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Alpha • Beta • Delta - Superior Truck Equipment Inc.

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1. OPERATIONAL STATUS Truck Off Keys Removed 2 Remove the capscrews 1 lockwashers 2 cover 8 and cover weldment 4 for the track hole of the roller or rollers to be removed OPERATIONAL STATUS Truck Running PTO Engaged Sol Off Sw 3 Shiftthe operating control levers and cycle the pan els as necessary to align the upper and lower roller assemblies with the track holes NOTES 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 PACKER CARRIER PANEL gt PANEL LEVER LEVER 9 21 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off Keys Removed 4 Remove one roller and shaft assembly at a time 5 Replace any roller that is excessively worn cracked or out of round Inspect the condition of the track bar Replace if necessary 6 Install a grease fitting in roller and the original shims or the same amount of new shims as removed 54 YZ SHIMS d GREASE FITTING OPERATIONAL STATUS Truck Running PTO Engaged Sol an Sw 7 Repeat step 1 to determine if additional shims are required Do not over shim rollers Excessive sh
2. gt MAIN CONTROL VALVE 9 35 9 SERVICE AND REPAIR REMOVAL OF THE MAIN CONTROL VALVE 1 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 valve assembly and bracket weigh approxi mately 100 Ibs Use appropriate lifting procedures and techniques when handling this assembly 7 Remove the capscrews washers and nuts holding the valve bracket to the tailgate CARRIER PANEL PACKER PANEL INTERRUPTED CYCLE CARRIER PANEL LEVER 9 36 DELTA 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 three 3 bolts which secure the valve sections and covers Separate carefully noting the location of o ri
3. 8 TROUBLESHOOTING 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 packer operation if pressure increases to the main relief setting excess flow will be diverted from the front control valve back to tank TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK NC CARRIER N CYLINDER a 5 PUSHOUT L O CYLINDER CARRIER CYLINDER gt TAILGATE LIFT CYLINDER PACKER A CYLINDER A PRESSURE O RETURN LEACH 8 10 SECTION 8 TROUBLESHOOTING 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 cylinders 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 TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK CARRIER CYLINDER PUSHOUT CYLINDER T ONRHIER CYLINDER
4. 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 PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON SIGNAL PUSH BUTTON 7 2 ALPHA 7 CHECK OUT CHECK PACKING CYCLE TIME OPERATIONAL STATUS Truck Running PTO Engaged Sol On Sw Activate both the packer panel lever and carrier panel lever Using a stopwatch time a complete cycle A complete cycle should take 26 to 28 sec onds IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 2 Adjust the cable length between the solenoid or air cylinder and throttle linkage as needed to obtain the correct cycle time SOLENOID NOTE It is important the the cycle time is correct before performing the following pressure checks SIGNAL PUSH BUTTON 26 SECONDS CONTAINER HANDLING CONTROL LEVERS CARRIER PANEL LEVER PACKER PANEL LEVER LENGTHEN FOR LONGER CYCLE SHORTEN FOR SHORTER CYCLE lt gt CHECK PRESSURES The pressure checks provided below will indicate the operating condition of the hydraulic system Detailed adjustment procedures are provided later in
5. 4 2 2i peine 2 3 Electric 4 2 Container 2 4 Oxy Acetylene 4 3 Container Handling Systems 2 4 Removal Disassembly and Repair 4 3 cider eld da rdc atta 2 5 Reassembly and Installation 4 4 Terms You Need to 2 5 Electrical Testing 4 4 Pone ic UN 2 5 Checking for Voltage 4 2 5 Checking 4 4 Container 1 2 5 Welding eee eee ee eee 4 4 LLL 2 6 Lifting Instructions 4 5 Container Lifting Cylinder CLC 2 6 Capacity of Lifting Device Required for Removal 4 5 Container Push Bar 2 6 Sling Strap Specifications 4 5 Basic 2 7 Chain and Hardware Specifications 4 5 URN 2 Capscrew Marking and Torque Values 4 6 Dump uma ie REO x E ene 2 7 1 2 7 SECTION 5 SPECIFICATIONS Hydraulic 5 1 SECTION 3 OPERATION Leach Hydraulic Fluid Recommendation 5 1 General MT 3 1 Hydraulic 5 5 1 Descri
6. 9 SERVICE AND REPAIR DESCRIPTION OF LEACH HYDRAULIC PUMP 307451 01 The pump which serves the complete hydraulic system is a gear type coupled to the PTO shaft through a yoke 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 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 N CAP Remove the hose clamp MEE 4 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 and cap the end 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 51 9 SERVICE AND REPAIR DISASSEMBLY OF HYDRAULIC PUMP 307451 01 1 After removal thoroughly clean and dry the p
7. 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF PACKER PANEL OPERATIONAL STATUS Truck Off Keys Removed A INSPECT 1 Carefully inspect all pivot areas for excessive or FOR WEAR uneven wear scoring or other damage 2 Check the plate for broken welds bent edges or warpage 3 Inspect the edge for damage Replace a badly worn edge as described below 4 Replace parts as necessary See Sec 4 GENER AL REPAIR INSTRUCTIONS REPLACEMENT OF PACKER PANEL EDGE OPERATIONAL STATUS Truck Off Keys Removed 1 Remove the old edge with an Air Arc to obtain a clean cut 2 Smooth the edge of the packer panel where the new edge will be attached 3 Weld a new edge in place NOTE See Sec 4 GENERAL HEPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains INSTALLATION OF PACKER PANEL Install the packer panel in the approximate reverse order of disassembly Prior to installation inspect the pivot bushings in the carrier panel and replace if worn INSPECT PIVOT BUSHINGS 9 20 9 SERVICE AND REPAIR ROLLER REPLACEMENT SHIMMING 1 Shift the operating control levers and cycle the unit several times while observing the rollers and action of the packer and carrier panels Watch for side ways movement or twisting to determine where shimming and or new rollers may be needed
8. A E CYLINDER LA A TAILGATE LIFT CYLINDER PACKER X CYLINDER PRESSURE RETURN LEACH SECTION 8 TROUBLESHOOTING RETRACTING PUSHOUT PANEL PUSHOUT LEVER OPERATOR ACTION TAILGATE LIFT LEVER 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 caus ing flow to the pushout cylinder As the cylinder retracts the pushout panel is positioned near the front of the body TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK C CARRIER NA VALVE A A A ZA A A CYLINDER 2 7 TAILGATE LIFT CYLINDER PACKER E CYLINDER M PRESSURE RETURN 8 TROUBLESHOOTING LOWERING TAILGATE PUSHOUT LEVER TAILGATE LIFT LEVER OPERATOR ACTION Operator moves the tailgate lift lever forward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the tailgate lift lever forward shifts a spool in the front control valve allowing fluid in the tailgate lift cylinders to drain back to the tank The weight of the tailgate forces fluid out of the cylinders the cylinders retract and the tailgate lowers TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK NN FRONT CONTROL VALVE N
9. 9 12 Inspection and Replacement 9 12 Reassembly and Installation 9 12 DELTA Pink Pages Disassembly of Packer Panel Cylinders 9 13 Inspection and Replacement 9 13 Reassembly and Installation 9 13 Disassembly of Carrier Panel Cylinders 9 14 Inspection and Replacement 9 14 Reassembly and Installation 9 14 Description of Tailgate Lift Cylinder 9 15 Removal of Tailgate Lift Cylinder 9 15 Disassembly of Tailgate Lift Cylinder 9 16 Inspection Reassembly and Installation 9 16 Description of Tailgate Assembly 9 17 Removal of Tailgate Assembly 9 17 Inspection and Replacement of Tailgate 9 18 Description of Carrier and Packer Panels 9 18 Removal of Packer 9 19 Inspection and Replacement of Packer Panel 9 20 Replacement of Packer Panel Edge 9 20 Installation of Packer Panel 9 20 Roller Replacement Shimming 9 21 Removal of Carrier 9 23 SECTION 9 SERVICE AND REPAIR continued Track Bar Replacement Inspection and Replacement of Carrier Panel Installation of Carrier Panel Description of Pushout Panel Inspection and Replacement of Wear Blocks Shimming Wear Blocks With Panel In Place Removal of Pushout Panel Ins
