rear of unit lower than cab Refuse jammed behind clamp lever preventing Clean out area around clamp clamp from being applied Leaking piston seal in clamp cylinder Perform test for leaking cylinder and repair See Sec 9 Service and Repair Clamp cylinder mounting broken or loose Repair or replace mounting See Sec 9 Service and Repair Sequence valve pressure is too low Adjust sequence valve pressure See Sec 9 Service and Repair Clamp parts worn Replace worn parts See Clamp Assembly Sec 9 Service and Repair SECTION 8 TROUBLESHOOTING PACKER PANEL DRIFTS OPEN WHILE PACKING LOAD INTO BODY 1 Packer panel cylinder seal leaking 1 Perform test for leaking cylinder See Sec 9 Service and Repair 2 Packer panel valve section pressure too high 2 Perform pressure test as described in Sec 7 Check out CYCLE TIME TOO SLOW Solenoid to carburetor or governor linkage cable 1 Adjust cable to achieve 32 seconds cycle out of adjustment time Hydraulic fluid level too low Fill to proper level See Sec 6 Preventive Maintenance Hydraulic fluid filter needs servicing Service filter See Sec 6 Preventive Maintenance Hydraulic tank breather dirty Service breather See Sec 6 Preventive Maintenance Hydraulic pump worn or defective Rep
57. Running PTO Engaged 6 Shift the packer panel lever inward to retract the packer panel cylinder to the interrupted cycle A CAUTION position OPERATIONAL STATUS Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components Truck Off PTO Disengaged 7 Disconnect and cap the hydraulic lines which con nect to the case end of a packer panel cylinder 9 3 SECTION 9 SERVICE AND REPAIR 8 Shift the packer panel lever inward to apply hydraulic pressure to the rod end of the packer panel cylinder Hold the lever and observe the fluid flow from the port on the case end of the cylinder The flow of hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces indicates an excessive piston seal leak Disassemble the cylinder and replace the piston seal as described later in this section OPERATIONAL STATUS Truck Off PTO Disengaged Keys Removed 9 f the cylinder does not leak reconnect the hydraulic lines to the cylinder Repeat steps 7 9 for the other cylinder TEST FOR LEAKING CARRIER PANEL CYLINDERS NOTE Before testing any cylinder make sure the main line pressure is correct as described under MAIN LINE PRESSUHE CHECK Sec 7 CHECK OUT PROCEDURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet over the operating cylinders for better accessibility during testing 9 4
58. T PUSHOUT CYLINDER CYLINDER 8 16 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM RAISING TAILGATE OPERATOR ACTION IBI TAILGATE Operator opens the packer panel to release pressure LIFT Operator loosens and swings away from the body the LEVER tailgate clamps Operator depresses the speed up but ton Operator moves the tailgate lift lever rearward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the tailgate lift lever rearward shifts a spool in the front control valve causing flow to the tailgate lift cylinders The cylinders extend causing the tailgate to raise Excess fluid flow from the front control valve returns back to the tank ANN PRESSURE RETURN OPERATING VALVE LIFT CYLINDER SPC VALVE QS ER RRIER CYLIND HYDRAULIC FLUID TANK a TAILGATE PACKER LIFT CYL CYLINDER PUSHOUT CYLINDER SECTION 8 TROUBLESHOOTING CLAMP SYSTEM EJECTING LOAD PUSHOUT OPERATOR ACTION LEVER Operator depresses speed up button and moves pushout lever rearward BUTTON HYDRAULIC SEQUENCE Pushing the pushout lever rearward shifts a spool in the front control valve causing flow to the clamp cylinder As the cylinder extends it clamps the pushout panel to the pushout bar attached to the pushout cylinder When the hydraulic pressure reaches 1200 PSI 83 BAR the sequence pilot check valve SPC opens diverting the flow to the case end of the pushout cy
59. TAILGATE egg age TA wis 7 DO NOT ENTER UNLESS All pressure against ejector M PUPA panel has been relieved TA L G AT E Engine is stopped and MOVE CONTROL OUTWARD FOR CARRIER DOWN FOR CARRIER UP key removed MOV CONTROL INWARD MOVE CONTROL OUTWARD FOR PACKER OPEN NY FOR PACKER CLOSE Be sure tailgate area is clear of WARN persons before operating controls 1 10 SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL PACKER a PACKER CONTAINER DUMP CONTROL c3 HYDRAULIC FLUID ONLY Both container latch arms must be in place and latched before raising container FILTER ELEMENT CHANGE ads cei To ensure oil cleanliness and longe dessin machine life change the ele requirements Z 245 1 in effect on DRIVER SIGNALE eee change the element the date of manufacture T SAM 250hi intervals thereafter i Es E LEACH BEACON LIGHT CARRIER E ee gt CARRIER HYD PUSH BAR CARRIER a HYD PUSH BAR LEACH COMPANY OSHKOSH WI TA WARNING Rotating power take off shaft hazard DO NOT FILL BEYOND THIS LINE Do not enter under chassis unless engine is stopped and key removed EJECTION EJECTION EJECTION 12 000 LB CAPACITY 1 T SECTION 1 SAFETY PRECAUTIONS SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW TAILGATE ASSEMBLY H
60. TON HYDRAULIC SEQUENCE Moving the pushout lever rearward shifts a spool in the front control valve causing flow to the telescopic cylin der As the cylinder extends the load is ejected from the body NENNEN PRESSURE 00090 RETURN TAILGATE OPERATING LIFT VALVE CYLINDER TELESCOPIC CYLINDER TAILGATE PACKER CYLINDER LIFT CYLINDER 8 28 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RETRACTING PUSHOUT PANEL LEVER OPERATOR ACTION Operator releases speed up button Operator moves the pushout lever forward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever forward shifts a spool in the front control valve causing flow to the telescopic cylin der As the cylinder retracts the pushout panel is posi tioned near the front of the body NENNEN PRESSURE 00099 RETURN TAILGATE OPERATING LIFT VALVE CYLINDER SS TELESCOPIC CYLINDER TAILGATE LIFT CYLINDER PACKER CYLINDER 8 29 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM LOWERING TAILGATE TAILGATE OPERATOR ACTION LIFT Operator moves the tailgate lift lever forward HYDRAULIC SEQUENCE Moving the tailgate lift lever forward shifts a spool in the front control valve allowing fluid in the tailgate lift cylin ders to drain back to the tank The weight of the tailgate forces fluid out of the cylinders the cylinders retract and the tailgate lowers ees PRESSURE 00099 RET
61. UID TAILGATE OPERATING 22 LIFT VALVE CYLINDER TELESCOPIC CYLINDER oe 7 ZL TAILGATE LIFT CYLINDER PACKER CYLINDER 8 24 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PLATE SWEEPS HOPPER OPERATOR ACTION Operator shifts the control levers outward to start com paction HYDRAULIC SEQUENCE Fluid flow is through the operating valve packer section to the case end of the packer panel cylinders As the cylinders extend the packer panel sweeps the load for ward in the hopper As the packer cylinder extension stroke continues pressure builds to 1200 PSI 83 BAR causing the operating valve to shift NENNEN PRESSURE 00000 RETURN TAILGATE OPERATING 222 LIFT VALVE CYLINDER TELESCOPIC CYLINDER a TAILGATE LIFT CYLINDER PACKER CYLINDER 8 25 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKING REFUSE OPERATOR ACTION None Operating Valve shifts automatically HYDRAULIC SEQUENCE Fluid flows from the operating valve to the case end of the carrier panel cylinders The cylinders extend mov ing the carrier and packer panels up packing refuse against the pushout panel When the pressure reaches 1800 PSI 125 BAR the operating valve shifts into neutral and the packing cycle is completed As the car TAILGATE OPERATING 22 LIFT VALVE es CYLINDER NI rier cylinders apply force to compact refuse the pres su
62. URN TAILGATE OPERATING LIFT VALVE CYLINDER TELESCOPIC CYLINDER ho TAILGATE LIFT CYLINDER PACKER CYLINDER 8 30 SECTION 9 SERVICE AND REPAIR GENERAL This section contains the instructions necessary for the repair and replacement of the main components of the unit Before attempting any repair of the unit become thor oughly familiar with the OPERATION instructions Sec 3 and GENERAL REPAIR PRACTICES Sec 4 Also before performing any work on the unit know and OBSERVE all SAFETY PRECAUTIONS listed in Section 1 AWARNING There are some procedures in this section that will require that the truck is running In these instances the operational status will be indicat ed 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 units parts can cause serious injury or death DESCRIPTION OF OPERATING CYLINDERS CARRIER PANEL CARRIER AND PACKER PANEL CYLINDERS PACKER PANEL CYLINDERS The four double acting hydraulic cylinders that control movement of the carrier and packer panels during the compaction cycle are called the operating cylinders All four cylinders are the same The two packer panel cylinders mount in the the opposite direction of the car rier panel cylinders and the pivot mountings are differ ent 9 1 SECTION 9 SERVICE AND REPAIR TEST FOR LEAKING PACKER PANEL CYLINDERS NOTE PAC
63. YSTEM COMPONENT NOMENCLATURE OPERATING VALVE v TAILGATE x LIFT CYLINDER SPC VALVE C ER CYLINDER S AL HYDRAULIC CARR 5 FLUID TANK A A 23 TAILGATE LIFT CYL PACKER CYLINDER PUSHOUT CYLINDER SECTION 8 TROUBLESHOOTING CLAMP SYSTEM NEUTRAL with the packer panel in home position OPERATOR ACTION Operator starts the truck and engages the PTO and speed up system HYDRAULIC SEQUENCE Hydraulic fluid flows from the tank by gravity to the pump from there it is pumped to the front control valve Flow continues through the valve to and through the operating valve and then back to the tank During pack er operation if pressure increases to the main relief setting excess flow will be diverted from the front con trol valve back to tank OPERATING VALVE gi 4 TAILGATE X LIFT CYL Sw SPC VALVE 4 CARRIER SS MEN HYDRAULIC BET FLUID TANK v el Je PACKER uere CYLINDER O PRESSURE qo RETURN SECTION 8 TROUBLESHOOTING CLAMP SYSTEM PACKER PANEL SWEEPS BACK OVER LOAD OPERATOR ACTION The operator moves the control levers inward to start the compaction cycle HYDRAULIC SEQUENCE Operator action causes the operating valve to shift diverting flow to the rod end of the packer panel oylin ders The packer panel cylinders retract causing the packer panel to sweep rearward over the load Return fluid flow from
64. acker panels are back into the home position and the hopper is cleared for more refuse CARRIER PANEL PACKER PANEL COMPACTION POSITION PUSHOUT PANEL Also during the compaction cycle considerable CARRIER PANEL hydraulic pressure is applied to the cylinders which control movement of the carrier and packer panels This causes the refuse to be compacted tightly allowing for a large carrying capacity On units with the standard clamp pushout system the operator must manually release the pushout panel clamping system to allow movement of the pushout panel PUSHOUT PANEL Once the body is full the 2RIl Packmaster can be DIAS IIIS moved to the dumpsite for moved to the dumpsite for unloading PUSHOUT PANEL MOVES FORWARD PUSHOUT PANEL MOVES FORWARD UNLOADING At the dumpsite the unit is unloaded in two easy steps First the tailgate is raised by the operator Second the pushout panel is moved to the rear of the body pushing out the load TAILGATE After unloading on telescopic units the tailgate is low ered and latched to the body TAILGATE RAISED On clamp style units the the pushout cylinder is retract ed and then the clamp is set by extending the cylinder a couple of inches The tailgate is then lowered and latched to the body PUSHOUT PANEL TAILGATE PUSHOUT PANEL MOVES REARWARD EJECTING THE LOAD 2 3 SECTION 2 INTRODUCTION CONTAINER ATTACHMENT The Leach Contai
65. age will result if pump is hicl connect pump drive to r i A WARNING e You are qual lified by training and experience in the safe operation run dry Disconnect pump drive to run engine if tank valve is required to be closed or if oil tank is not at proper fill level ious pump damage will result if vehicle 0 a refuse collection compaction vehicle at speeds less than 10 mph SECTION 1 SAFETY PRECAUTIONS Ns A WARNING Falling hazard Do not operate vehicle at speeds in excess of 10 mph for distances over 2 tenths mile or in reverse gear when rider or riders are on To prevent possible serious injury or riding steps un death do not use this refuse collection qu vehicle to tow other equipment It is sped Stand clear when intended designed or equipp or towing tailgate is in motion amp during unloading cycle Stand clear when e Do not stand or packer panel is cross under raised in motion tailgate SOLENOID BEFORE OPERATING THIS MACHINE BE SURE TO READ AND UNDERSTAND OPERATION MANUALS SUPPLIED WITH THIS UNIT REPLACEMENT MANUALS CAN BE OBTAINED FROM A LEACH DISTRIBUTOR ae Oe MUST BE OFF WHEN EMEN T ba D TRUCK IS PARKED is vehicle requires gt of overhead 0 F F MOVE CONTROL INWARD E MOVE CONTROL OUTWARD FOR CARRIER DOWN FOR CARRIER UP MOY CONTROL INWARD MOVE CONTROL OUTWARD FOR PACKER OPEN FOR PACKER CLOSE Be all persons
66. all backup rings and o rings 18 4 Lightly oil and install the o ring amp backup ring 17 Install needle roller 16 5 Apply a liberal amount of general purpose grease 2 Apply thread locking compound to threads on into the detent ball holes on the spool Insert one spring guide 15 Install spring guide 15 and detent ball 9 into each hole Carefully slide detent torque to 5 ft lbs 7 Nm sleeve 8 over the spool and into place Install knockout plunger 14 inner spring 13 if 6 Install spring collars 7 and centering spring 6 used follower 12 outer spring 11 and spring Install spool collar 5 and torque to 32 in lbs 3 6 guide 10 Nm 7 Install adjustment screw 4 and turn the number of ACAUTION turns recorded during disassembly Install and tighten lock nut 3 The centering spring will have to be com 8 Install bonnet 2 and screws 1 Torque screws to pressed during assembly by applying pressure 10 ft Ibs 13 6 Nm to the spool collar Caution should be used 9 27 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PUSHOUT CYLINDER CLAMP CYLINDER This hydraulic cylinder works in conjunction with the clamp cylinder to provide the rearward motion of the pushout panel during the unloading cycle First the pushout cylinder rod which is connected to the pushout bar is fully retracted into the pushout cylin der Next the clamp cylinder is engaged locking the pushout panel to the p
67. alve also contains the main pressure relief for the hydraulic system REMOVAL OF FRONT CONTROL VALVE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Disconnect the hydraulic lines to the valve Cap the lines and plug the valve ports to prevent dirt from entering the valve and the hydraulic system 2 Remove the capscrews lockwashers nuts and remove the valve DISASSEMBLY AND INSPECTION OF FRONT CONTROL VALVE 1 Wash the valve body with solvent to prevent conta mination NOTE Service should be limited to seal replacement car tridges and individual valve sections Field repairs of the spool assemblies are not recommended 2 To separate valve sections from the inlet or outlet covers remove the three 3 tie bolts which secure the valve sections and covers Separate carefully noting the location of o ring seals NOTE Before disassembly it is suggested that each work section be marked numerically to avoid incorrect assembly 3 Thoroughly clean the o ring counter bores and ground surfaces of each section 4 To remove handle bracket remove the two cap screws securing the bracket to the work section 9 20 HANDLE TIE BOLT OUTLET PUSHOUT NOTE Do not remove the spool from the valve body as the seals can be replaced externally LEACH Remove retainer plate retainer plate washer and o ring seal Thoroughly clean center bore To remove the bonnet remove two 2 capscrews secu