10. Foam ge bees ieee Pass Pass Pass Vickers Vane Pump Pass Pass Pass Dielectric Strength ASTM 877 EC 180 F 25Kv 25Kv 25Kv 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 SYSTEM ALPHA BETA DELTA Approximate Capacity 45 Gallons 45 Gallons 45 Gallons Filtration Suction Line Reusable wire mesh type Reusable wire mesh type Reusable wire mesh type Filtration Return Line Disposable filter element Disposable filter element Disposable filter element Pump Positive displacement Positive displacement Positive displacement gear type gear type gear type Pump Capacity 42 GPM 1200 RPM 42 GPM 1200 RPM 35 GPM 1200 RPM System Pressure 2150 PSI 148 BAR 2300 PSI 157 BAR 2300 PSI 157 BAR LUBRICANTS SETS SAE 10 or equivalent Grease Multiservice quality grade 5 1 SECTION 5 SPECIFICATIONS LEACH SECTION 6 PREVENTIVE MAINTENANCE GENERAL The Alpha Beta and Delta have been designed for long periods of efficient uninterrupted operation Careful attention 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 an
11. 3 14 TABLE OF CONTENTS IV Using a Container Push Bar CPB 3 15 Packing the Load 3 15 Pushout Panel Operation During Packing Pushout Cylinder 3 16 SECTION 1 SAFETY PRECAUTIONS Disconnecting the Container 3 16 General nea r EET CUENTE LER 1 1 Ar DIOR ahi Ri Danger Warning and Caution Decals 1 1 Lifting the Tailgate 3 17 Prior To Start Up 1 2 AN Toad ud RIM ha ES REAT e 1 3 Lowering the Tailgate 3 18 FAVOR AUNGS EM RECTE TERT TO TET TTE 1 5 Shut Down nes cesses nnn nnn 913 Fire 1 5 Housekeeping 1 5 Sh tdOown aes Graat Ee RE 1 5 Decal Locations 1 6 SECTION 4 GENERAL REPAIR PRACTICES Preparation for 4 1 Replacement Parts 4 1 Service Bulletins 4 1 SECTION 2 INTRODUCTION Safety Precautions IE feet ene E 4 2 Terms You Will Need To Know 2 1 Prior to Performing Any Service or Repair 4 2 Eoading Wes 2 2 Safety During Service and Repair 4 2 2 2 Welding lt
12. 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 CHECK ENGINE SOLENOID SWITCH OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw IF ENGINE SPEEDS UP OPERATIONAL STATUS Truck Off PTO Disengaged The system is grounded Locate the short and repair as described under ELECTRICAL SYSTEM in Sec 9 SERVICE AND REPAIR CHECK ENGINE SPEED UP SWITCHES OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Depress the engine speed up pushbutton The 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 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 PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON SIGNAL PUSH BUTTON CONTAINER HANDLING CONTROL LEVERS 7 18 DELTA CHECK OUT CHECK PACKING CYCLE TIME OPERATIONAL STATUS Truck Running PTO Engaged Sol
13. 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 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 83 8Nm 3 Torque the 3500 Ib relief cartridge load check and blanking plugs to 20 ft Ibs 27 Nm BONNET KNOCKOUT POSITIONER OUTLET COVER O RINGS CARRIER SECTION 9 33 9 SERVICE AND REPAIR BETA DISASSEMBLY AND INSPECTION OF THE KNOCKOUT POSITIONER 1 2 3 4 To remove the knockout positioner remove the four bonnet capscrews 2 and bonnet 3 Using 74e allen wrench remove the spool collar 6 If the control rod assembly is not installed on the spool end it may be necessary to insert a rod through the spool clevis to keep the spool from rotating when removing the spool collar The spool collar is under spring tension and caution should be used when removing NOTE It may be necessary to turn the pressu
14. 9 42 9 SERVICE AND REPAIR SINGLE STAGE PUSHOUT CYLINDER CASE GLAND RETAINER PLUNGER ROD YE ex BUSHING PIN SINGLE STAGE PUSHOUT CYLINDER 9 43 9 SERVICE AND REPAIR SINGLE STAGE PUSHOUT CYLINDER PACKING REPLACEMENT 1 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to pre vent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up Remove the setscrew 1 and plastic plug 2 from the head nut Remove the head nut 3 using a strap or chain wrench If the tube turns with the head nut tighten the next head nut slightly Using a suitable lifting device attached to the rod 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 5 Prior to installing new packing 4 clean the area thoroughly and lubricate the new packing set inside and out with an all purpose grease If the 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 Replace the head nut 3 being careful no
15. 40 80 54 63 60 16 81 60 91 28 QAU ONN ee 440 60 85 O N 660 91 28 2 W D OooER SEONMOT OO oO 2 37 34 280 38 72 NOTES 1 Always use the torque values listed above when specific torque values are not available 2 The above is based on use of clean dry threads 3 Reduce torque by 10 when engine oil is used as a lubricant 4 Reduce torque by 2096 if new plated capscrews are used 5 General Formula for calculating Torques is as follows Torque in Inch Lbs 2 x Nominal Diameter of Screw x Loads in Lbs where Load 8096 of Yield Strength expressed in Lbs not pounds per square inch LEACH 4 6 SECTION 5 SPECIFICATIONS 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 ea
16. A TAILGATE LIFT CYLINDER PRESSURE RETURN CYLINDER 8 TROUBLESHOOTING 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 knockout setting causing the operating valve to shift diverting flow to the case end of the carrier cylinders The cylinders extend moving the carrier and packer panels down to the interrupted cycle position trapped fluid keeps the packer panel cylinders retracted At the end of the carrier cylinder exten sion stroke pressure builds to knockout setting causing the operating valve to shift to neutral TAILGATE LIFT CYLINDER 225 eS Qs 9 HYDRAULIC 6 p LUID TANK S3 FRONT CONTROL VALVE PUSHOUT Sow CYLINDER CARRIER CYLINDER Ne lt A TAILGATE LIFT CYLINDER PACKER CYLINDER PRESSURE RETURN m RAPPED LEACH 8 12 SECTION 8 TROUBLESHOOTING 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 hopper With the packer cylinder exte
17. ACCESSORY SECTION OUTLET COVER CARRIER LEVER e The knockout pressures should be set at 1800 PSI 124 BAR for the packer panel section and 2100 PSI 145 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 23 SECTION 7 CHECK OUT CHECK WEAR BLOCKS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Visually inspect all wear blocks for excessive wear These items must be replaced before there is metal to metal contact 2 Shim or replace worn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL 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 manufacturers service manual LEACH 7 24 SECTION 8 TROUBLESHOOTING GENERAL Troubleshooting is a matter of quickly and logically iso lating the cause of a problem and taking corrective action Factory trained mechanics experience
18. oR SERVICE THIS E ration Serious pump damage will result if vehicle Training es is operated at highway speed with pump rules all gover menta h Monon and manufactur S oper Muir engaged Move unit with pump engaged and Safety manuals relative to this machines safe u only as required to perform its function as AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO refuse collection compaction vehicle at DEATH OR SERIOUS INJURY speeds less than 10 mph SECTION 1 SAFETY PRECAUTIONS OT a WARNING 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 wd death do not use this refuse collection vehicle to tow other equipment It is Stand clear when not intended designed or equipped tailgate is in for towing motion amp during unloading cycle Stand clear when Do not stand or packer panel is cross under raised in motion tailgate SOLENOID RTO MUST BE OFF WHEN ON OFF TRUCK IS PARKED ce ON OFF clearance as originally mounted Be sure all persons are clear of hopper opening before operating controls STROBE LIGHT ON OFF WARNING TAILGATE Do not transport container Do not operate OPEN vehicle exc
19. To ensure oil cleanliness and longer machine life change the element at intervals of 20hrs 50hrs and at 250hr intervals thereafter PACKING OPERATION INSTRUCTIONS Keep access door closed when ejector panel is in motion Use only the side access door to enter or exit the body Do not open access door unless pressure against ejector panel has been relieved engine is stopped and key removed TAILGATE TAILGATE TAILGATE DANGER b e Stand clear when tailgate is in motion amp during unloading cycle e Do not stand or Cross under raised tailgate PACKING OPERATION INSTRUCTIONS WARNING LEACH DO NOT FILL BEYOND THIS LINE ADD HYDRAULIC FLUID A WARNING cing t th h WARNING DO NOT ENTER UNLESS All pressure against ejector panel has been relieved Engine is stopped and key removed SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL PACKER PACKER CONTAINER DUMP CONTROL C7 P PACKER M DOWN UP R SIDE HYDRAULIC FLUID ONLY NOTE Both container latch arms must be in place and latched before raising container FILTER ELEMENT CHANGE This unit conforms to all American To ensure oil cleanliness and longer National Standards Institute safety machine life change the element at requirements Z 245 1 in effect on intervals of 20hrs 50hrs and at the date of manufacture 250hr intervals thereafter LEACH BEACON
20. attention to hose fittings and connections at the cylinders and valves A build up of hydraulic fluid and dirt indicates a small leak that can probably be should identify any broken wires or obvious dam age A visual inspection of the chains should identify any damaged or elongated links corrected by tightening the fitting or connection c Make a visual inspection of the hook for obvi ous damage Make sure that the hook latch is working properly b Check the visual indicator to determine the condi tion of the return line element c Inspect the mounting sills and mounting hard d Check the operation of the container handling ware The springs should be compressed to 3 2 system The lifting mechanism should move inches 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 and 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 LATCHES 3 LUBRICATION Frequent inspection of grease points will indicate when lubrication is needed 6 7 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 ha
21. 17 over end of the KO ramp 15 Insert this assembly into the end of the valve spool and push into place Apply a liberal amount of general purpose grease into the detent ball holes 9 in the valve spool and push into place 6 10 11 Insert one detent ball 9 into each hole and care fully slide the detent sleeve assembly 16 includ ing the seals and retainers over the valve spool into place next to the valve housing Insert the adjustment screw 1 into the spool collar 6 from the inside and turn a few revolutions Do not turn the adjustment screws in too far or it will interfere with installation of the spool collar Slide inner spring collar 7 centering spring 5 and outer spring collar 4 onto end of valve spool While holding in place screw the spool collar 6 into the spool end Torque the spool collar 6 to 10 12 ft Ibs 13 6 16 3 Nm Reassemble parts in reverse order of disassembly Torque the bonnet screws and linkage end bracket to 60 in Ibs 6 75 Nm LEACH 9 34 DELTA SERVICE AND REPAIR MAIN CONTROL VALVE MAIN CONTROL VALVE The main control valve is located on the tailgate above the packer and carrier panels The valve controls the operation of the packer and carrier panels through the entire packing cycle It may have additional valve sec tions depending on the installation of options
22. 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF TAILGATE OPERATIONAL STATUS Truck Off Keys Removed 1 Inspect all sheet metal for badly bent or dented conditions Check the hardware holes for enlarge ment or breaks in the metal Check threaded holes for stripped or otherwise damaged threads Check the rubber seal for any sign of deterioration Check handles for looseness 2 Replace any defective part Follow all safety pre cautions pertaining to welding described in Sec 4 GENERAL REPAIR SAFETY PRECAUTIONS 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 disassembly and removal DESCRIPTION OF CARRIER AND PACKER PANELS The carrier and packer panels operate as a single unit to sweep refuse from the hopper and pack it against the pushout plate Their movement through the different cycles is controlled by the operating cylinders Movement of the panels within the body is kept in align ment by the roller assemblies located at each corner of the carrier panel The rollers ride inside a track channel on each side of the tailgate CYLINDERS PACKER 9 18 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL OPERATIONAL STATUS Truck Running PTO En
23. BUSHING ROD INSPECTION AND REPLACEMENT Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage new rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay particular attention to me way the parts are positioned before disassembly REASSEMBLY AND INSTALLATION Reassemble and install the cylinder in the approximate reverse order of assembly NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 10 SERVICE TOOLS may be necessary to properly reassemble the cylinder PISTON SEALS d BUSHING PISTON SERVICE AND REPAIR B ETA DISASSEMBLY OF INSPECTION AND REPLACEMENT CARRIER PANEL CYLINDERS 1 Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices f ing to di le th linder dL Md 2 A new rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay
24. Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices f ing to di le th linder 2 rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay particular attention to me way the parts are positioned before disassembly 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 device with a minimum lifting capacity of 500 Ibs REASSEMBLY AND INSTALLATION de REMOVE TE ee ow em ane Reassemble and install the cylinder in the approximate reverse order of assembly 5 Remove the gland retainer NOTE Slowl te the lifti ice t full Il th If the cylinder is not to be installed immediately piston rod assembly out of the cylinder NOTE Use an electric drill with an internal grinding wheel to remove any burrs from the internal groove on the cylinder case Otherwise the cylinder may be diffi cult to take apart keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 10 SERVICE TOOLS may be necessary to properly reas
25. Check Pushout Pressure 7 21 Check Resistance Pressure 7 22 Check Packer and Carrier Panel Shifting Pressure 7 23 Check Wear Blocks 7 24 Power Take Off 7 24 SECTION 8 TROUBLESHOOTING General ox ees bk aw hag eel ete ee 8 1 Compaction 8 1 Dieseling in Hydraulic Systems 8 2 Operation is Erratic 8 3 Pump Noise is Excessive 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 Packer Panel Valve Section Shifts Too Soon 8 4 Carrier Panel Valve Section Shifts to Neutral Too 8 5 Packer Panel Valve Section Will Not Shift 8 5 Carrier Panel Valve Section Will Not Shift To Ne tral bread 8 5 Packer Panel Does Not Deliver Full Force to Pack Load Into Body 8 5 Loud Squealing Noise When Manually Retracting Telescopic Cylinder 8 6 Load Will Not Push 8 6 Pushout Panel Slides Forward Too Fast While Packing Refuse 8 6 Pushout Panel Will Not Slide Forward 8 6 Carrier and Packer Panel Stop Short of Home Position After Each Cycle 8 6 Push
26. LUBE POINT QTY NOTE ILLUS LUBE POINT QTY NOTE Ei Control levers 2 NOTE e PTO shaft 2 The packer panel must be in the home position to Tailgate lift cylinders 4 lubricate the following lube points top and bottom e 6 Packing lever control 10 3 e 4 Tailgate clamps 2 linkage e 5 Rollers 4 1 amp 2 e7 Packer panel pivot 2 Operating cylinder 4 NOTES rod ends 1 Move roller track access covers to grease roller e 9 Operating cylinder 4 3 2 Rollers need lubrication roller tracks do not case ends Grease on tracks will only cause rollers to slide e 10 Optional control 2 Keep tracks clean and dry levers 3 Remove top covers for access to lube points Not shown cylinder 4 pivot pins 6 2 LEACH 2 O Lu o PREVENTIVE MAINTENANCE 6 3 SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE See accompanying Hydraulic System illustration Proper maintenance of the hydraulic components is of vital importance to the service life of the system and the operation of the unit as a whole CHECKING FLUID LEVEL DAILY Position and fully retract the pushout carrier and pack er cylinders to check the fluid level 1 When checking the fluid level in the hydraulic tank also note any fre quent or sudden loss of fluid This may indicate leak age which must be traced and corrected to avert equipment failure and possible damage to other com ponents If low fi