68. ashers and nuts holding the valve bracket to the tailgate SECTION 9 SERVICE AND REPAIR INTERRUPTED CYCLE POSITION CARRIER PANEL was PACKER PANEL PACKER PANEL LEVER CARRIER PANE OPERATING VALVE 9 25 SECTION 9 SERVICE AND REPAIR DISASSEMBLY AND INSPECTION OF MAIN CONTROL VALVE 1 Wash the valve body with solvent to prevent conta mination NOTE Before disassembly it is suggested that each work section be marked numerically to avoid incorrect assembly 2 To separate valve sections from inlet or outlet cov ers remove the four 4 tie bolts which secure the valve sections and overs Separate carefully noting the loca tion of o ring seals 3 Thoroughly clean the o ring counter bores and ground surfaces of each section TIE ROD CONTAINER HANDLING PACKER SECTIONS SECTION 9 26 O RINGS REASSEMBLY OF MAIN CONTROL VALVE 1 Replace work sections and covers with the tie bolts in the same order in which they were removed NOTE Use care in replacing the work section to avoid dis lodging o rings from the counterbores 2 Secure tie bolts and tighten evenly to 25 ft Ibs 33 8Nm 3 Torque the 3500 Ib relief cartridge load check and blanking plugs to 20 ft lbs 27 Nm BONNET KNOCKOUT POSITIONER OUTLET COVER CARRIER SECTION SECTION 9 SERVICE AND REPAIR DISASSEMBLY AND INSPECTION OF KNOCKOUT POSITIONER 1 Remove bonnet scre
69. avity Pour Point Viscosity SSU 100 F SSU 210 F cSt 40 C cSt 100 C Viscosity Index ASTM Oxidation Test Hours to 2 0 No ASTM Rust Test A amp B Foam Test Vickers Vane Pump Test Dielectric Strength ASTM 877 EC 180 F 40 37 3 10 40 37 3 15 40 37 3 15 Do not use engine oil automatic transmission fluid ATF or add diesel ACAUTION fuel or kerosene to the hydraulic fluid Service life of all hydraulic sys tem 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 incorporated to provide additional resistance to wear corrosion oxidation decomposition and foaming All additive blending should be done by the lubricant supplier so that they are compatible with each other A reputable lubricant supplier backed 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 2 SECTION 6 PREVENTIVE MAINTENANCE GENERAL The 2HII Packmaster has been designed for long peri ods of efficient uninterrupted operation Careful atten
70. be used to support the tail gate place them as shown in Section 9 SERVICE AND REPAIR under TAILGATE REPAIR SAFETY DURING SERVICE AND REPAIR 1 Always wear safety glasses 5 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 6 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 4 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 supported WELDING PRECAUTIONS ELECTRIC WELDERS 1 Electric arc welders should have a separate fused 4 disconnect circuit 2 Welders must be used according to the manufac turers specifications 5 3 All electric welding should be done in well venti lated area 4 2 When working on the unit always use the service tools listed in Section 10 SERVICE TOOLS if so directed by the instructions in Section 9 SERVICE AND REPAIR 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 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
71. c system pump main relief setting and the condition of the operating cylinder seals will all have an effect on unit performance and com paction Some chassis components will also affect compaction The engine speed during packing fluid level in an automatic transmission and the condition of the clutch assembly in a standard transmission chassis may also affect compaction 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 the the Service manual then it is safe to assume that it is getting maximum compaction for your particu lar conditions 8 1 SECTION 8 TROUBLESHOOTING DIESELING IN HYDRAULIC SYSTEMS Any hydraulic system should be a sealed environment free of foreign material including air Unlike solid conta mination air is compressible and contains oxygen It is these two 2 properties of air contamination that pro vide the elements needed to support the phenomenon known as dieseling Dieseling can only occur when the elements of fuel oxygen and heat are all present at the same time In the hydraulic system the hydraulic fluid is the fuel The presence of air provides not only the oxy gen to support combustion but also the means for gen erating sufficient heat to ignite the fuel air mixture When air is rapidly compressed heat is generated A rapid
72. ced as described in Sec 9 SERVICE AND REPAIR REDUCTION FROM EVIDENCE OF HEAT NORMAL 7 AGE FROM ANY CAUSE DIAMETER OF MORE THAN 764 WIRE ROPE CHART MORE THAN 1 WEAR GREATER BROKEN WIRE AT THAN DIAMETER A DEAD END CONNECTION OF OUTSIDE INDIVIDUAL WIRES 5 CHECK OUT PROCEDURES Each week perform the CHECK OUT PROCE DURES listed in Sec 7 of this manual 6 CONTAINER HANDLING SYSTEM HARDWARE Check all container handling system hardware to make sure that no damage exists and that all fas teners are secure 7 PIVOT POINTS Check all pivot points for wear and smooth opera tion 8 WIRE ROPE CABLE A detailed inspection of all wire rope cable should be made weekly or every 40 hours of use which includes checking the wire rope for damage dete rioration and secure end connections Damage or deterioration requiring replacement of wire rope is indicated by broken wires excessive wear heat damage corrosion stretching or distortion as shown in the wire rope illustration below NOTE A lay of rope is that length of rope in which one strand of wire makes a complete revolution about the core KINKING CRUSHING OR DISTORTION OF ROPE STRUCTURE 6 BROKEN WIRES IN ANY ONE LAY OR 3 BROKEN WIRES IN ONE STRAND IN ANY LAY 6 9 SECTION 6 PREVENTIVE MAINTENANCE MAINTENANCE RECOMMENDATIONS CARRIER The packer carrier assembly should be visually inspect ed
73. chment m ATTACHING CONTAINER After setting the vehicle parking brake the right and left ee container latch arms must be engaged AWARNING m Lifting a container without both latch arms secured can allow the container to swing away from the unit and cause severe injury or death NOTE If the container is equipped with wheels it should ATTACHED be rolled into position only after the vehicle parking brake has been set Even small containers must use the latch arms to ce secure them to the packer 3 13 SECTION 3 OPERATION USING A WINCH OR CONTAINER LIFT CYLINDER Once the container is secured within the latch assem bly the lifting cable should be attached Place the load in the base of the hook with the safety latch closing the throat opening It is important that hooks are used in a proper manner Proper use of a lifting hook not only includes placing the load in the base of the hook but also includes ensuring that the hook is lifting on the proper area of the attachment point The hook must completely encircle the attachment point Equally as important at the time load is applied to the base of the hook the positioning must be correct to prevent the hook from dislodging When using an eye type attachment point the base of the hook must be positioned to lift on the inside of the eye The diagrams show both correct and incorrect positioning of
74. d 6 Install o ring 8 into groove in rear housing 1 the scribe mark visible 7 Lubricate the gear shaft extensions with grease to 2 For easier assembly use clean hydraulic fluid as a protect lip seals lubricant 8 Install seals 12 and snap rings 13 into front 3 Install pressure balance 2 and pressure plate 3 housing 9 as described in steps 1 6 of the replac into rear housing 1 ing seals instructions NOTE 9 Install dowels 7 into holes in rear housing 1 Pressure plates must be assembled with the traps opening to the outlet side of the pump 10 Carefully lower front housing 9 with seals installed onto rear housing 1 Insert washers 11 4 Carefully lower gears 4 into the rear housing 1 and capscrews 10 Tighten opposite and even to Install the gears one at a time 80 ft Ibs 5 Install pressure plate 6 and pressure balance 2 11 Test the pump by turning on one gear shaft The pump should turn with a maximum of 10 ft Ibs of torque If shaft does not turn properly disassem ble find the problem and carefully reassemble the pump A WARNING Be sure to wear eye protection 9 54 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF ELECTRICAL SYSTEM The packer electrical system includes all of the body running and marker lights operational soeed up switch es the operator ready and back up warning buzzers and all interconnected wiring as shown on the accom panying wiring diag
75. d 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 nonshedding screw on cap The bottle should be labeled with the date type of fluid 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 fluid samples taken on a regularly scheduled basis The cost is about 20 to 30 per sample The most important analysis are particle count Spectro chemical analysis water content and viscosity IN HOUSE HYDRAULIC FLUID TEST ING After your sample has been allowed to stand for 20 to 30 minutes to eliminate air bubbles hold the bottle up to the light to 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 under sealed reservoir covers or dirty air breather filters If the sample is the least bit cloudy it is an indication SECTION 6 PREVENTIVE MAINTENANCE of water contamination the source of which must be found and eliminated immediately Common sources are
76. d cap the end 5 Loosen the setscrew 1 and free the yoke 2 from the pump shaft by telescoping the PTO drive shaft toward the PTO 6 Remove the key 3 from the pump shaft keyway 7 Remove the attaching hardware 4 The pump assembly may now be removed from the mounting bracket 9 52 SECTION 9 SERVICE AND REPAIR INSTALLATION OF HYDRAULIC PUMP 307451 01 FRONT VIEW OPERATIONAL STATUS AKO i i 00 Truck Off PTO Disengaged Disengaged 1 Install pump the reverse order of removal NOTE 209 Fill pump with clean hydraulic oil up to the threads 2 of the ports for the pressure and suction hoses AN Make sure the hoses are installed correctly NS V 2 Be sure to reinstall any shaft guards that may have PRESSURE C been removed NEW PUMP PREPARATION Before installing a new pump refer to Sec 6 PRE VENTIVE MAINTENANCE and the following This will prevent contamination of the new pump 1 Remove and clean the hydraulic tank strainer 1 2 Change the filter element 2 3 Drain and flush the hydraulic tank as described in Sec 6 PREVENTIVE MAINTENANCE 3 SUCTION 4 Clean the magnetic plug 4 TESTING A NEW PUMP OPERATIONAL STATUS Truck Running PTO Engaged After installing a new pump check for correct cycle time and main line pressure as described in Section 7 CHECK OUT 9 55 SECTION 9 SERVICE AND REPAIR
77. dge stop in the interrupted cycle position and the carrier panel lever will automatically shift to neutral 2 To finish the cycle move both the packer panel lever and the carrier panel lever outward away from the tailgate then let go The packer panel will sweep the hopper and the packer panel lever will automatically shift to neutral The carrier panel will then move up into the body and stop in the home position and the carrier panel lever will automatically shift to neutral Stand clear of the hopper area during the pack ing cycle 3 Repeat steps 1 and 2 each time the hopper is filled to but not above the loading edge SECTION 3 OPERATION DUMPING WITH CPB CONTAINER p y CONTROL 4 4 LEVERS Releasing the CPB control handle when the container begins to tip will allow the container trunnion bar to lower within the latch slots with ease CARRIER PANEL LEVER PACKER PANEL LEVER PACKER ua LEVER Failure to periodically manually release the clamp can cause damage to the pushout bar and clamping components CARRIER PANEL LEVER 3 15 SECTION 3 OPERATION PUSHOUT PANEL OPERATION DURING PACKING CLAMP As each load is packed into the body the load will become tighter and denser until the carrier panel stops short of the home position With the packer in the inter rupted cycle position the operator pulls the pushout control lever to the front releasing the clamp The pusho
78. e any trapped pressure Watch for inadvertent movement of components OPERATIONAL STATUS Truck Off PTO Disengaged 7 Disconnect and cap the hydraulic lines which con nect to the case end of the carrier panel cylinder OPERATIONAL STATUS Truck Running PTO Engaged 8 Shift the carrier panel lever inward to apply hydraulic pressure to the rod end of the carrier cylinder Hold the lever and observe the fluid flow from the port on the cylinder case end The flow of hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces CARRIER PANE indicates an excessive piston seal leak LEVER Disassemble the cylinder and replace the piston seal OPERATIONAL STATUS Truck Off PTO Disengaged 9 f the cylinder does not leak reconnect the hydraulic lines to the case end of the carrier panel OBSERVE FLUID FLOW cylinder LEACH 9 6 SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet to provide better accessibil ity to the packer panel NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Secure nylon sling around the cylinder as shown and attach to a suitable lifting device with a capac ity of 500 Ibs 227 kg Operate the hoist to make the lifting cable snug without applying strain on the cyli
79. e and Perform the PRE OPERATIONAL INSPECTION packer body pre operating inspection also check described in Sec 3 OPERATION the container handling system Each day perform the following inspection A DANGER a Check the condition and operation of the con tainer latch assemblies If the latch arms will not Never go under the vehicle with the engine run latch securely in the assembly do not use the ning Death or serious injury could result unit a When checking for hydraulic leaks pay particular b A visual inspection of the wire rope cable attention to hose fittings and connections at the should identify any broken wires or obvious dam cylinders and valves A build up of hydraulic fluid age A visual inspection of the chains should and dirt indicates a small leak that can probably be identify any damaged or elongated links corrected by tightening the fitting or connection c Make a visual inspection of the hook for obvi b Check the visual indicator to determine the condi ous damage Make sure that the hook latch is tion of the return line element working properly c Inspect the mounting sills and mounting hard d Check the operation of the container handling ware The springs should be compressed to 3 1 2 system The lifting mechanism should move inches 1 8 inch The mounting bolts should be smoothly with no jerkiness or binding torqued to 700 ft Ibs and inspected daily 2 CLEANING Hose the entire unit inside a