27. 7 center separator 8 and sealing strips 11 With the bronze side facing up lower the bottom pres sure plate 14 into place in the bottom pressure plate 14 into place in the bottom of the body bore Do not force Install driver gear 12 by lowering carefully 8 Install idler gear 13 10 11 12 13 Install the top pressure place 14 with the bronze side facing down Install end separators 7 center separator 8 sealing strips 11 and isolation plates 10 Examine the flange cover shaft seal 18 and wiper 2 If replacement is necessary see Seal Replacement Instructions Install o rings 6 and back up rings 5 on the extend ed portion of the bearings inside the flange 15 plate Install o ring 4 into the groove in the flange cover 15 Use heavy grease to hold the o ring in place NOTE Coat the drive gear shaft extension with clean heavy grease to protect the seal lip as the seal slides over the shaft 14 Slide the flange cover 15 down on the drive gear 12 until it touches the dowels 2 in the body NOTE Use extreme care when seating the flange cover against the body If not pressed down carefully the extended por tion of the flange cover bearings can pinch the sealing strips 15 16 Insert washer 16 and capscrews 17 into the holes in the flange cover 15 Tighten opposite and even to 80 foot pounds of torque Test the pump by using
28. 7 1 Check Engine Solenoid Switch 7 2 Check Engine Speed Up Switches 7 2 Check Packing Cycle Time 7 3 Check Pressures 7 3 Check Main Line Pressure 7 4 Check Pushout Pressure 7 5 Check Resistance Pressure 7 6 Check Packer and Carrier Panel Shifting Pressure 7 7 Check Wear Blocks 7 8 Power Take Off 7 8 SECTION 7 CHECK OUT BETA Blue Pages 7 9 Check Hydraulic Tank Fluid Level 7 9 Check Engine Solenoid Switch 7 10 Check Engine Speed Up Switches 7 10 Check Packing Cycle Time 7 11 Check Pressures 7 11 Check Main Line Pressure 7 12 Check Pushout Pressure 7 13 Check Resistance Pressure 7 14 Check Packer and Carrier Panel Shifting Pressure 7 15 Check Wear Blocks 7 16 Power Take Off 7 16 SECTION 7 CHECK OUT DELTA Pink Pages Generali 0 kr cer QUT 7 17 Check Hydraulic Tank Fluid Level 7 17 Check Engine Solenoid Switch 7 18 Check Engine Speed Up Switches 7 18 Check Packing Cycle Time 7 19 Check Pressures 7 19 Check Main Line Pressure 7 20
29. 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 TAILGATE LIFT PUSHOUT SYSTEM 5 LEVER The pushout panel is attached directly to the pushout eC oh cylinder Moving the control lever rearward toward the Dr tailgate will move the pushout panel to the rear Moving i the control lever forward toward the cab will move the pushout panel to the front TAILGATE LIFT LEVER 6 The lower lever controls the tailgate Moving the lever rearward toward the tailgate will raise the tailgate 7 Moving the lever forward toward the cab will lower the Y p tailgate ENGINE SPEED UP BUTTON 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 po
30. 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 TYPICAL EXAMPLE TOOTHED WASHER 9 55 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 described in Section 9 Service and Repair 10 1 SECTION 10 SERVICE TOOLS NO PART NO DESCRIPTION EXPLANATION UNIT 1 30522 Pressure Gauge To measure system pressure All except FL104 Beta 2 T SK 793 100 Pin Puller Remove pivot pins All 3 T 2R 1006 2 Tube Nut Wrench 172 Remove Install tube nut 2R 2RIll 4 T 2R 1313 2 Tube Nut Wrench 2 Remove Install tube nut 2R 2RHII 5 T SR 9541 20 Pump Shaft Seal Tool Install seal All 6 100368 Snap Connector Quick coupling for pressure gauges All 7 402325 Pivot Puller Remove upper carrier pivots 2HII 8 103081 O Ring Kit Various size o rings All excep
31. The pressure should be 600 PSI 42 BAR IF NOT 4 Verify all pressure in the signal line is relieved by moving the tailgate control lever forward to relieve any pressure in the circuit Repeat step 3 IF NOT 5 Disconnect signal line at the two stage workport relief 6 Loosen locknut and adjust the relief If reading was below 600 PSI 42 BAR turn adjustment clock wise If reading was over 600 PSI 42 BAR turn adjustment counter clockwise 7 Secure locknut connect signal line and confirm resistance pressure reading PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 600 PSI TWO STAGE WORKPORT RELIEF MAIN RELIEF TEST COUPLER 7 6 ALPHA SECTION 7 CHECK OUT CHECK PACKER AND CARRIER PANEL SHIFTING PRESSURES There are two methods to determine accurate pressure settings OPERATIONAL STATUS Truck Off PTO Disengaged 1 Use an electronic pressure gauge that maintains and records maximum system pressures 2 Ifan electronic gauge is unavailable and a mechan ical gauge must be used the following procedure is recommended a Install a 0 3000 PSI 0 207 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 the low
32. Truck Running PTO Engaged Sol Sw 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 0 3000 PSI GAUGE PACKER PANEL SECTION INLET COVER SCREW ACCESSORY SECTION OUTLET COVER CARRIER LEVER e The knockout pressures should be set at 2000 PSI 138 BAR for the packer panel section and 2100 PSI 145 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 15 SECTION 7 CHECK OUT CHECK WEAR BLOCKS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Visually inspect all wear blocks for excessive wear These items must be replaced before there is metal to metal contact 2 Shim or replace worn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL POWER TAKE OFF P T O OPERATIONAL STATUS Truck Off PTO D
33. 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 LEACH 3 10 SECTION 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 OPERATION POSITIONING PUSHOUT PANEL To load the unit the pushout panel must be positioned toward the rear of the body 1 Check the tailgate clamps to make sure both are securely tightened TAILGATE CLAMPS 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 4 Release the speed up button PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON LEACH 3 12 SECTION OPERATION EN 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 i 3 Do not load refuse higher than the loading edge Always follow proper loading procedur
34. between the con tainer and the tailgate while standing on the ground without placing yourself between them ATTACH CONTAINER LOWER TO CHECK CONTENTS INCORRECT CORRECT Ii IP ATTACHMENT POINT CONTAINER CONTROL LEVERS NOTE On units with a roof mounted container lifting cylin der the speed of the device is limited during both the up and down movement This speed reduction is for safety considerations 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 OPERATION 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 t
35. 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 long pole while standing to the side 1 Depress and hold engine speed up button 2 Push the tailgate lift lever rearward and hold until the tailgate is fully raised i PUSHOUT LEVER TAILGATE LIFT LEVER The tailgate open light and backup lights should illuminate The backup alarm should also sound SPEED UP BUTTON 3 17 OPERATION EJECTING THE LOAD 1 Depress and hold engine speed up button push the pushout lever rearward and hold until the pushout panel stops This will eject the entire load 2 Slowly pull the unit ahead to clear the refuse 3 Clean debris from the edges with a long pole while standing clear off to one side SPEED UP A WARNING diia Never drive the unit more than 10 feet with the tailgate in a raised position The pushout cylinder remains fully extended If the unit is going to travel over one mile empty PUSHOUT LEVER completely retract the cylinder When packing is about to resume extend the cylinder and start packing 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 SLAM
36. 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 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 83 8Nm 3 Torque the 3500 Ib relief cartridge load check and blanking plugs to 20 ft Ibs 27 Nm BONNET KNOCKOUT POSITIONER OUTLET COVER O RINGS CARRIER SECTION 9 29 9 SERVICE AND REPAIR ALPHA DISASSEMBLY AND INSPECTION OF THE KNOCKOUT POSITIONER 1 2 3 4 To remove the knockout positioner remove the four bonnet capscrews 2 and bonnet 3 Using 74e allen wrench remove the spool collar 6 If the control rod assembly is not installed on the spool end it may be necessary to insert a rod through the spool clevis to keep the spool from rotating when removing the spool col
37. control button depending on the style Be sure to read all safe ty decals associated with the Pump PTO before attempting operation 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 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 lem 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 SV CAUTION d TAILGATE A WARNING Operation of the unit with an illuminated or defective warning system can result in person al injury and or equipment damage 3 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 TE PUSHOUT L LEVER NOTE
38. cylinder to an overhead hoist or other suitable lifting mechanism with a min imum lifting capacity of 500 Ibs Remove the six nylock screws and three lock seg ments securing the head gland to the cylinder Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder NOTE Use an electric drill with an internal grinding wheel to remove any burrs from the internal groove on the cylinder case Otherwise the cylinder may be diffi cult to take apart LOCK SEGMENTS SCREW GLAND ROD INSPECTION AND REPLACEMENT 1 Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 2 Anew rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay particular attention to me way the parts are positioned before disassembly REASSEMBLY AND INSTALLATION Reassemble and install the cylinder in the approximate reverse order of assembly NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 10 SERVICE TOOLS may be necessary to properly reassemble the cylinder PISTON 9 13 9 SERVICE AND REPAIR DELTA INSPECTION AND REPLACEMENT DISASSEMBLY OF CARRIER PANEL CYLINDERS 1
39. guards that may have 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 4 Clean the magnetic plug 4 TESTING A NEW PUMP OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw After installing a new pump check for correct cycle time and main line pressure as described in Section 7 CHECK OUT FRONT VIEW SUCTION PRESSURE SUCTION 9 54 9 SERVICE AND REPAIR DESCRIPTION OF ELECTRICAL SYSTEM The packer electrical system includes all of the body running and marker lights operational speed up switch es the operator ready and back up warning buzzers and all interconnected wiring as shown on the accom panying wiring diagram 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
40. in the hook Cracks nicks and section wear must not exceed 10 percent of any dimension b Each month check the tailgate lift cylin der air breather If Visually inspect before each use for obvious damage plugged replace it LATCH with a new breather THROAT OPENING us AN POINT BACK A HEEL 7 YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a year drain flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SER VICE in this section b Once a year replace the hydraulic tank air breather c Once a year replace the fibrous tailgate lift cylin ders air breathers 6 9 SECTION 6 PREVENTIVE MAINTENANCE LEACH ALPHA 7 CHECK OUT GENERAL The Alpha has been designed to provide long periods of trouble free operation Performing the check out pro cedures below at regular weekly intervals will help to prevent unscheduled downtime Make sure you know and observe all safety precautions 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 peop
41. 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 with more than one container handling system PUSH BAR DRUM WINCH LIFTING CYLINDER 2 4 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 1 Loading sill 2 Arm 3 Latch 4 Guide ear ufi emm 2 5 SECTION 2 INTRODUCTION WINCH 1 Control lever 2 Engine speed up button 3 Hook 4 Hook safety latch 5 Cabl
42. ounces indicates an excessive piston seal leak If the cylinder does not leak excessively continue test OPERATIONAL STATUS Truck Off PTO Disengaged 5 If the cylinder does not leak reconnect hydraulic lines to the rod end of cylinder Repeat steps 3 5 for other cylinder Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components PACKER CARRIER PANEL PANEL LEVER LEVER OBSERVE FLUID FLOW 9 5 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 6 Shift the carrier panel lever inward to retract the carrier panel cylinder 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 Sol Sw 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 indicates an excessive piston seal leak Disassemble the cylinder and replace the piston Seal OPERATIONAL STATUS Truck Off PTO Disengaged 9 If the cylinder does not leak reconnect the hydra
43. particular attention to me way the parts are positioned before disassembly 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 device with a minimum lifting capacity of 500 Ibs REASSEMBLY AND INSTALLATION he Reassemble and install the cylinder in the approximate reverse order of assembly 5 Remove the gland NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination NOTE from entering the cylinder 6 Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder Use an electric drill with an internal grinding wheel NOTE from the int th Special tools listed in Section 10 SERVICE li Otherwise the cyli diffi Dee ee EEEE TOOLS be necessary to properly reassemble cult to take apart the cylinder PISTON SEALS ROD WIPERS SEALS O RINGS CASE BUSHING PISTON ROD BUSHING LEACH 9 12 DELTA 9 SERVICE AND REPAIR DISASSEMBLY OF PACKER PANEL CYLINDERS Remove grease fittings clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices before proceeding to disassemble the cylinder Secure the case end of the cylinder to the floor or workbench Secure the rod end of the
44. pin Use special pin puller See Section 10 SERVICE TOOLS CAPSCREW LEACH 9 8 ALPHA 9 SERVICE AND REPAIR DISASSEMBLY OF PACKER PANEL CYLINDERS Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices before proceeding to disassemble the cylinder Secure the case end of the cylinder to the floor or workbench Secure the rod end of the cylinder to an overhead hoist device with a minimum lifting capacity of 500 Ibs Remove the setscrew from the gland retainer Remove the gland retainer Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder NOTE Use an electric drill with an internal grinding wheel to remove any burrs from the internal groove on the cylinder case Otherwise the cylinder may be diffi cult to take apart ROD WIPERS SEALS O RINGS BUSHING ROD INSPECTION AND REPLACEMENT Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage new rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay particular attention to me way the parts are positioned before disassembly REASSEMBLY AND INSTALLATION Reassemble and install t
45. sig nal line Then remove the relief REASSEMBLY OF FRONT CONTROL VALVE 1 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 2 Reassemble parts in reverse order of disassembly SPOOL COLLAR 3 Torque the spool collar to 10 ft Ibs 13 6 Nm 4 Torque the bonnet and handle bracket capscrews to 10 ft Ibs 13 6 Nm vb 5 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 BONNET CAPSCREW LEACH 9 40 9 SERVICE AND REPAIR 6 Torque tie bolts evenly to 32 ft Ibs 48 Nm If tie bolts are not tightened to the proper torque valve spools may bind or stick or cause section seals to extrude TWO STAGE WORKPORT RELIEF 7 Torque value of the workport relief main relief car tridge and load check plugs will be 20 ft lbs 27 2 Nm REINSTALLATION OF FRONT CONTROL VALVE 1 Secure the valve to the mounting bracket with the appropriate hardware 2 Remove plugs and caps then attach hydraulic lines 9 41 9 SERVICE AND REPAIR REMOVAL OF PUSHOUT CYLINDER OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Move the pushout lever to position the pus