80. e check out proce dure Prior to performing pressure checks OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install a gauge capable of reading at least 3000 PSI 207 BAR on the test coupling 2 Start the unit engage the PTO and turn solenoid p e switch ON Pec 7 3 SECTION 7 CHECK OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged 1 Depress speed up button 2 Move pushout control lever to fully extend pushout cylinder SPEED UP BUTTON 3 Hold lever and read gauge Pressure on all clamp units should be at least 1650 PSI but no more than 1700 PSI On telescopic units the pressure should be at least 1950 PSI but no more than 2000 PSI AWARNING Make sure the area above the tailgate is clear before raising the tailgate 4 Release the tailgate clamps Move the tailgate con trol lever rearward to completely raise the tailgate TELESCOPIC 5 Hold the lever and read the gauge Pressure on all 20 25 yd clamp units should be at least 1650 PSI 114 BAR but no more than 1700 PSI 117 BAR On 20 and 25 yd telescopic units the pressure should be at least 1950 PSI 135 BAR but no more than 2000 PSI 138 BAR On 31 and 33 yd telescopic units the pressure should be at least 2200 PSI 152 BAR but no more than 2250 PSI 156 BAR 6 Lower tailgate to the lowered position Lower in small stages avoid slamming the tailgate down TAILGATE RA
81. e checks listed in Section 3 Operation of the Operators Service manual Never start or operate any equipment found to have malfunctions a Report any malfunctions immediately to the proper authorities b Prior to leaving any malfunctioning unit the parking brakes must be set the PTO system disengaged the engine turned off the ignition key removed and using a non reusable fasten ing device place a sign on the steering wheel indicating the unit is inoperative Proper servicing requires specialized tools and pro cedures Service must be performed by authorized personnel only following procedures in the 2RIl Service manual o 10 11 Walk completely around the vehicle to make sure all persons and obstructions are clear before start ing the unit The container handling system is a critical compo nent of the unit use only the proper replacement parts Inspect all hooks chains and cables daily to ensure serviceable condition Replace damaged or worn parts See Section 5 Preventive Maintenance 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 Be sure to 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 Should the height of a refuse collection vehicle be altered by i
82. e fitting should be installed in the replacement roller OPERATIONAL STATUS Truck Running PTO Engaged 7 Repeat step 1 to determine if additional shims are required Do not over shim rollers Excessive shimming may damage the tailgate walls or wear the track channels 9 14 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 8 Remove the appropriate rollers and add shims as required to obtain smooth operation of the packer and carrier panel This may require adding or removing shims and operating the packing lever several times until the correct alignment is achieved Sra ON ol 9 Once alignment is correct lubricate each roller as SS DY described in the LUBRICATION CHART Sec 6 PREVENTIVE MAINTENANCE 10 Using the cap screws 1 and lockwashers 2 secure the covers 3 and cover weldment 4 over the four track holes DESCRIPTION OF TAILGATE LIFT CYLINDERS These two hydraulically operated cylinders mounted on each side of the tailgate lift and lower the tailgate assembly The rod end is pinned to a pivot ear on the body frame near the discharge opening while the cylin TAILGATE LIFT weldment pivot ear is bolted to mounting hub on CYLINDERS Sek NEE the tailgate V TEST FOR LEAKING TAILGATE CYLINDER NOTE This check will require two people OPERATIONAL STATUS MUL ZZ en 1 XE hy EE aer
83. eck the tailgate clamps to make sure both are securely tightened n 2 Depress and hold the speed up push button SPEED UP BUTTON 3 Push the pushout lever rearward until the pushout cylinder is fully extended NOTE On units with a telescopic pushout cylinder the pushout panel is now in position for loading PUSHOUT LEVER 4 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed 5 Repeat steps 2 3 and 4 until the pushout panel is as far back as it will go and then pull forward on the pushout lever to fully retract the pushout cylinder Now extend the cylinder a few inches to reset the clamp SPEED UP BUTTON SECTION 3 OPERATION LOADING THE HOPPER There are only a few but important points to remember during loading of refuse 1 Load the hopper evenly on both sides 2 Load heavy objects in the center of the hopper 3 Do not load refuse higher than the loading edge Always follow proper loading procedures ATTACHING A CONTAINER TO THE PACKER Place the container on a flat level surface For large goa non moveable containers the driver should back the unit toward the container following all vehicle and refuse body safety restrictions The vehicle should be backed with latch arms open until the container trun nion bar is between the guide ears and Games 4 within the latch assem bly Center the contain er on the atta
84. er Test for Leaking Pushout Cylinder Removal of Pushout Cylinder Disassembly of Pushout Cylinder Inspection and Replacement of Pushout Cylinder Reassembly and Installation of Pushout Cylinder Description of Clamp Mechanism Wear 1 Disassembly and Removal of Clamp Mechanism Inspection and Replacement of Clamp Mechanism Heassembly and Installation of Clamp Mechanism Clamp Adjustment Description of Clamp Cylinder Test for Leaking Clamp Cylinder Removal of Clamp Cylinder Disassembly of Clamp Cylinder TABLE OF CONTENTS Inspection and Replacement of Clamp 9 38 Reassembly and Installation of Clamp 9 38 Removal of Telescopic Cylinder 9 39 Telescopic Cylinder Packing Replacement 9 40 Telescopic Cylinder Disassembly 9 41 Description of Pushout Panel 9 42 Front Wear Block Replacement 9 42 Rear Wear Block Replacement Telescopic 9 43 Shimming Upper Wear Blocks with Panel in Place 9 43 Removal of Pushout Panel 9 44 Inspection and Replacement of Wear Blocks and Pushout Shoes Panel Re
85. fective methods for per forming 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 recommended Since Leach Company could not possibly know evaluate and advise the service trade of all possible ways in which service might be done or of the possible haz ardous consequences of each way we have not PREPARATION FOR SERVICE Proper preparation is very important for efficient safe service work A clean work area at the start of each job will allow you to perform the repair as easily and quick ly 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 The cleaning process may include the use of high pressure equipment and strong chemicals Follow the manufacturer s instructions and precautions during this process 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 specific job are listed in Section 11 REPLACEMENT PARTS Of growing concern to the Leach Company is the use of counterfeit will fit or substitute parts Leach Signature replacement parts are designed and manufactured to exacting standards The use of counterfeit will fit or sub
86. first been applied All bracing and supports must be able to support 7500 Ibs Never enter the body when the load is under com paction pressure Bring the packer plate to the interrupted cycle stop position and retract the pushout plate slightly The radiation given off by the arc will destroy the retina of the eye Wear an approved welder s hel met Welding radiation will produce severe burns on unprotected skin similar to sunburn so wear heavy clothing Use natural fiber or leather avoid synthetic fiber clothing LEACH SECTION 4 GENERAL REPAIR PRACTICES OXY ACETYLENE TORCHES 1 Acetylene is a highly explosive gas which should be treated with the greatest care At pressures above15 psi acetylene will explode by decompo sition without the presence of air No other indus trial gas has such a wide explosive range Oxygen will spontaneously ignite in the presence of oil and grease The hoses torch handles and regulators must be kept free of petroleum prod ucts Before using the equipment inspect it for cleanli ness and for leaks 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 internal adjustments on the regulators yourself REMOVAL DISASSEMBLY AND REPAIR 1 Cleanliness is very important dirt is
87. forward to completely retract the pushout cylinder Now push the pushout lever 5 Clear debris from the edges with a pole while stand rearward extending the pushout cylinder a few inches ing clear off to one side thus clamping the bar to the pushout panel With the telescopic circuit the pushout cylinder remains fully extended If the unit is going to travel over one mile empty completely retract the cylinder When packing is about to resume extend the cylinder and start packing PUSHOUT LEVER LOWERING THE TAILGATE 1 Pull forward on the tailgate lift lever slowly and in small increments to lower the tailgate a little at a time AVOID SLAMMING SHUT the tailgate TAILGATE LIFT 2 Place the tailgate clamps in the closed position and tighten securely NOTE The tailgate open light backup lights and backup alarm should be off after closing the tailgate 3 18 SECTION 3 OPERATION SHUTDOWN i Move the packer panel lever and carrier panel lever to place the packer panel in the home position Put all controls in neutral Set parking brake Disengage PTO Shut off engine Shut off solenoid dashboard switch Remove key Lock truck 3 19 SECTION 3 OPERATION SECTION 4 GENERAL REPAIR PRACTICES Proper service and repair is important for the safe reliable operation of all mechanical products the service procedures recommended and described in this service manual are ef
88. gs etc badly worn Replace pump Improper grade of hydraulic fluid fluid foaming Replace with proper grade of hydraulic fluid See Section 5 Specifications Air entering the system Tighten the suction hose Tighten packing on the gate valve stem Replace the pump shaft seal Replace the suction hose Replace the o rings on the pump Tighten or repair any leaks in the hydraulic system SECTION 8 TROUBLESHOOTING ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR SPEED UP BUTTON IS ENGAGED POSSIBLE CAUSE REMEDY 1 Short in electrical wiring Repair broken wire See Electrical System Sec 9 Service and Repair 2 Blown fuse on speed up relay Replace fuse and check electrical system for shorts See Electrical System Sec 9 Service and Repair Relay solenoid or switch is defective Check for and replace defective parts as described in the Electrical System Section See Sec 9 Service and Repair Solenoid to carburetor or governor cable is broken Replace cable Electrical system not grounded properly Check all ground connections for corrosion or breaks Clean or repair as described in the Electrical System Section See Sec 9 Service and Repair Carrier panel lever speed up switch or linkage Repair replace or adjust as required defective Solenoid mounting loose broken or incorrect Be sure solenoid mounting is correct and Secure Truck engine mounts loose worn
89. he brakes engage the PTO and ensure the transmission is in neutral Relieve the pressure on the tailgate by moving the packer panel to the inter rupted cycle position 2 Loosen both tailgate clamps and swing them out and forward as far as they will go LIFTING THE TAILGATE TAILGATE RAISED Stand clear when the tailgate is raised If you need to clean debris from the edges use a pole while standing to the side 1 Depress and hold engine speed up button 2 Pushthe tailgate lift lever rearward and hold until the tailgate is fully raised LEVER N The tailgate open light and backup lights SPEED UP should illuminate The backup alarm should BUTTON also sound SECTION 3 OPERATION EJECTING THE LOAD PUSHOUT LEVER 1 Depress and hold engine speed up button push the pushout lever rearward and hold until the pushout panel stops N NOTE SPEED UP On units with a telescopic pushout cylinder this will i BUTTON eject the entire load go on to step 4 2 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed A WARNING 3 Repeat steps 1 and 2 until the pushout panel is as far back as it will go completely ejecting the load Never drive the unit more than 10 feet with the tailgate in a raised position 4 Slowly pull the unit ahead to clear the refuse pile when the tailgate is lowered 6 Pull the pushout lever
90. he way parts are positioned for correct assembly Parts that must be replaced together are available as a repair kit from your authorized Leach distribu tor NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent dirt from entering the cylinder 9 32 SECTION 9 SERVICE AND REPAIR REASSEMBLY AND INSTALLATION 5 PUSHOUT CYLINDER Reassemble and install the pushout cylinder the approximate reverse order of disassembly GEA DESCRIPTION OF CLAMP MECHANISM CLAMP CYLINDER The clamp mechanism in conjunction with the clamp cylinder locks or clamps the pushout panel to the pushout bar The panel is automatically clamped dur ing the unloading operation prior to the pushout cylin der being extended Proper maintenance of the clamp mechanism is important to achieve proper loading and unloading of the unit If the pushout bar begins to slide through the pushout clamp mechanism while pushing out or packing check for wear PUSHOUT BAR WEAR POINTS The clamping mechanism has 8 wear points that should be checked periodically or whenever the pushout bar starts slipping OPERATIONAL STATUS Truck Off PTO Disengaged 1 Socket clamp shoe lamp mechanism is removed Pushout bar clamp mechanism is removed 2 Clamp shoe 3 Pushout clamp block pin contact area 4 Clamp pin 5 Pivot arm pin contact area NOTE 6 Pivot ar
91. hose that are large and apply forces through hydraulic pressures the ultimate responsibility for safe ty rests with you the user 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 illustration for the location and label content of all safety decals 1 These decals must be obeyed at all times 2 hese 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 AND CAUTION 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 amp Health Act OSHA and American National Standards Institute ANSI regulations DANGER 4 CAUTION Throughout this manual DANGER WARNING and CAUTION notations accompanied by the International Hazard Symbol are used to alert the operator and mechanics to special inst
92. ibed in Section 9 Service and Repair ACC 10 1 SECTION 10 SERVICE TOOLS NO PART NO DESCRIPTION 1 30522 Pressure Gauge 2 T SK 793 100 Pin Puller 3 T 2R 1006 2 Tube Nut Wrench 17 4 T 2R 1313 2 Tube Nut Wrench 2 5 T SR 9541 20 Pump Shaft Seal Tool 6 100368 Snap Connector 7 402325 Pivot Puller 8 103081 O Ring Kit 9 405 638 Carrier Cylinder 10 2 Fitting Wrench EXPLANATION To measure system pressure Remove pivot pins Remove Install tube nut Remove Install tube nut Install seal Quick coupling for pressure gauges Remove upper carrier pivots Various size o rings Remove install fittings UNIT All except FL104 Beta All 2R 2HII 2R 2HII All All 2HII All except FL104 2HII LEACH Parts Order Form Parts Fax 920 231 5597 Date OrderNumber Phone 920 231 2770 Ed company Name m mu Address BERN Routing instructions City State Zip Fax Model number Unit serial number REF NO PART NO DESCRIPTION QTY S Leach Company 2737 Harrison Street P O Box 2608 Oshkosh Wisconsin 54903 2608 oMMiIT7 S O A 9 e S Thi LING Re SB Ok O d bs Prin 20 int e d 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 info