46. the vehicle with a container attached Always 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 0 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 LEACH SE
47. 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 and 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 47 9 SERVICE AND REPAIR DISASSEMBLY OF THE HYDRAULIC PUMP 203834 1 After removal thoroughly clean the outside with solvent and a brush Then blow dry the pump with compressed air Scribe flange cover 15 and body 1 so they can be matched for reassembly Carefully place the pump body in a vise and remove capscrews 17 and washers 16 Lift flange cover 15 off pump body and remove the o ring 4 from the flange Remove o ring 6 and back up ring 5 from each gear shaft Remove top isolation plates 10 sealing strips 11 end separators 7 and center separator Remove top pressure plates 14 drive gear 12 and idler gear 13 Remove the bottom pressure plate 14 by using an expandable bearing puller and lifting straight up out of the body NOTE It may be necessary to use a sharp knife to remove the r
48. will fit or sub 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 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 If steel supports are to be used to support the tail gate place them as shown in Section 9 SERVICE AND REPAIR under TAILGATE REPAIR When working on the unit always use the service tools listed in Section 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 SAFETY DURING SERVICE AND REPAIR 1 Always wear safety glasses 5 2 Disengage
49. 1 9 SERVICE AND REPAIR TEST FOR LEAKING PACKER PANEL CYLINDERS NOTE 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 OPERATIONAL STATUS Truck Running PTO Engaged Sol B n Sw 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 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 PACKER PANEL CYLINDERS a PACKER PANEL LEVER 9 2 CARRIER PANEL LEVER 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 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 l
50. 76 BAR turn adjustment clock wise If reading was over 1100 PSI 76 BAR turn adjustment counter clockwise 7 Secure locknut connect signal line and confirm resistance pressure reading PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 1100 PSI TWO STAGE WORKPORT RELIEF MAIN RELIEF TEST COUPLER 7 14 SECTION 7 CHECK OUT CHECK PACKER AND CARRIER PANEL SHIFTING PRESSURES There are two methods to determine accurate pressure settings OPERATIONAL STATUS Truck Off PTO Disengaged 1 Use an electronic pressure gauge that maintains and records maximum system pressures 2 Ifan electronic gauge is unavailable and a mechan ical gauge must be used the following procedure is recommended a Install a 0 3000 PSI 0 207 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 the low est knockout pressure OPERATIONAL STATUS 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
51. ACH 4 4 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 Cylinder Saa tn nr aed ate ha doa Es due vun ied Mande wot Gee d 500 Ibs 227 kg Telescopic Pushout Cylinders l l ee 1000 Ibs 454 kg Gartrier Panel n ratede ekbiatebrehau eub E ei ook die a Ad dca Gk My aoe 1600 Ibs 726 kg Packer Panel Viste ie ats Vin eels ete EUR 1600 Ibs 726 kg PusShout Panel adeu sog pa Fut Leste E Ert uper i mex eg a 2800 Ibs 1270 kg Tailgates PEDEM 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 use for lifting Type USS 26 EN1 Rating Vertical llf 2i rie ho Lr ads Dee he te ee mb Qd ies eA TE EN EN 4800 Ibs 2177 kg eae eee as ne tun bee d denke deitas 3600 Ibs 1633 kg Basket lif o uon deco sta eter daten Dah ey eatin pee Rad axem Bk a 9600 Ibs 4354 kg Wit s cate c
52. CTION 1 SAFETY PRECAUTIONS HYDRAULICS 1 Hydraulic fluid operates under high temperatures 3 In case of injury seek proper medical treatment Avoid contact with piping hoses or cylinders to immediately prevent burns 2 Never use hands to check for leaks Hydraulic fluid escaping under pressure may cause injury FIRE PROTECTION 1 Keep a fire extinguisher accessible at all times as recommended by the Bureau of Motor Carrier Safety 2 Never use lighted smoking materials open flame or sparks 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 3 Rubbish scrap paper and litter are highly com dent prevention 1 Keep handrails and steps clean and free of grease or debris bustible Such material should be stored in metal containers entirely clear of sparks and flames 2 Do not store brooms or other equipment where they could inadvertently activate the packer con trols SHUTDOWN pc Put all control e e i 99 Q 1 ut all controls in neutra e get e e 2 Set parking brake 2 3 Disengage PTO 4 Shut off engine U 5 Shut off solenoid da
53. EF MAIN RELIEF TEST COUPLER 7 22 DELTA SECTION 7 CHECK OUT CHECK PACKER AND CARRIER PANEL SHIFTING PRESSURES There are two methods to determine accurate pressure settings OPERATIONAL STATUS Truck Off PTO Disengaged 1 Use an electronic pressure gauge that maintains and records maximum system pressures 2 Ifan electronic gauge is unavailable and a mechan ical gauge must be used the following procedure is recommended a Install a 0 3000 PSI 0 207 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 the low est knockout pressure OPERATIONAL STATUS 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 Truck Running PTO Engaged Sol Sw 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 0 3000 PSI GAUGE PACKER PANEL SECTION INLET COVER SCREW
54. ERVICE amp REPAIR for detailed instructions pertaining to those items requiring repair or replacement 6 5 SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE CONTAMINATION It is estimated that as much as 90 of all hydraulic problems may be traced directly to the fluid It is of utmost importance that all foreign matter be kept from the hydraulic fluid Invisible quantities of abrasive type contamination may cause serious pump wear malfunc tioning of pumps and valves and sludge accumulations within the system in relatively short periods of time It is also essential that moisture and water be kept from the hydraulic fluids and system COMMERCIAL HYDRAULIC FLUID TESTING Hydraulic fluid samples should be taken periodically for laboratory analysis The actual sampling method is crit ical It should be done according to ANSI Standard B93 19M R1980 This standard is available from the National Fluid Power Association 3333 N Mayfair Rd Milwaukee Wl 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 commerc
55. I NN P Al PUSHOUT NI YS 4 gt CYLINDER Se a PUMP lt lt CARRIER V 2 CYLINDER A O A A O TAILGATE LIFT CYLINDER PACKER N CYLINDER A PRESSURE RETURN LEACH 8 18 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 A WARNING 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 CYLINDERS CARRIER AND PACKER PANEL The two 2 double acting hydraulic cylinders that con trol the movement of the carrier panel are called the carrier cylinders The two 2 double acting hydraulic cylinders that con trol the movement of the packer panel are called the packer cylinders CARRIER CYLINDERS PACKER CYLINDERS 9
56. INSPECTION Each day before starting the unit perform the following walk around inspection J AD E 2 2d 1 Refer to the decal location illustration in Section 1 SAFETY of this manual and make sure all decals are in place and readable Replace any decals that are not NOTE 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 MOUNTING SILL at the hydraulic cylinders valves and fittings 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 NOTE SPRING LATERAL RESTRAINT Torque mounting bolt to 700 ft lbs and front mount LEACH ing springs to 3 2 plus or minus 1 3 6 SECTION 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 cylinders i