93. ic 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 the carrier and packer panels in the interrupted cycle position and fully retract the pushout cylinder to check the fluid level 1 When checking the fluid level in the hydraulic tank also note any frequent or sudden loss of fluid This may indicate leakage which must be traced and corrected to avert equipment failure and possible damage to other components If low fill the hydraulic tank to the NORMAL FILL LEVEL with hydraulic fluid as specified in Sec 4 SPECIFICA TIONS according to operating and weather conditions CLEAN TANK BREATHER WEEKLY Clean the air breather 2 every week Replace a breather that cannot be cleaned adequately CHECK REPLACE RETURN LINE FILTER ELEMENT The return line filter is a vital component of the hydraulic system Without proper filtration problems are bound to occur among the hydraulic system compo nents Stick to the 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 hydraulic pump operation 3 Thereafter every 250 hours of hydraulic pump oper ation or sooner if so indicated by the filter replace ment indicator 3 The condition of the filter element must be checked weekly by looking at the vis
94. icient operation of the 2RIl Packmaster It is important that you know the location and function of each control before attempting to operate the unit Refer to the accompanying illustrations for their locations 3 1 SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS age M EIN NY B 4 KN i lt f J t eee _ e 7 n a M lt 0 ec M En T 2 E x v Em ne mE aly os oe 225 PEE _ AGRA AS T CPV EN gt v e rupes LEM Be inn ee ae C s SECTION 3 OPERATION PUMP PTO CONTROL 1 The Pump PTO Power Take Off is engaged to put the hydraulics operation The exact location of the Pump PTO control will vary depending on the type truck chassis style and control panel location The Pump PTO may be engaged by use of a lever rocker switch push pull cable toggle lever or positive control button depending on the style Be sure to read all safe ty decals associated with the Pump PTO before attempting operation qmm A cR rtu c cipra eee SOLENOID ON OFF SWITCH 2 This switch energizes the engine speed up system It is located on the cab control panel exact location depen dent on cab make and style NOTE The engine speed up system consists of the
95. ift Cylinders 9 15 Test for Leaking Tailgate Cylinder 9 15 Removal of Tailgate Lift Cylinders 9 16 Disassembly of Tailgate Lift Cylinder 9 17 LEACH SECTION 9 SERVICE AND REPAIR continued Inspection and Replacement of Tailgate Lift Cylinder Reassembly and Installation of Tailgate Lift Description of Tailgate Assembly Removal of the Tailgate Assembly Inspection of Tailgate Reassembly and Installation of Tailgate Front Control Removal of Front Control Valve Disassembly and Inspection of Front Control Reassembly of Front Control Valve Reinstallation of Front Control Valve Description of SPC Valve Disassembly of Sequence Valve Cartridge Inspection and Replacement of Sequence Cartridge Disassembly of Pilot Check Inspection and Replacement of Pilot Check Reassembly and Installation of Pilot Check Operating Valve Removal of the Main Control Valve Disassembly and Inspection of the Main Control Reassembly of Main Control Valve Disassembly and Inspection of the Knockout Positioner Reassembly of Knockout Positioner Description of Pushout Cylind
96. in imum lifting capacity of 500 Ibs 4 Remove the six nylock screws 1 and three lock segments 2 securing the head gland 3 to the cylinder 5 Slowly operate the hoist to carefully pull the piston rod assembly out of the cylinder 6 Disassemble the cylinder and install replacement part s NOTE During disassembly note the condition of each part as aN it is removed to aid in diagnosing Note the position of 3 each part as it is removed to aid in reassembly 1 INSPECTION AND REPLACEMENT OF OPERATING CYLINDERS 1 Carefully and thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear Check all parts for damage 2 Use an electric drill with an internal grinding wheel to remove burrs from the internal groove on the cylinder case 6 3 A new rod wiper 1 rod seal 2 o ring 3 seal 4 and wear rings 5 must be installed any time the cylinder is disassembled Pay particular atten tion to the way parts are positioned for correct assembly Parts that must be replaced together are available as a repair kit from your authorized Leach distributor 9 11 SECTION 9 SERVICE AND REPAIR REASSEMBLY AND INSTALLATION OF OPERATING CYLINDERS Reassemble and install the operating cylinders in the approximate reverse order of dissassembly DESCRIPTION OF THE PACKER PANEL The packer panel works in conjunction with the carrier panel and four operating cylinders to make up the com
97. inadequate outdoor storage unsealed reservoir covers or condensation 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 Test will provide an indication that a more complete test may be necessary A If 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 cor rect additive 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 TESTS 6 7 SECTION 6 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE 4 CONTAINER HANDLING Each day perform the following maintenance EQUIPMENT 1 INSPECTION In addition to performing the daily vehicl
98. inspection 1 Refer to the decal location illustration in Section 1 SAFETY of this manual and make sure all decals in place and readable Replace any decals that are INTR not il a A decal kit free of charge is available from your local authorized Leach distributor 2 As you are checking for decals also look for fluid leaks on and around the unit Check for fluid leaks at the hydraulic cylinders valves and fittings Torque rear body bound mounting bolt to 700 ft Ibs and front mounting springs to 372 plus or minus 78 3 Inspect the mounting sills and attaching hardware Make sure everything is tight and that there are no broken or excessively worn parts Check cap screws and fasteners for looseness visible welds for cracks and control levers for each movement SPRINGS 3 6 SECTION 3 OPERATION 4 Make sure the tailgate clamps are in the closed position and securely tightened 5 Check the hydraulic tank gauge to make sure the fluid is in the safe range Add fluid if necessary See Sec 5 SPECIFICATIONS for the correct type of fluid to use The pushout cylinder must be retracted the tailgate down the carrier and packer panels in the interrupted cycle position to check the hydraulic fluid level 6 Make sure all operating levers the neutral PUSHOUT position PANEL Check LEVER c a Packer pane
99. is metal to metal contact between the pushout panel and trough floor PUSHOUT PANEL TROUGH OPERATIONAL STATUS PUSHOUT SHOES 1 Raise the front of the pushout panel enough to take PNG the weight off the wear blocks one side at a time Use a hydraulic jack wedge or pry bar Support the pushout panel and remove the two 2 capscrews the wear block holder retainer Y cd ee p ERAN 2 Slide the upper and lower wear blocks out and dS E T 3 replace 2 3 Reinstall the wear block holder retainer and tighten WEAR BLOCKS the two 2 capscrews 4 Lower the pushout panel 5 Repeat this procedure for the other side 9 42 SECTION 9 SERVICE AND REPAIR REAR WEAR BLOCK REPLACEMENT TELESCOPIC SYSTEM The wear blocks should be replaced before there is metal to metal contact between the pushout panel and the trough floor 1 Move the pushout control lever rearward and posi SUPPORT tion the pushout panel at the rear of the body JACKS 2 Move the tailgate lift control lever rearward to raise the tailgate allowing access to the pushout panel OPERATIONAL STATUS Truck Off PTO Disengaged TROUGH 3 Support the tailgate with support jacks capable of supporting at least 7500 lbs 3402 kg NN 4 Raise one side of the pushout panel slightly with a N pry bar or wedge Support the panel in this position L and remove the access cover Remove the cap l
100. l lever b Carrier panel lever c Pushout lever d Tailgate lift lever Never operate the 2RIl Packmaster with any part of the control system or levers removed or serious damage will result Never under any circumstances enter the body if the truck is running Open the packer panel and release the pushout panel clamp before entering the body Always make sure the truck engine is off and the keys are in your pocket before entering the body TAILGATE LIFT LEVER d PACKER CARRIER PANEL PANEL LEVER a LEVER b 3 7 SECTION 3 OPERATION 7 Look around the clamp and pushout panel area Clean out any refuse caught in this area that could possibly hamper the clamp and pushout panel operation Never under any circumstances enter the body if the truck is running Open the packer panel and release the pushout panel clamp before entering the body Always make sure the truck engine is off and the keys are in your pocket before entering the body 8 Start the truck according to the manufac turers instructions and while it is warming up continue the walk around inspection AWARNING The tailgate open warning light should be off Do not operate the unit if the light is illuminated Never place hands in or near the packer panel during operation 10 With the engine running the speed up solenoid switch ON the PTO engaged and the transmission in neutral and the brakes applied depress the speed u
101. lace pump See Sec 9 Service and Hepair Operating cylinder piston seals leaking Perform test for leaking operating cylinder seals and repair as required Incorrect grade of hydraulic fluid for current Refill with proper grade of hydraulic fluid operating conditions See Sec 5 Specifications Solenoid mounting loose or broken Remount solenoid securely on engine if pos sible Solenoid or wiring defective Repair or replace as required See Electrical System Sec 9 Service and Repair Defective governor diesel engine Diesel engine must have a full variable speed governor to properly operate packer TAILGATE WILL NOT RAISE Tailgate clamps still engaged Disconnect clamps and swing free of tailgate Insufficient hydraulic pressure Check main pressure See Sec 7 Check out Hydraulic pump is defective Replace pump See Sec 9 Service and Hepair Relief section of 2 spool directional valve out Adjust or replace spring as necessary See of adjustment or broken Sec 9 Service and Repair Tailgate lift cylinders leaking or defective Repair or replace as required Restriction in tailgate cylinder hose Remove and clean hose SECTION 8 TROUBLESHOOTING CONTAINER WON T LIFT Insufficient hydraulic pressure Check hydraulic pressure following proce dures in service manual Cable broken Replace cable Cable loose from the lifting device drum cylinder
102. lier in this section ASSEMBLY SS 5 Remove the roller assemblies as described earlier in this section 6 Remove the outside bearing assemblies as described earlier in this section 7 With the bearing assemblies removed carefully operate the hoist and lift the packer panel out of the hopper Use care to avoid damaging the hopper INSPECTION AND REPLACEMENT OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot bearing and roller sur faces for excessive or uneven wear scoring or other damage 2 Check the panel for broken welds bent edges or warpage 3 Inspect the packer panel edge for damage EDGE Replace a badly worn edge as described below 4 Replace parts as necessary See Sec 4 GENER AL REPAIR PRACTICES 9 48 REPLACEMENT OF PACKER EDGE 1 Remove the old edge with an air arc to obtain a clean cut 2 smooth the packer panel where the new edge will be attached 3 Weld a new edge in place NOTE Pay particular attention to the torque tube Ensure that it is perfectly straight INSTALLATION OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the packer panel in the approximate reverse order of disassembly Pay particular attention to the installation of roller and bearing assemblies as described earlier in this section SECTION 9 SERVICE AND REPAIR 9 49 SECTION 9 SERVICE AND REPAIR CARRIER
103. lin der As the cylinder extends the pushout panel moves to the rear ejecting the load AEN PRESSURE RETURN OPERATING VALVE Y TAILGATE SSX LIFT f CYLINDER SPC VALVE a HYDRAULIC p FLUID TANK Or TAILGATE LIFT CYL PACKER CYLINDER PUSHOUT CYLINDER 8 18 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM RETRACTING PUSHOUT BAR LEVER OPERATOR ACTION Operator releases speed up button Operator moves the pushout lever forward SPEED UP BUTTON HYDRAULIC SEQUENCE NOTE Moving the pushout lever forward shifts a spool in the Ejecting the load and retracting the pushout panel front control valve causing flow to the rod end of the sequences are repeated by the operator as many pushout cylinder and to the pilot check valve Releasing times as needed to fully eject the load The pushout this check valve allows fluid to drain from the clamp panel being left further back each time the clamp is cylinder releasing the clamp mechanism so that the released and the pushout cylinder is retracted pushout panel remains where it is while the pushout cylinder is retracted AEN PRESSURE RETURN OPERATING VALVE O Cd TAILGATE LIFT Y CYLINDER SPC VALVE S HYDRAULIC FLUID TANK TAILGATE LIFT CYL CYLINDER PUSHOUT CYLINDER 8 19 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM DESCR
104. lowers The operator then attempts to penetrate down through the refuse that is in the hop per with the packer panel This incorrect method of operation results in much the same kind of failures as skimming because the torque tube and lower carrier channel are put into a shear situation This incorrect method of operation will also adversely affect the hop per bottom because the force of the packer panel cylin ders is being dissipated down through the refuse and into the hopper structure Anytime a repaired area has a repeat failure suspect that the core problem whether it is mechanical or oper ator has not been adequately addressed REMOVE TOP SHEETS INSPECTION AND REPLACEMENT OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot bearing and roller sur faces for excessive or uneven wear scoring or damage 2 Check the panel for broken welds bent edges or warpage 3 Inspect the track bar for excessive wear or damage 4 Replace parts as necessary INSTALLATION OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the carrier panel in the approximate reverse order of disassembly Pay particular attention to the installation of roller and bearing assemblies as described earlier in this section TRACK BAR REPLACEMENT OPERATIONAL STATUS Truck Off PTO Disengaged Refer to Sec 4 GENERAL REPAIR INSTRUCTION for welding instructions
105. luid flow is through the operating valve packer section to the case end of the packer panel cylinders As the cylinders extend the packer panel sweeps the load for ward in the hopper As the packer cylinder extension stroke continues pressure builds to 1200 PSI 83 BAR causing the operating valve to shift SEES PRESSURE RETURN OPERATING VALVE TAILGATE LIFT CYLINDER SPC VALVE ER 3 HYDRAULIC ARRIER CYLIND be S FLUID TANK N C J on aes PUMP PACKER CYLINDER LIFT PUSHOUT CYLINDER CYLINDER 8 15 SECTION 8 TROUBLESHOOTING CLAMP SYSTEM PACKING REFUSE OPERATOR ACTION None Operating Valve shifts automatically HYDRAULIC SEQUENCE Fluid flows from the operating valve to the case end of the carrier panel cylinders The cylinders extend mov ing the carrier and packer panels up packing refuse against the pushout panel When the pressure reaches 1500 PSI 104 BAR the operating valve shifts into neutral and the packing cycle is completed As the car rier cylinders apply force to compact refuse the pres sure of the trapped fluid in the packer cylinders will increase Should this pressure reach 3500 PSI 242 BAR a relief valve will open reducing the pressure by allowing some trapped fluid to escape and return to the wae PRESSURE hydraulic tank Teer RETURN TRAPPED FLUID OPERATING VALVE TAILGATE O LIFT X CYLINDER SPC VALVE HYDRAULIC CYLINDER LIF
106. ly 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 Start the engine following the manufacturer s rec ommended procedure Always set the parking brake before leaving the cab 16 Turn on appropriate warning lights put on a safety 17 18 19 20 21 ee 23 24 25 26 27 28 29 30 31 32 33 SECTION 1 SAFETY PRECAUTIONS 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 Hide only in the cab or on riding platforms designed for that purpose Riding steps shall not be used when speeds are expected to exceed 10 mph or when distance traveled without stopping will exceed 10 of one mile Do not mount or dis mount riding step when vehicle is in motion Never allow anyone to ride on the steps when the vehicle is backing up otop the vehicle immediately if warning lights for the TAILGATE AJAR system come on Never use controls or hoses for hand hold
107. m bushing These parts can be more closely inspected if the f 8 Pushout clamp block face Wear in the above areas if not excessive can be com pensated for by adding shims SECTION 9 SERVICE AND REPAIR DISASSEMBLY AND REMOVAL OF CLAMP MECHANISM OPERATIONAL STATUS Truck Running PTO Engaged 1 With the body empty raise the tailgate and support it as shown Truck Off PTO Disengaged 2 10 Remove the 8 capscrews 1 and the access hole Remove the 2 capscrews 3 2 lockwashers 4 Remove the pivot arm pin 6 with a 8 pin puller To disassemble the remaining portion of the Remove the yoke pin 4 with a pin puller Now To replace or examine the clamp block remove ANG AE OD wb fie OPERATIONAL STATUS Pull the pushout panel to mid point position by use of a come a long cover plate 2 and keeper plate 5 clamp mechanism remove the 2 capscrews 1 2 lockwashers 2 and keeper plate 3 the pivot arm can be lifted out The clamp pin is also now loose and can be removed 5 the 4 capscrews 6 4 lockwashers 7 and cover 8 The block 9 can now be removed To examine the clamp shoe 1 and shoe socket 3 2 remove the 4 capscrews 3 and 4 lockwash 22222 ers 4 2 To remove the clamp shoe 1 and shoe socket 2 you must first take off KO v the cover plate 5 To do this remove the 4 ca
108. m your LEACH distributor See Sec 9 SERVICE AND REPAIR Clamp Mechanism CHECK PUSHOUT SHOES AND WEAR BLOCKS OPERATIONAL STATUS Truck Off PTO Disengaged Visually inspect all pushout shoes and wear blocks for excessive wear These items must be replaced pu before there is metal to metal contact SS 2 Shim or replace worn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL WEAR BLOCKS POWER TAKE OFF P T O OPERATIONAL STATUS Truck Off PTO Disengaged 1 Periodically re torque the mounting bolts or studs as outlined in the P T O manufacturers service manual 7 9 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 tion or control linkage adjustment COMPACTION Before troubleshooting a unit it is important to remem ber that the compaction may vary with the foll
109. mber 4 Raise the cylinder and slowly extend it until it can be attached to the pushout panel with the bearing clamp halves and capscrews SECTION 9 SERVICE AND REPAIR DESCRIPTION OF CARRIER AND PACKER PANELS The carrier and packer panels operate as a single unit to sweep the refuse from the hopper and to pack it against the pushout panel Their movement through the different cycles is controlled by the operating cylinders The two panels are connected together and pivot on the inside and outside bearing assemblies Movement of the panels within the body is kept in alignment by the roller assemblies located at the upper corners of each panel The rollers ride inside a roller track on each side of the hopper OPERATING CYLINDERS PACKER PANEL 9 46 p Vj 2 This section focuses on some factors that need to be taken into consideration when performing packer carri er repairs The packer carrier assemblies and interre lated components are designed for relatively trouble free use however they are subject to reduced service life due to the lack of or ineffective maintenance Methods of operation other than for which the unit was designed can also affect the longevity of these compo nents CARRIER PANEL REMOVAL OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 IF THE CARRIER PANEL IS ALSO TO BE REMOVED remove all four operating cylinders as described earlier in this section a
110. moved 9 45 Installation of Pushout Panel 9 45 Description of Carrier and Packer Panels 9 46 Removal of Packer Panel 9 47 Inspection and Replacement of Packer Panel 9 48 Replacement of Packer Edge 9 49 Installation of Packer Panel 9 49 Carrier 9 50 Removal of Carrier Panel 9 50 Inspection and Replacement of Carrier Panel 9 51 Installation of Carrier Panel 9 51 Track Bar Replacement 9 51 Description of Leach Hydraulic Pump 9 52 Removal of Hydraulic Pump 9 52 New Pump Preparation 9 53 Disassembly of Hydraulic Pump 9 54 Replacing Shaft Seals on the Hydraulic Pump 9 54 Reassembly of 203834 Hydraulic Pump 9 55 Installation of Hydraulic Pump 9 56 Testing a New Pump 9 56 Description of Electrical System 9 56 festing 9 56 9 56 Inspection 9 56 Grounding the Electrical System 9 57 2HII Electrical Schematic 9 59 SECTION 10 SERVICE TOOLS 10 1 Manual Order Form Reward VI GENERAL The 2HII Packmaster has been designed with the oper ator in mind However as with any industrial machinery especially t
111. n screws from the wear block retainer Slide the upper and lower wear blocks out and replace 5 Reinstall the wear block retainer and tighten the capscrews Lower the pushout panel and replace the access cover WEAR BLOCKS 6 Repeat this procedure for the other side SHIMMING UPPER WEAR BLOCKS WITH PANEL IN PLACE Shims can be added to the upper wear blocks in the front without removing the pushout panel as follows OPERATIONAL STATUS Truck Off PTO Disengaged 1 Loosen the friction brake adjusting bolt 2 Pry the panel at the forward nearest cab end to one side 3 Add shims behind wear block 5 Tighten the friction brake adjusting bolt until the 4 Repeat the procedure for the other side panel does not move when stopping or starting 9 43 SECTION 9 SERVICE AND REPAIR REMOVAL OF PUSHOUT PANEL OPERATIONAL STATUS PUSHOUT LEVER Truck Running PTO Engaged TAILGATE LIFT LEVER 1 Move the pushout lever rearward and position the pushout panel at the extreme rear of the body 2 Move the tailgate lift lever rearward to raise the tail SPEED UP gate after swinging away the tailgate clamps BUTTON OPERATIONAL STATUS Truck Off PTO Disengaged 3 Support the tailgate with an overhead lift capable of supporting at least 7500 Ibs 3402 kg 4 Disconnect and PUSHOUT 6 Disconnect the hydraulic fluid line to the clamp remove the BAR cylinder Cap and plug the tubes and cylinder port pu
112. n a slightly bent torque tube may cause damage to other components Replace the tube if bent or worn ROLLER REPLACEMENT SHIMMING OPERATIONAL STATUS Truck Running PTO Engaged 1 Shift the control levers and cycle the unit several times while observing the rollers and action of the packer and carrier panels Watch for sideways movement or twisting to determine where shim ming and or new rollers may be needed OPERATIONAL STATUS Truck Off PTO Disengaged 2 Remove capscrews 1 lockwashers 2 covers 3 and cover weldments 4 for both upper and lower track holes on each side of the tailgate 9 13 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged 3 Shift the control levers and cycle the panels as nec essary to align the upper and lower rollers with the track holes NOTE If the top roller is removed first place a wedge between the carrier panel and the partition sheet to take the weight off of the roller assemblies If the bottom roller is removed support the carrier and packer panel assembly before removing the roller OPERATIONAL STATUS Truck Off PTO Disengaged 4 Remove one roller at a time SHIMS 5 Replace any roller that is excessively worn ROLLER cracked or out of round Inspect the condition of the track bar j GREASE 6 Replacement rollers should be installed with the FITTING original shims or the same amount of new shims A greas
113. n the home position and stopped before loading the hopper The dashboard solenoid switch must be OFF between pickups or when parked This prevents inadvertent engine speed up if the tailgate carrier panel control lever is shifted The tailgate clamps must be tightened securely before starting to load Do not step on the throttle pedal while the speed up system is engaged Vehicles with automatic transmissions require the shift lever to be in gear to engage the PTO and then shifted to neutral to activate the PTO pump Never use a rear loader to transport a container Follow all safety directions listed in the refuse body Operator and Service manual under SAFETY PRE CAUTIONS Never use container handling chains or cable for towing or pulling When not handling containers keep the container attachment closed and latched Do not operate the rear loaders packing mecha nism with a container off the ground If it is necessary to manually free debris from the container use a long metal probe while the con tainer is on the ground and DO NOT place yourself between the container and the packer body Attach hook to the tailgate and take up the excess slack when not in use Never hold the hook on an attachment point while taking up slack Take up excess cable slack before moving the vehi cle Check overhead clearance before dumping a con tainer Do not move the vehicle with a container attached Always
114. nd out with clean water Make sure no refuse is lodged in the body through or behind the pushout plate especially near the clamp area or rear of the tank Make sure there is no grease on the pushout bar 3 LUBRICATION Frequent inspection of grease points will indicate when lubrication is needed 6 8 SECTION 6 PREVENTIVE MAINTENANCE WEEKLY PREVENTIVE MAINTENANCE 1 CLEANING Clean and paint exposed metal 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 acces sible mounting hardware and fittings for tight ness Refer to the CAPSCREW MARKING AND TORQUE VALUE CHART provided in Sec 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 Check the replacement indicator on the filter assembly weekly Refer to HYDRAULIC SYSTEM SER VICE 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 cannot be cleaned thoroughly or is missing NOTE A leaking breather on the clamp cylinder indicates a defective piston seal which must be repla
115. nd proceed to step 3 below OR OPERATIONAL STATUS Truck Off PTO Disengaged IF THE CARRIER PANEL IS NOT TO BE REMOVED attach a chain connected to a suitable lifting device capable of supporting 1600 Ibs 726 kg to the lower end of the carrier panel as shown This will support the carrier panel once the packer panel is removed NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of Slings and lifting chains OPERATIONAL STATUS Truck Running PTO Engaged 2 Move the packer panel operating lever inward to bring the packer panel up When the panel reach es a vertical position bring the packer panel con trol lever back to neutral This will take the pres sure off the rod eye when the pin is removed OPERATIONAL STATUS Truck Off PTO Disengaged Remove the capscrews 1 lockwashers 2 and pivot pin covers 3 from the rod end Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin SECTION 9 SERVICE AND REPAIR PACKER PANEL LEVER 9 47 SECTION 9 SERVICE AND REPAIR Attach a chain connected to a suitable lifting device capable of lifting 1600 165 726 kg to the packer panel as shown Operate the lifting device to support the weight of the packer panel without causing strain on the bearing and roller assem blies INSIDE 4 Remove the inside bearing assemblies as BEARING described ear
116. nder OPERATIONAL STATUS Truck Running PTO Engaged PACKER 22 PANEL LING LEVER CYLINDER Shift the packer panel lever inward to partially retract the packer panel cylinders Disengage the lever when the panel is vertical This relieves the weight of the panel from the cylinder rod end OPERATIONAL STATUS Truck Off PTO Disengaged 4 Remove the capscrews 1 lockwashers 2 and pivot pin cover 3 from the rod end 9 7 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged PTO Dsengaged 5 Make sure the cylinder weight is securely support ed by the hoist and carefully remove the pivot pin PIVOT PIN OPERATIONAL STATUS Truck Running PTO Engaged 6 Shift the packer panel lever inward to completely retract the cylinder A CAUTION 7 Disconnect both the case end 1 and rod end 2 Loosen the hydraulic fittings slowly to release pressure tubes Immediately cap or plug the pres any trapped pressure Watch for inadvertent sure tubes and cylinder ports to keep fluid in and movement of components dirt out 8 Remove capscrew 1 lockwashers 2 and nut 3 securing the pivot pin retainer 4 and remove the retainer 9 Remove the pivot pin by using special packer pin puller See Sec 10 SERVICE TOOLS 10 Check for bent pivot pins and inspect pin hubs for broken welds and elongated holes 9 8 SECTION 9 SERVICE AND REPAIR R
117. ner Attachment system consists of a loading edge with a latch assembly and a guide ear ear on each side of the packer tailgate The latches and ears are installed to accomodate containers from one 1 to ten 10 cubic yard capacity The standard container for use with the Leach rear loader must have an ANSI Standard 174 1 diameter trunnion bar which is between 7772 and 78 end to end This trun nion bar length will center the container between the ears and prevent the container from moving side ways The latch arms must be manually raised and secured by the arm latch The container arms when properly latched together with the guide ears will secure the container to the packer Only containers that meet the American National Standards Institue ANSI regulations should be used in conjuction with Leach Container Handling Systems CONTAINER HANDLING SYSTEMS To lift or dump a container several systems are avail able A hydraulically operated container push bar is available to handle containers of 1 to 3 cubic yard capacity The handling of containers with capacities of four 4 or more cubic yards requires the use of a drum winch or roof mounted container lifting cylinder Drum winches are rated at various pounds of pull Leach Company offers winches with 8 000 12 000 and heavy duty 12 000 Ib ratings The Leach container lift cylinder is rated at 12 000 pounds NOTE Leach bodies are capable of being equipped