57. Install the cover and secure to the bowl with the attaching hardware 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 2 Remove cover 7 and gasket 8 Unscrew and remove strainer 9 Clean strainer thoroughly in a suitable cleaning sol vent Reinstall strainer Remove clean and reinstall magnetic ring 10 Inspect the gasket 8 and replace if necessary Align the gasket carefully and secure the cover 7 to the tank with the attaching hardware LEACH 6 4 SECTION 6 PREVENTIVE MAINTENANCE FLUSHING HYDRAULIC SYSTEM YEARLY 1 Drain all fluid from the hydraulic tank into a suitable container Dispose of it properly 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 S
58. LEACH Alpha Beta Delta Service Manual Over Serial Number 3500 TO ORDER PARTS Contact your local Leach Signature Original Factory parts distributor Your Authorized Leach Distributor provide the following information A Company name B Date C Your order number D Routing instructions E Quantity part number and description F Model and serial number of unit Accept only Leach Signature Original Factory Parts SERIAL NUMBER LOCATION Copyright Leach Company 2737 Harrison Street Box 2608 Oshkosh Wisconsin 54903 2608 April 15 1998 PREFACE The Alpha Beta and Delta rear loaders over serial number 3500 share many safety operational and design similarities This manual combines the necessary information for these models into one publication FOREWORD The Leach Company has been a leader in the refuse industry for over 100 years The Leach Alpha is the industry standard for both quality and performance We at the Leach Company are justifiably proud of the quality engineering material and workmanship that goes into each and every packer we produce This commitment to quality extends to the best parts service and dis tributor organization in the industry One area of great importance to us at the Leach Company is your safety This unit was built in accordance with the American National Standards Institute ANSI standard for Mobile Refuse Col
59. LIGHT ON OFF CARRIER _ CARRIER HYD PUSH BAR CARRIER HYD PUSH BAR HYD PUSH BAR LEACH COMPANY OSHKOSH WI DO NOT FILL BEYOND THIS LINE WARNING Rotating power take off shaft hazard Do not enter under chassis unless engine is stopped and key removed EJECTION EJECTION ADD HYDRAULIC FLUID EJECTION 12 000 LB CAPACITY 8 000 LB CAPACITY g SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW TAILGATE BODY ASSEMBLY Z 2 Ee LOADING HOPPER EDGE HYDRAULIC TANK 2 1 SECTION 2 INTRODUCTION The main purpose of the packer 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 components read the complete Alpha Beta and Delta SERVICE MANUAL Before going further look at the accompanying illustrations and become familiar with the terms you will need to know LOADING PANE Refuse is first loaded into the hopper of the tailgate PACKER assembly The carrier and packer panels which sweep PANEL up and pack the refuse from the hopper
60. MING SHUT the tailgate TAILGATE LIFT LEVER 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 OPERATION SHUTDOWN 1 Move the packer panel lever and carrier panel lever to place the packer panel in the home position 2 Put all controls in neutral 3 Set parking brake 4 Disengage PTO 5 Shut off engine 6 Shut off solenoid dashboard switch 7 Remove key 8 Lock truck 3 19 SECTION 3 OPERATION LEACH SECTION 4 GENERAL REPAIR PRACTICES Proper service and repair is important for the safe reliable operation of all mechanical products the ser vice procedures recommended and described in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as 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 hazardous consequences of each way we have not accordingly anyone who uses a ser vice procedure or tool which is not recommended by Leach Company must first thoroughly satisfy himself that neither his no
61. R 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 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 p
62. SECTION 8 TROUBLESHOOTING RAISING TAILGATE PUSHOUT LEVER OPERATOR ACTION TAILGATE LIFT LEVER Operator opens the packer panel to release pressure Operator loosens and swings away from the body the 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 TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK C J s a FRONT CONTROL VALVE lt SS A 2 NS CYLINDER CYLINDER Sd TAILGATE LIFT CYLINDER PACKER CYLINDER SS PRESSURE RETURN 8 15 8 TROUBLESHOOTING EJECTING LOAD PUSHOUT LEVER OPERATOR ACTION TAILGATE Operator depresses speed up button and moves pushout lever rearward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever rearward shifts a spool in the front control valve causing flow to the pushout cylinder As the cylinder extends the load is ejected from the body TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK C CARRIER NU SZ SS AY 4 a Z 04 A
63. SIGNAL n Sw 1 Activate both the packer panel lever and carrier panel lever Using a stopwatch time a complete cycle A complete cycle should take 23 to 26 sec CONTAINER HANDLING CONTROL LEVERS onds CARRIER PANEL LEVER IF NOT PACKER PANEL LEVER OPERATIONAL STATUS LENGTHEN FOR Truck Off PTO Disengaged LONGER CYCLE J 2 Adjust the cable length between the solenoid or air cylinder and throttle linkage as needed to obtain the correct cycle time SOLENOID NOTE It is important the the cycle time is correct before performing the following pressure checks SHORTEN FOR SHORTER CYCLE CHECK PRESSURES The pressure checks provided below will indicate the operating condition of the hydraulic system Detailed adjustment procedures are provided later in this section and are referenced at the appropriate check out proce dure Prior to performing pressure checks OPERATIONAL STATUS Truck Off PTO Disengaged 7 Lp 10 1 Install a gauge capable of reading at least 3000 PSI 207 BAR on the main relief test coupling 2 Start the unit engage the PTO and turn solenoid MAIN RELIEF switch ON TEST COUPLER 7 19 SECTION 7 CHECK OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw On 1 Depress speed up button 2 Move pushout control leve
64. VI 9 24 9 24 9 25 9 25 9 25 9 25 9 26 9 27 9 28 9 29 9 29 9 30 9 30 9 31 9 32 9 33 9 33 9 34 9 34 9 35 9 36 9 37 9 37 9 38 9 38 9 39 9 39 9 39 9 40 9 41 9 42 9 43 9 44 9 44 9 45 LEACH TABLE OF CONTENTS SECTION 9 SERVICE AND REPAIR continued Telescopic Cylinder Disassembly Leach Hydraulic Pump 203834 Description of Hydraulic Pump Removal of Hydraulic Pump Disassembly of Hydraulic Pump Replacing Shaft Seals Reassembly of Hydraulic Pump Installation of Hydraulic Pump New Pump Preparation Testing a New Pump Leach Hydraulic Pump 307451 01 Description of Hydraulic Pump Removal of Hydraulic Pump Disassembly of Hydraulic Pump Replacing Shaft Seals Reassembly of Hydraulic Pump Installation of Hydraulic Pump New Pump Preparation Testing a New Pump Description of Electrical System sacs 3s ace React iiw Inspection LER Grounding the Electrical System Electrical SECTION 10 SERVICE TOOLS General s Joc seis ett tete ete om e on Manual Order Form Reward VII SECTION 1 SAFETY PRECAUTIONS GENERAL The Alpha Be
65. acker and carrier panels The valve controls the operation of the packer and carrier panels through the entire packing cycle It may have additional valve sec tions depending on the installation of options 9 27 9 SERVICE AND REPAIR REMOVAL OF THE MAIN CONTROL VALVE 1 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 valve assembly and bracket weigh approxi mately 100 Ibs Use appropriate lifting procedures and techniques when handling this assembly 7 Remove the capscrews washers and nuts holding the valve bracket to the tailgate CARRIER PANEL PACKER PANEL INTERRUPTED CYCLE CARRIER PANEL LEVER PUSHOUT PLATE MAIN CONTROL VALVE 9 28 ALPHA 9 SERVICE AND REPAIR DISASSEMBLY AND INSPECTION OF MAIN CONTROL VALVE 1 Wash the valve body with solvent to prevent