118. ng capacity of 500 Ibs 227 kg Operate the hoist to snug the lifting cable without applying strain to the cylinder OPERATIONAL STATUS Truck Running PTO Engaged 6 Slowly operate the carrier panel lever inward to completely retract the carrier cylinder piston rod This will provide enough clearance to remove the cylinder OPERATIONAL STATUS Truck Off PTO Disengaged 7 Disconnect both the case end 1 and rod end 2 pressure tubes from the carrier cylinder Immediately plug the pressure tubes and cap the cylinder ports to keep fluid in and dirt out 8 Remove capscrew 1 nut 2 and lockwashers 3 securing the cylinder pivot pin retainer 4 and remove retainer 9 Carefully remove the pivot pin and lift out the cylin der assembly 10 Check for bent pivot pins and inspect pin hubs for broken welds and elongated holes NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering 9 10 CARRIER PANEL LEVER SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF OPERATING CYLINDERS 1 Remove the grease fittings clean parts drain fluid and follow all other applicable guidelines for disas sembly provided in Sec 4 GENERAL REPAIR PRACTICES before proceeding to disassemble the cylinder 2 Secure the case end of the cylinder to the floor or workbench 3 Secure the rod end of the cylinder to an overhead hoist or other suitable lifting mechanism with a m
119. ngesting air SECTION 8 TROUBLESHOOTING OPERATION IS ERRATIC POSSIBLE CAUSE REMEDY Solenoid receiving erratic electrical current Check electrical system See Sec 9 Service and Repair Solenoid flexing at mounting point Make sure solenoid is mounted firmly and mounting does not flex Engine motor mounts defective Repair or replace as required Hydraulic fluid too hot Check for proper grade of fluid See Sec 6 Preventive Maintenance Hydraulic fluid level too low Check fluid level Add fluid if necessary Bypass in cylinders Test for leaking cylinders See Sec 9 Service and Repair Hydraulic fluid too cold Bring fluid to operating temperature Check for proper grade of hydraulic fluid See Sec 5 Specifications Operating linkage bent or binding Repair replace or realign damaged linkage PUMP NOISE IS EXCESSIVE NOTE ALL PUMPS MAKE A CERTAIN AMOUNT OF NOISE POSSIBLE CAUSE REMEDY 1 Pump starving for fluid Open gate valve Check fluid level Check hydraulic fluid filter and tank Check for obstruction in suction lines hoses kinked or collapsed Hydraulic fluid too cold Bring fluid to normal operating temperature Change hydraulic fluid to proper grade for operating conditions See Sec 5 Specifica tions PTO driveshaft and or u joints badly worn or Repair replace and or balance all parts out of balance Pump gears end plates bearin
120. nstalling a container handling system be sure the overall height is rechecked and overall height plus 3 inches is noted on the decals OPERATION GENERAL 10 11 12 13 14 15 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 area behind the unit is clear before traveling in reverse Do not travel in reverse for distances greater than those dictated by local ordinances If reverse trav el exceeds 10 feet use a spotter or move the vehicle in 10 foot increments only and then check to make sure the area behind the unit is clear between increments Do not attempt to dislodge any material above waist level 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 Before operating the vehicle the driver must be thorough
121. ntainer lifting cylin der the speed of the device is limited during both the up and down movement This speed reduction is for safety considerations USING A CONTAINER PUSH BAR CPB Once the container is secured within the latch assem bly the container is ready to be dumped After assuring that all persons are standing clear the operator moves the CPB control lever in the direction shown on the instruction decal to raise the container When raising a container with the push bar it is normal for the contain er to first lift upward within the container latch assem bly then tip toward the hopper and finally lower or drop to the bottom of the latch slots Do not overfill the hopper After assuring that all per sons are standing clear lower the container to check the load condition of the container and the hopper Lower the container enough to see between the con tainer and the tailgate while standing on the ground without placing yourself between them PACKING THE LOAD NOTE The compaction cycle can be stopped at any time by moving both the packer panel lever and the car rier panel lever to the center neutral 1 Cycle the packer panel and the carrier panel by mov ing both the packer panel lever and the carrier panel lever inward toward the tailgate then let go The packer panel will open and the packer panel lever will automatically shift to neutral The carrier panel will then move down to above the loading e
122. o adjacent parts 4 Use the following rods rod AWS number for welding Body except top hinge area hinge jr TII 5 Use ER 70S 6 wire for all locations 4 4 ee eee eee E6010 E6011 E6013 Tren E7018 ee ee ee ee ees eee E6010 E6011 E6013 ee ee ee ee ee ee E6010 E6011 bt Hp EE i p s ERE siete tree ad E7018 LEACH SECTION 4 GENERAL REPAIR PRACTICES LIFTING INSTRUCTIONS Because of the size and weight of the major components found on the unit it is necessary to use suitable lifting devices for removal The following components require lifting devices for removal cylinders carrier panel packer panel pushout panel and tailgate CAPACITY OF LIFTING DEVICE REQUIRED FOR REMOVAL 500 Ibs 227 kg Telescopic Pushout 5 1000 Ibs 454 kg Camer Panel Se ee ee ee ee os ee BREE 1600 Ibs 726 kg PacCKken roel eee een en cee pees ee ease 1600 Ibs 726 kg x i al TEE 2800 165 1270 kg HE 5 gore aaa be ee ed be Oe ee we ee ae E 7500 Ibs 3402 kg SLING STRAP SPECIFICATIONS 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 u
123. o increase pressure or out to decrease pressure 5 Repeat steps 1 thru 4 until pressure is correct OPERATIONAL STATUS Truck Running PTO Engaged JAM NUT NUT 7 7 SECTION 7 CHECK OUT CHECK FRICTION BRAKE CLAMP 1 The body must be empty before checking the fric tion brake 2 The pushout panel should not move freely on its own when stopping or starting the truck It should be held in position by the friction brake IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 3 Turn in the adjusting screw until the pushout panel does not move when starting or stopping the truck The friction brake can be turned in until a socket will no longer grasp the screw head in which case shims or a new block must be installed as described in PUSHOUT PANEL Section 9 SER VICE AND REPAIR CHECK CLAMP MECHANISM OPERATIONAL STATUS Truck Running PTO Engaged 1 With the unit partially loaded push the pushout control lever rearward and hold 2 Observe the clamp action the pushout bar should not slip through the clamp mechanism IF NOT OPERATIONAL STATUS Truck Off PTO Off Keys Removed 7 8 ADJUSTING SCREW PUSHOUT LEVER SECTION 7 CHECK OUT 3 If slippage is occurring check for wear on the items shown Rocker Clamp Pin 1 Clamp Block 2 Clamp Shoe 3 Clamp Shoe Socket 4 Rocker Arm 5 Parts wear if not excessive can be compensated for by adding shims available fro
124. ods 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 pre cautions listed in Sec 2 before performing any of the following check out procedures Use extreme caution to avoid coming near any mov ing parts Never enter the body of the unit when the truck is running Make sure the unit is in the correct operational mode as indicated by the OPERATIONAL STATUS block presented at the beginning of each check NOTE Because of the location of various controls some checks will require two people CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down and clamped securely 2 Position the packer panel to the INTERRUPTED CYCLE position 3 Pull the pushout lever to position the pushout cylin der in the retract position 4 The fluid level should be between the safe range marks on the sight gauge IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 5 Add hydraulic fluid for normal operating and weath er conditions See Sec 6 PREVENTIVE MAINTE NANCE for additional information about servicing the hydraulic tank SECTION 7 CHECK OUT 7 1 SECTION 6 CHECK OUT CHECK ENGINE SOLENOID SWITCH OPERATIONAL STATUS Truck Running PTO Engaged IF ENGINE SPEEDS UP OPERATIONAL STATUS Truck Off PTO Disengaged The system is grounded Locate the shor
125. of Tailgate Closed 74 Height Above Chassis Frame tailgate Raised 194 Loading Lip Below Chassis Frame 5 Center of Gravity Measured From Front of Body Body Only 117 Payload 94 Hopper Capacity 2 7 Cu Yd Approx Body Weight 14 495 Ibs Min Truck GVWR Requirement 46 000 Ibs 25 Cu Yd 24 270 171 146 101 96 90 17 4 19 23 80 56 80 74 194 131 103 2 7 Cu Yd 15 020 Ibs 52 000 Ibs NOTES 31 Cu Yd 24 316 217 192 101 96 90 17 4 19 23 80 56 80 74 194 151 120 2 7 Cu Yd 16 125 Ibs 60 000 Ibs SECTION 5 SPECIFICATIONS 15m 610mm 6325mm 3810mm 3175mm 2560mm 2439mm 2286mm 432mm 102mm 483mm 585mm 2032mm 1423mm 2032mm 1880mm 4928mm 127mm 2388mm 2388mm 2 0m 6575 kg 21000 kg 19m 610mm 6858mm 4340mm 3708mm 2560mm 2439mm 2286mm 432mm 102mm 483mm 585mm 2032mm 1423mm 2032mm 1880mm 4928mm 127mm 2617mm 2617mm 2 0m 6813 kg 24000 kg 24m 610mm 8026mm 5512mm 4877mm 2560mm 2439mm 2286mm 432mm 102mm 483mm 585mm 2032mm 1423mm 2032mm 1880mm 4928mm 127mm 3048mm 3048mm 2 0m 7314 kg 28000 kg e Truck selected must be capable of carrying net weight of body plus weight of refuse to be collected e A full variable speed governor is preferred on trucks equipped with a diesel engine e CA must be useable with no obstructions protruding above the frame e Specifications subject
126. onsibility of the customer There is no warranty on expendable items wear components or used parts 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 2RII Packmaster 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 distributor 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 proper operation and servicing of your refuse packer It was produced with the latest informa tion available at the time of publication We do however reserve the right to redesign and or dis continue the manufacture of part
127. owing conditions 1 Type of refuse Tree branches dry leaves 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 rear loader is a skill Placement of items in the hopper not over loading the hopper and releasing the pushout plate clamp at the right time are all learned skills that will affect the com paction rate of a unit SECTION 8 TROUBLESHOOTING Hydraulic flow diagrams are provided in this section These diagrams can be helpful in determining which parts are associated with a particular function For example the clamp cylinder is part of the load pushout function An electrical wiring diagram is included in Sec 9 SER VICE AND REPAIR under ELECTRICAL SYSTEM Problems in the hydraulic system may be found by per forming the PRESSURE CHECKS found in Sec 7 CHECK OUT PROCEDURES Refer to Section 10 for telescopic troubleshooting 4 Preventive maintenance A properly maintained unit will achieve higher compaction rates than one that is poorly maintained The condition of the hydrauli
128. p push button on the forward left street side of the body You should hear the engine speed up 3 8 Never hold the packer or the carrier panel lever in position by hand Always engage and let go immediately The only exception is at the end of a load SPEED UP BUTTON gt 11 Move both the packer panel lever and carrier panel lever inward and let go Check for the following a Engaging the carrier panel lever will activate an engine speed up switch you should hear the engine speed up b Observe the carrier and packer panel move ment it should be smooth The panels should stop automatically at the interrupted cycle posi tion 12 Move both the packer panel lever and carrier panel lever outward and let go Observe the carrier and packer panel movement it should be smooth The panels should stop automatically at the home posi tion 13 Depress the two driver signal push buttons located on both sides of the tailgate to make sure that the audible alarm located in the cab is working 14 Back the unit up a few feet to ensure that the back up alarm is working properly 15 Loosen the tailgate clamps and swing out Raise the tailgate approximately 6 and check to see if the tailgate ajar light on the dash is on and if the backup alarm is audible Do not have the unit in reverse SECTION 3 OPERATION CARRIER PANEL LEVER PACKER PANEL LEVER TAIL
129. perly 2 Wipe off the magnetic ring and wipe out the bottom of the tank 3 Clean strainer as described previously 4 Fill the hydraulic tank with fresh fluid as specified in Sec 5 SPECIFICATIONS according to operating and weather conditions 5 Start the unit and operate all hydraulic levers as described in Sec 3 OPERATION Leave all hydraulic cylinders in the retracted position and shut down unit 6 Recheck the fluid level and add fluid as necessary to bring level to the NORMAL FILL LEVEL on the sight gauge NOTE Refer to Sec 9 SERVICE amp REPAIR for detailed instructions pertaining to those items requiring repair or replacement 6 6 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 according to ANSI Standard B93 19M R1980 This standard is available from the National Flui
130. possible that Nitrocarburized compo nents may turn various shades of white and may appear streaked This condition is normal and does not affect cylinder performance or serviceability 9 17 SECTION 9 SERVICE AND REPAIR REASSEMBLY AND INSTALLATION OF TAILGATE LIFT CYLINDER Reassemble and install the tailgate lift cylinder in the approximate reverse order of disassembly DESCRIPTION OF THE TAILGATE ASSEMBLY The tailgate assembly consists of the operating cylin ders carrier and packer panels and the hopper where refuse is first loaded into the unit The tailgate is lifted for unloading and lowered by the tailgate lift cylinders which are actuated by the tailgate lift lever located at the front of the body The need to remove the tailgate is rare and limited to repair of the hopper area and removal of the carrier panel Procedures for carrier panel removal are differ ent and are covered under REMOVAL OF CARRIER PANEL REMOVAL OF THE TAILGATE ASSEMBLY OPERATIONAL STATUS Truck Off PTO Disengaged 1 Release the tailgate clamps swing away 2 Disconnect and remove the tailgate lift cylinders as described earlier in this section 3 Disconnect and cap the hydraulic lines NOTE See Sec 4 GENERAL REPAIR PRACTICES for detailed information about the correct use of slings and lifting chains 4 Attach chains connected to a suitable lifting device with a minimum lifting capacity of
131. pressure change of only 600 psi may be enough to generate the heat required to ignite the fluid and air mixture The oxygen in the heated compressed air and the hydraulic fluid ignite resulting in dieseling The igni tions that result from dieseling in the hydraulic system are small in size and many may be needed to eventu ally damage a piston seal to the extent that bypass will occur Where does the air come from The answer is that the air comes out of the fluid itself Hydraulic fluid can con tain 10 air by volume As the pressure on the fluid increases the amount of air that can be absorbed also increases Now we know that the air is most likely present in the fluid but the next question is How does the air get out of the fluid The air while it is in Suspension will pose no problem to the operation of the hydraulic system But once it is separated into bubbles then all the factors are present to support combustion The air in Suspension can be separated when the fluid is subjected to a neg ative pressure vacuum of as little as 3 5 psi This can occur when the fluid is squeezed through a restriction or an orifice The resulting pressure decrease can be sufficient to allow trapped air to separate from the fluid 8 2 A good example may be a front mounted pump dry valve system In the dry mode of operation system hydraulic fluid is drawn through a small orifice This pro vides lubrication and cooling for the pump
132. pscrews 4 lockwashers NX 9 34 SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CLAMP MECHANISM OPERATIONAL STATUS Truck Off PTO Disengaged Replace all excessively worn parts as determined by checking wear points REASSEMBLY AND INSTALLATION OF CLAMP MECHANISM OPERATIONAL STATUS Truck Off PTO Disengaged 1 Reassemble and install parts in the reverse order of disassembly NOTE Make sure that after the clamp mechanism is replaced the pivot is thoroughly greased CLAMP ADJUSTMENT OPERATIONAL STATUS Follow the illustrations below for proper clamp adjust Truck Off PTO Disengaged ments 1 Check the clamp cylinder stroke adjust if neces LOOSEN SET SCREW TURN CLEVIS TO ADJUST sary to 1 maximum Check the lever arm position Dv 23 en s Check the pushout bar clearance should be shim if necessary m S to obtain a maxi 4 40 4 lt 27 mum of 46 clear y 3 ance 4 Test x2 va MAXIMUM COVER CLEARANCE CHECK POSITION OF ARM 9 35 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF CLAMP CYLINDER This hydraulically operated single acting cylinder is mounted on the pushout panel It provides the force necessary to clamp the pushout panel to the pushout bar during the pushout cylinder extension stroke eject ing the load The internal clamp spring releases the clamping action once hydraulic pressure is released TEST FOR
133. ram TESTING To locate a defective component or break in the wiring perform a continuity check across the between sus pected components as described in Sec 4 GENERAL REPAIR 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 insure that they are operating normally 2 Check all wiring for breaks frayed or worn insula tion and loose terminal connections GROUNDING THE ELECTRICAL SYSTEM To insure a proper ground for the electrical system make sure an internal lockwasher is installed in the fol lowing areas 1 Buzzer System between the pushbutton and bracket 2 Speed Up System between the pushbutton and bracket 3 Back Up Alarm between the backup alarm and bracket 4 Taillight between the light and bracket The internal lockwasher will bite into the metal and ensure a positive ground 9 56 TYPICAL EXAMPLE TOOTHED WASHER SECTION 9 SERVICE AND REPAIR 2RII ELECTRICAL SCHEMATIC MARKER LT CLEARANCE LT STOP LT SW R S TURN LT e ALC CLEARANCE LT FRONT OF BODY JUNCTION BOX HEADLIGHT SW RD e RD ed x WE o4 UL FLASHER a YW IDENT LT S REVERSE sw BE Tiva TURN SIGNAL BUZZER 5 PK TOGGLE SW RD WE oe FUSE T LIUTILITY LIGHTS pes BATTERY
134. re of the trapped fluid in the packer cylinders will increase Should this pressure reach 3500 PSI 242 BAR a relief valve will open reducing the pressure by allowing some trapped fluid to escape and return to the hydraulic tank MEE PRESSURE 0000 RETURN TRAPPED FLUID act HYDRAULIC CARRIER lt 4 FLUID TANK TELESCOPIC 7 CYLINDER i di L TAILGATE PACKER CYLINDER LIFT CYLINDER 8 26 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RAISING TAILGATE OPERATOR ACTION TAILGATE Operator opens the packer panel to release pressure LIFT Operator loosens and swings away from the body the LEVER tailgate clamps Operator depresses the speed up but ton Operator moves the tailgate lift lever rearward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the tailgate lift lever rearward shifts a spool in the front control valve causing flow to the tailgate lift cylinders The cylinders extend causing the tailgate to raise Excess fluid flow from the front control valve returns back to the tank Es PRESSURE RETURN TAILGATE OPERATING LIFT VALVE CYLINDER lt HYDRAULIC lt FLUID TANK TELESCOPIC CYLINDER TAILGATE PACKER CYLINDER LIFT CYLINDER 8 27 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM EJECTING LOAD PUSHOUT OPERATOR ACTION LEVER Operator depresses speed up button and moves pushout lever rearward BUT
135. ring the bonnet to the work section The spool positions is now exposed for inspection and repair Remove the capscrew securing the spring collar to the valve spool Remove the spring collar and spring to expose the retainer plate retainer plate washer and o ring seal Thoroughly clean counterbore The removal of the resistance cartridge is accom plished in two 2 steps First unscrew the adjust ment cartridge care should be taken as there are loose parts within the cartridge body Since the resistance cartridge consists of two 2 pieces the piston and seat components remain internal in the work section To remove the piston and seat remove the load check plug on the opposite side of the resistance cartridge With the plug removed the piston and seat can be tapped out with a 72 drift It would not be necessary to use force to remove the piston and seat REASSEMBLY OF FRONT CONTROL VALVE With all o ring seals removed and counterbores thoroughly clean lightly oil the new seals Slide over spools and cartridges and insert the seals in the counterbores Reassemble parts in reverse order of disassembly Torque the spool collar to 10 ft Ibs 13 6 Nm Torque the bonnet and handle bracket capscrews to 10 ft Ibs 13 6 Nm Heplace work sections and covers with the tie bolts in the same order in which they were removed NOTE Use care in replacing the work section to avoid dis lodging o rings from the counterbore
136. rmation and mail If you are the first you will receive a hat by return mail believe found an error 2H II Service Manual manual Thanks for your help Return this form to Service Department Leach Company 2737 Harrison Street Box 2608 Oshkosh Wisconsin 54903 2608
137. rt as it is removed to aid in diagnosing problems and to help prevent them in the future Clean and inspect disassembled parts for wear cracks dirt etc After cleaning and inspection reusable hydraulic parts should be immediately coated with clean fresh hydraulic fluid to prevent rust formation If these parts are not going to be reinstalled imme diately they should be wrapped in a clean lint free cloth or paper to prevent nicks or scratches When repacking a cylinder or resealing a valve replace all seals and o rings that are disturbed during repair The price of a few seals is very little compared to a return repair job 4 3 SECTION 4 GENERAL REPAIR PRACTICES REASSEMBLY AND INSTALLATION 1 Assemble parts in the same position as removed 2 Align parts accurately before mating 3 Inspect o ring and seal grooves for sharp edges nicks or burrs before installing new sealing parts 4 Lubricate all new sealing parts with clean fresh hydraulic fluid before installation 5 Use care not to damage new sealing parts on reassembly 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 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
138. ructions concerning a particular operation or service that may be hazardous if performed incorrectly or carelessly AWARNING Strict compliance to these safety alerts combined with common sense operations are important accident pre DANGER Immediate hazards which WILL result in severe personal injury or death vention measures The word NOTE is also used throughout the manual It precedes information that provides special emphasis or clar WARNING Hazards or unsafe practices which COULD result in severe personal injury or death ification on a specific operation or procedure CAUTION Hazards or unsafe practices which could result in minor personal injury or prop erty or product damage SECTION 1 SAFETY PRECAUTIONS PRIOR TO START UP Never operate machinery while wearing jewelry or loose clothing These items may become caught by or entangled in the machinery causing serious injury Wear proper safety equipment as required by your employer Never operate machinery while under the influence of alcohol narcotics or other mood altering sub stances Workers who operate machinery while under the influence are a hazard to themselves and others Perform a pre operation walk around inspection of the truck chassis in accordance with the chassis manufacturer s guidelines Perform a walk around inspection of the refuse packer in accordance with th
139. s SECTION 9 SERVICE AND REPAIR RETAINER PLATE MAIN RELIEF RESISTANCE CARTRIDGE SPOOL BONNET TIE BOLT SPOOL RO CAPSCREW 9 21 SECTION 9 SERVICE AND REPAIR 6 Torque tie bolts evenly to 32 ft lbs 43 Nm If tie bolts are not tightened to the proper torque valve spools may bind or stick or cause section seals to extrude RESISTANCE CARTRIDGE 7 Torque valve of the resistance main relief cartridge and load check plugs will be 20 ft lbs 27 2 Nm e FRONT REINSTALLATION OF ALES FRONT CONTROL VALVE 3 1 Secure the valve to the mounting bracket with the appropriate hardware 2 Remove plugs and caps then attach hydraulic lines DESCRIPTION OF SPC VALVE SPC stands for Sequence Pilot Check Different styles of SPC valves may be used Although the appearance and internal components are different they function identically The SPC valve has a cartridge type sequence valve which is preset at the factory to con trol the sequence and timing of the clamp system An internal Pilot Check maintains the clamp mecha nism in a locked position and does not allow the clamp cylinder to bleed off until the pushout lever is shifted LEACH DISASSEMBLY OF SEQUENCE VALVE CARTRIDGE 1 Wash the area around the sequence cartridge with solvent to prevent contamination 2 Turn the sequence cartridge nut counterclockwise until the cartridge can be removed 3
140. s components or assemblies at any time The Leach Company has an aggressive manual and product improvement program In any conversation or corre spondence dealing with information provided in any Leach manual please refer to the part num ber 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 ref erence We ask that if you have comments or suggestions concerning this manual please con tact us at 414 231 2770 We are here to be of service to you our valued customers LEACH A Original Factory Parts LEACH ORDERING PARTS FOREWORD TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS Danger Warning and Caution Decals Prior TO Start Up ac heee bruce bee tae a wae ex FAY QRAUNCS uat dede aded dos E m ede eae S Fire Housekeeping Decal Locations SECTION 2 INTRODUCTION Terms You Will Need To Know
141. s when mounting or dismounting Controls and hoses are movable They do not provide proper support and may cause accidental equipment movement Make sure the backup alarm is working properly Always ensure that all persons are clear before raising or lowering the tailgate It is the operator s responsibility to warn all persons not to stand or cross under a raised 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 lowered and during the unloading cycle If it is nec essary to manually clear debris from the hopper use a long metal probe and DO NOT stand under the tailgate Never load the hopper above the loading sill Never allow material to extend outside of the hop per when packing Allow the packer panel control lever and carrier panel control lever to shift automatically To avoid possible bodily injury or equipment dam age lower the tailgate slowly Never enter the body unless the pushout panel clamp or the telescopic ejection system cylinder is released PTO disengaged and ignition key removed and placed in your pocket Do not attempt to load refuse into the hopper after 1 3 SECTION 1 SAFETY PRECAUTIONS 34 35 36 37 38 39 40 41 42 43 44 54 46 47 48 49 50 51 the packing cycle has begun The packer panel must be i
142. se for lifting Type USS 26 EN1 Rating ME So ewe ae ase GSH Ow Se ot os 4800 165 2177 kg Choker lifl 0405445 cod A ee Oe eee ed 3600 Ibs 1633 kg BAS 9600 Ibs 4354 kg NCU 2 2 sae a ee Mee ee ae ee a ee 2 in Eolo M T c E E E EE depends on type of lifting device used CHAIN AND HARDWARE SPECIFICATIONS Chains should be used to lift and or support the carrier and packer panel pushout panel and tailgate The follow ing specifications should be used to determine the type of chain and hardware to use for lifting Chain Lo C m D O F Double Branch Oblong link Foundry Hook uz 75 in HAMME 7b in Oblong TIBUS e re RR US doas ms mI REICHEN NE E dost REPRE E ERE NIE NEMPE in 4 5 SECTION 4 GENERAL REPAIR PRACTICES CAPSCREW MARKING AND TORQUE VALUES Usage Much Used Used at Times Used at Times Capscrew Diameter To 34 120 000 To 140 000 150 000 amp Minimum Tensile To 1 115 000 To 133 000 Strength PSI Quality of Material Min Commercial Med Commercial Best Commercial SAE Grade Number 5 7 8 CA
143. set the vehicle parking brake before attach ing or lifting a container Never lift a container which is non compatible with the Leach container attachment Never lift a container without first latching both con tainer latch arms 52 53 54 55 56 57 58 59 60 61 62 63 64 65 Raise the container with a smooth even movement Do not bounce the container Do not slam the container against the packer tail gate or bump bar Do not attach the hook to any lift point which will not be completely encircled by the hook with the safe ty latch closed Do not remove the hook safety latch Read and obey all container decals issued by the container manufacturer Read and follow container manufacturers informa tion on accepted use practices Do not attempt to lift overloaded containers Center the container on the attachment All containers should be inspected for serviceabili ty and repaired if not in a safe usable condition Do not use a non standard or damaged trunnion bar Never cross under a raised container Stand clear when dumping containers Before attempting to lift a container below 32 F 0 C make sure it is not frozen to the ground When using an eye type container attachment point the base of the hook must be positioned to lift on the inside of the eye Place the container on a flat level surface HYDRAULICS Hydraulic fluid operates under high temperatures
144. shout bar N XB 5 Loosen the friction brake adjusting bolt N Weld an eye to the center of the panel and attach a chain to prevent the panel from tipping over upon removal 8 The pushout panel can now be removed from the body The method of removal will depend on the equipment available Whatever method is used the ADJUSTING we he BOLT equipment must be capable of lifting a minimum of 2800 lbs 1270 kg and the panel should be secured safely to the removal device LEACH 9 44 SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF WEAR BLOCKS AND PUSHOUT SHOES PANEL REMOVED CLAMP SYSTEM y OPERATIONAL STATUS Truck Off PTO Disengaged 1 Inspect the wear blocks and pushout shoes for wear Replace worn parts NE y zm FIBER WEAR BLOCK PLASTIC FRICTION BRAKE LEFT SIDE ONLY NOTE See wear block replacement earlier in this section INSTALLATION OF PUSHOUT PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install the pushout panel into the body of the unit 2 Slowly extend the telescopic cylinder until the case end is beneath the crossmember of the pushout panel where the lifting eye is welded NOTE Do not allow the cylinder to become stuck or wedged while it is being extended 3 Attach a lifting device capable of supporting 750 lbs 841 kg to the cylinder and the lifting eye welded to the crossme
145. side of the cylinder assembly to prevent dirt and foreign mat ter from contaminating the cylinder components during disassembly 3 Remove the plug from the port and drain the fluid 4 Remove the snap ring 1 and slide the rod assem bly 2 out of the cylinder case Goo JA gt A 5 Unscrew the piston disc 3 from the rod and remove the head gland 4 6 Remove and discard rod seal 5 o ring 6 o ring 7 O ring 8 and seal 9 INSPECTION AND REPLACEMENT OF TAILGATE LIFT CYLINDER 1 Thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear 2 Check to make sure the breather is not plugged 3 Check all cylinder components and mounting parts for damage and wear Replace as required Parts that must be replaced together are available as a repair kit from your authorized Leach distributor NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent dirt from entering the cylinder SECTION 9 SERVICE AND REPAIR All Leach Company rear loader tailgate lift cylinders are now Nitrocarburized This process greatly enhances the longevity of tailgate lift cylinder rods and inside tail gate lift cylinder casings by improving resistance to cor rosion Nitrocarburizing yields several unique charac teristics The cylinder rod is furnished with an attractive black finish which unlike chrome becomes smoother with use NOTE With use it is
146. sweep the load from the hopper and pack it against the ing the compaction cycle pushout panel Any time the carrier panel lever is shift ed the engine speed up automatically engages The NOTE packing cycle may be stopped at any point by moving The engine speed up system automatically both operating levers to neutral The packer or carrier engages any time the carrier panel lever is shifted panel can be moved independently CONTAINER HANDLING CONTROL LEVERS 11 12 CONTAINER HANDLING JSt These control levers are provided when container han CONTROL LEVERS dling attachments drum winch reeving cylinder or con tainer push bar are added to the unit They are used to raise and lower the container causing the refuse to be deposited in the hopper for compaction The levers are located on the right curb side of the tailgate directly above the packer and carrier panel control levers A refuse vehicle may have none one or two control levers depending on the configuration of the unit 3 5 SECTION 3 OPERATION OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the 2RIl Packmaster including specific instructions for loading packing and unloading the unit NOTE It is important that operators and mechanics understand these procedures PRE OPERATING WALK AROUND INSPECTION Each day before starting the unit perform the following walk around
147. t and repair as described under ELECTRICAL SYSTEM in Sec 9 SERVICE AND REPAIR CHECK ENGINE SPEED UP SWITCHES OPERATIONAL STATUS Truck Running PTO Engaged 1 Depress the engine speed up pushbutton The engine should speed up SPEED UP BUTTON IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or switch and repair See Sec 9 SERVICE AND REPAIR ELECTRICAL SYSTEM 2 Activate carrier panel lever Engine should speed up IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or switch and repair See Sec 9 SERVICE AND REPAIR ELECTRICAL SYSTEM CARRIER LEVER 7 2 SECTION 7 CHECK OUT CHECK PACKING CYCLE TIME 1 Activate both the packer panel lever and carrier panel lever Using a stopwatch time a complete cycle A complete cycle should take 32 to 34 sec PACKER onds LEVER IF NOT CARRIER 34 SECONDS LEVER LENGTHEN CYCLE wt 2 Adjust the cable length between the solenoid or air cylinder and throttle linkage as needed to obtain the correct cycle time SOLENOID SHORTEN FOR SHORTER CYCLE NOTE It is important the the cycle time is correct before performing the following pressure checks 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 appropriat
148. the hook For the safety of yourself as well as others always ensure that a hook is positioned properly as slack is removed from the chain cable before lifting Slack should be removed from the cable without the use of the engine speed up button by moving the winch con trol lever in the direction shown on the instruction decal to raise the container When the cable is tight the speed up button should be depressed and held to provide suf ficient hydraulic power to lift the container The container should be raised until the contents begin to slide into the hopper of the packer or until it is resting against the container bump bar Do not overfill the hopper After assuring that all per sons are standing clear lower the container to check the load condition of the container and the hopper Lower the container enough to see between the con tainer and the tailgate while standing on the ground without placing yourself between them When the hopper is full lower the container to the ground assure all persons are standing clear and then engage the packer mechanism See Sec 3 Operation Packing Load After the packer panel has passed the loading sill the container may be raised to again fill the hopper Repeat this process until the container is empty 3 14 ATTACH CONTAINER LOWER TO CHECK CONTENTS INCORRECT CORRECT ATTACHMENT POINT CONTAINER CONTROL LEVERS NOTE On units with a roof mounted co
149. the number one cause of wear in bearings bushings and especially in hydraulic components Inspect hydraulic components for leaks before cleaning The dirt buildup on the component can aid in tracing fluid leaks Clean hydraulic connections before removal to prevent dirt from entering the component Loosen hydraulic fittings slowly to release pres sure Cap hydraulic fittings immediately after removal to prevent fluid from leaking Clean the component in non flammable solvent before disassembly Inspect the component after cleaning for signs of wear or external damage 8 If you suspect a leak in the system perform a leak test using an approved leak detection system DO NOT USE HOUSEHOLD OR LAUNDRY 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 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 explo sion Welding should be done in a location well away from flammable materials When disassembling a component note the posi tion of each part as it is removed to aid in reassembly During disassembly note the condition of each pa
150. to change without notice e Consult Chassis Requirement Manual for more information SECTION 5 SPECIFICATIONS LUBRICANTS c IPIS SAE 10 or equivalent Grease Multiservice quality grade HYDRAULIC SYSTEM CAPACITY approximately gnpEc dM n 45 gallons Total system System pressure settings Clamp 1650 PSI 114 BAR Tele 1950 PSI 135 BAR Type of fittings llle oteel tubing with brazed and flared fittings reinforced rubber hose with crimped full flow fittings o ring fittings gli Mr Suction Reusable wire mesh type Return line Disposable filter element located on the return line to the tank PUMP 203834 Pr Positive displacement gear type driven by the PTO from the truck transmission Soe e n m 42 gpm Q9 1200 rpm LEACH HYDRAULIC FLUID RECOMMENDATION All Leach hydraulic systems are factory filled with a high quality anti wear hydraulic fluid meeting an ISO 32 spec ification 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 appropriate The International Standards Organization assigns specification numbers so that a consumer receives the same product from various suppliers GRADE ISO VISCOSITY AGMA NO Gr
151. ual indicator on the filter Refer to item 3 on the tank illustration NOTE Under severe operating conditions the filter life may be reduced Replace the filter element regardless of elapsed time if the suction indicator is in the red zone SECTION 6 PREVENTIVE MAINTENANCE REPLACEMENT OF FILTER ELEMENT See Hydraulic System Illustration 1 Remove filter cover 4 Remove o ring 5 Remove element 6 and discard Install a new element 6 CR Coat a new o ring 5 with fresh hydraulic fluid and install in filter cover 4 6 Install the cover and secure to the bowl with the attaching hardware 7 Check the fluid level and replenish with fresh fluid as described earlier in this section under CHECK ING FLUID LEVEL Extended operation of the unit without proper filtration will result in reduced service life of hydraulic system components CLEANING HYDRAULIC STRAINER MONTHLY 1 Remove cover 7 and gasket 8 2 Unscrew and remove strainer 9 3 Clean strainer thoroughly in a suitable cleaning sol vent 4 Reinstall strainer 5 Remove clean and reinstall magnetic ring 10 6 Inspect the gasket 8 and replace if necessary 7 Align the gasket carefully and secure the cover 7 to the tank with the attaching hardware 6 5 SECTION 6 PREVENTIVE MAINTENANCE FLUSHING HYDRAULIC SYSTEM YEARLY 1 Drain all fluid from the hydraulic tank into a suitable container Dispose of it pro
152. ushout bar Then the pushout cylinder is extended causing the pushout panel to move rearward toward the tailgate opening At the end of the cylinder stroke the clamp cylinder is released allowing the pushout cylinder to be retracted and leaving the pushout panel where it was at the end of the last stroke This cycle can be repeated as many times as neces sary to push out the load PUSHOUT BAR PUSHOUT CYLINDER 9 28 SECTION 9 SERVICE AND REPAIR TEST FOR LEAKING PUSHOUT CYLINDER PUSHOUT LEVER OPERATIONAL STATUS m Truck Running PTO Engaged 1 Depress the speed up button and move the SPEED UP BUTTON pushout lever rearward to fully extend the pushout cylinder OPERATIONAL STATUS Truck Off PTO Disengaged Disconnect and cap the hydraulic line at the rod end of the pushout cylinder OPERATIONAL STATUS Truck Running PTO Engaged V lt 3 Depress the speed up button and move the _ 2 DY pushout lever rearward Hold the lever in this A 2 position while observing the fluid flow from the a open cylinder port Flow should be no more than 12 CHECK FLOW fl oz per minute OPERATIONAL STATUS Truck Off PTO Disengaged 4 Reconnect the hydraulic line to the rod end of the pushout cylinder OPERATIONAL STATUS PUSHOUT LEVER LR 0 Truck Off PTO Disengaged 5 Move the pushout lever toward the front of the unit to fully retract the cylinder 9 29 SECTION 9 S
153. ut panel will now slide forward as the packing cycle is completed The operator once more pushes the pushout lever rearward to lock the bar to the pushout panel Packing is resumed Packing the final hopper load on clamp pushout units is the only time that holding the carrier panel lever in position is permissible This will ensure a tight pack TELESCOPIC On units with a telescopic pushout cylinder the pushout panel is normally moved toward the front of the body automatically When the resistance circuit is adjusted to produce maximum load density it may become neces sary to manually retract the telescopic pushout cylinder in order to allow the compacted refuse to move forward in the body Also if the packer panel stops short of the DISCONNECTING THE CONTAINER Once the container is empty it should be lowered to the ground the latch arms released and the cable disconnected PUSHOUT LEVER TAILGATE LIFT home position the carrier panel operating lever may need to be held overridden to allow the refuse to move the pushout panel toward the front of the body When the pushout panel has reached the front of the body neither the packer panel operating lever nor the carrier panel lever should be overridden except to clear the final hopper load DISCONNECTED SECTION 3 OPERATION UNLOADING AT DUMPSITE Do not unload uphill or against a pile of refuse 1 Apply t
154. with a lifting capacity of 500 Ibs 227 kg _ See Sec 4 GENERAL REPAIR PRACTICES for 2 more detailed information about the correct use of slings and lifting chains ie m Y 9 Remove the cylinder from the unit using care to 4j avoid damaging the surrounding hydraulic lines DISASSEMBLY OF PUSHOUT CYLINDER 1 Clean the outside of the cylinder with solvent to prevent the entry of dirt during disassembly 2 Remove the plugs from the cylinder ports and drain the hydraulic fluid 3 Secure the case end of the operating cylinder to the floor or workbench 4 Secure the rod end of the cylinder to an overhead hoist or other suitable lifting mechanism with a min imum lifting capacity of 500 Ibs 227 kg 9 31 SECTION 9 SERVICE AND REPAIR 5 Remove the six nylock screws 1 and three lock segments 2 securing the gland head 3 to the cylinder 6 Slowly operate the hoist to carefully pull the piston CYLINDER rod assembly out of the cylinder PISTON ROD q 7 Disassemble the cylinder only as far as necessary to install replacement parts INSPECTION AND REPLACEMENT OF PUSHOUT CYLINDER 1 Carefully and thoroughly inspect the inside of the NZ cylinder for cracks scoring or uneven wear Check all parts for damage 2 Anew rod wiper 1 rod seal 2 o ring 3 seal 4 and wear ring 5 must be installed anytime the cylinder is disassembled Pay particular attention to t
155. ws 1 and bonnet 2 5 Carefully slide detent sleeve 8 off the spool The 2 Loosen locknut 3 and remove adjustment screw four detent balls 9 will be free to fall out when the 4 Count and record the number of turns needed sleeve is removed to remove 6 Remove spring guide 10 outer spring 11 and 3 Remove spool collar 5 If the control rod is not follower 12 installed on the opposite spool end it may be nec 7 Remove inner spring 13 if used and the knock essary to insert a rod through the spool clevis to out plunger 14 keep the spool from rotating 8 Remove spring guide 15 and needle roller 16 9 Remove back up ring and o ring 17 Remove ACAUTION back up rings and o ring 18 10 Clean and inspect parts for excessive wear or scor The spool collar is under spring tension and ing Clean the o ring counter bores Servicing of caution should be used when removing the detent assembly is limited to o ring and back 4 Remove spring collars 7 and centering spring 6 up washer replacement 12 BACK UP 17 amp 18 9 FOLLOWER RING O RING DETENT 4 7 10 14 ADJUSTMENT SPRING SPRING KNOCKOUT SCREW COLLARS GUIDE PLUNGER BACK UP DETENT RING BALLS 18 9 NOW 2 3 a i BONNET LOCK INNER DETENT SPRING NEEDLE SPRING SLEEVE GUIDE ROLLER 13 8 15 16 SPOOL CENTERING OUTER SCREW COLLAR SPRING SPRING 1 5 6 11 REASSEMBLY OF KNOCKOUT POSITIONER 1 Lightly oil and inst

2RII Serial #209719-15999 Service Manual

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