66. acks scoring or uneven wear Parts that must be sealed to prevent contamination replaced together such as seals and wear rings 6 After installation of the cylinder is complete clamp are available as a repair kit from your authorized the tailgate in the down position and remove the Leach dealer bleeder screw from the cylinder rod Operate the 2 Liberally coat all seals and wear rings with clean control lever until oil flows from e bleeder port fresh hydraulic fluid before installation Install the bleeder screw 3 Assembly of the tailgate lift cylinder is in approxi 7 Fully extend and retract the cylinder twice clamp mate reverse order of disassembly the tailgate in the down position and once again 4 Install the packing into the cylinder using a flat remove the bleeder screw Operate the control punch to push it in place Tighten the head gland lever After all air has exited the cylinder install the only enough to prevent leakage from the cylinder bleeder screw 5 Check all cylinder mounting components for cracks 8 Check for any external leaks on the cylinder and or excessive wear before installation If the cylinder connecting fittings PORT PACKING RETAINING RING BLEEDER FITTING SET SCREW un LEACH 9 16 9 SERVICE AND REPAIR DESCRIPTION OF THE TAILGATE ASSEMBLY The tailgate assembly houses the carrier and packer panel cylinders carrier and packer panels and the hopper where refu
67. aise the tailgate N p Il Pushout Cylinder Wear Blocks Wear Blocks Mounting Shims Shims PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON 9 25 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off Keys Removed 3 Support the tailgate from an overhead hoist or crane with a minimum lifting capacity of 7500 1 5 Loosen the hydraulic fittings slowly to release the pressure 4 Disconnect the pushout cylinder from the pushout panel by removing the four 2 bolts in each of the saddle bearings NOTE Be careful not to damage the pushout cylinder dur ing removal of the pushout panel 5 Weld an eye to the center of the panel and attach a chain to prevent the panel from tipping over upon removal 6 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 equipment must be capable of lifting a minimum of 2800 Ibs and the panel should be secured safely to the removal device INSTALLATION OF PUSHOUT PANEL Install the pushout panel in the reverse order of removal PUSHOUT PANEL WELD EYE Pushout Cylinder Saddle Bearing LEACH 9 26 L P H A SERVICE AND REPAIR MAIN CONTROL VALVE MAIN CONTROL VALVE The main control valve is located on the tailgate above the p
68. alve 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 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 reassembly 9 Use only Leach Signature replacement parts NOTE See Section 9 SERVICE AND REPAIR for specific repair instructions ELECTRICAL TESTING CHECKING CONTINUITY 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 go
69. an adjustable wrench with a key installed in the drive gear When attempting to turn the shaft it should feel tight with a maximum of 5 to 10 foot pounds of torque If the shaft does not turn properly dis assemble find the problem and carefully reassemble NOTE The check valves 3 located in the flange cover 15 are not replaceable They are only available as part of the flange cover 9 49 9 SERVICE AND REPAIR INSTALLATION OF HYDRAULIC PUMP 203834 OPERATIONAL STATUS Truck Off PTO Disengaged Install the pump in the reverse order of removal MAKE SURE suction and pressure lines are installed correctly for pump rotation Tighten all mounting hardware and hose clamps Be sure to re install any shaft guards that may have 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 2 Remove and clean the hydraulic tank strainer 1 Change the filter element 2 Drain and flush the hydraulic tank as described in Sec 6 PREVENTIVE MAINTENANCE 3 Clean the magnetic plug 4 TESTING A NEW PUMP OPERATIONAL STATUS Truck Running PTO Engaged Sol On Sw After installing a new pump check for correct cycle time and main line pressure as described in Sec 7 CHECK OUT CLOCKWISE PRESSURE SUCTION 9 50
70. aneously inward to open the packer panel and lower the carrier panel to the interrupted cycle position Both levers are shifted outward to sweep the load from the hopper and pack it against the pushout panel Any time the carrier panel lever is shift ed the engine speed up automatically engages The packing cycle may be stopped at any point by moving both operating levers to neutral The packer or carrier panel can be moved independently CONTAINER HANDLING CONTROL LEVERS 11 12 These control levers are provided when container han 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 SIGNAL PUSH BUTTON PACKER PANEL LEVER 3 5 OPERATION OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the Alpha Beta and Delta including specific instructions for loading pack ing and unloading the unit NOTE It is important that operators and mechanics understand these procedures PRE OPERATING WALK AROUND
71. attempting any operation of the unit make sure you are familiar with all of the safety information con tained 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 efficient operation of the Alpha Beta and Delta It 6 is important that you know the location and function of _ AG gt each control before attempting to operate the TT i unit Refer to the accompanying illustrations for o e Eh their locations 3 1 OPERATION LOCATION OF OPERATING CONTROLS 8 m Y 3 Rc fe d 7 99 e Ng 7 Si cv k es 7 Of cal 5 7 YL f LEACH SECTION OPERATION PUMP PTO CONTROL 1 The Pump PTO Power Take Off is engaged to put the hydraulics in 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
72. bank of hill Leaking piston seal in pushout cylinder Hydraulic tubing is damaged pinched shut Main relief pressure too low POSSIBLE CAUSE Unload unit as described in Sec 3 Operation Perform test for leaking cylinder and repair as Replace tubing Check pressure See Sec 7 Check out REMEDY required See Sec 9 Service and Repair REMEDY 1 Packer panel cylinder seal leaking 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 POSSIBLE CAUSE REMEDY 1 Solenoid to carburetor or governor linkage cable 1 Adjust cable to achieve 32 seconds cycle out of adjustment time 2 Hydraulic fluid level too low 2 Fill to proper level See Sec 6 Preventive Maintenance 3 Hydraulic fluid filter needs servicing 3 Service filter See Sec 6 Preventive Maintenance 4 Hydraulic tank breather dirty 4 Service breather See Sec 6 Preventive Maintenance 5 Hydraulic pump worn or defective 5 Replace pump See Sec 9 Service and Repair 6 Operating cylinder piston seals leaking 6 Perform test for leaking operating cylinder seals and repair as required 7 Incorrect grade of hydraulic fluid for current 7 Refill with proper grade of hydraulic fluid operating conditions See Sec 5 Specifications 8 Solenoid mounting loose or bro
73. can lead to a major explo sion Welding should be done in a location well away from flammable materials REMOVAL DISASSEMBLY AND REPAIR 1 Cleanliness is very important dirt is 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 10 11 12 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 part 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 v
74. ch 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 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 22 32 46 AGMANO oes tht become faa lt ice 1 Gravity APT outer du a ah uia Ri i LE 33 31 31 Flash E si ves es duis eto ae ras eer der o 375 380 390 Pour Point due tek wem gk 20 20 20 Viscosity S9U 01009 Metal Vos eher 112 158 228 SSUQ 210 E LI kobe niga 40 44 48 CSt 40 21 30 5 44 COL QD 1009 0 c c Eb 4 1 5 2 6 5 Viscosity 98 99 99 ASTM Oxidation Test Hours to 2 0 Neut No 2500 2500 2500 ASTM Rust Test A amp B
75. cycle has begun The packer panel must be in 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 loader s 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
76. 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 ingesting air LEACH 8 2 SECTION 8 TROUBLESHOOTING OPERATION IS ERRATIC POSSIBLE CAUSE REMEDY 1 Solenoid receiving erratic electrical current N Solenoid flexing at mounting point Engine motor mounts defective Hydraulic fluid too hot AO Hydraulic fluid level too low Bypass in cylinders oOo 7 Hydraulic fluid too cold 8 Operating linkage bent or binding RO N oo 7a 7b Check electrical system See Sec 9 Service Make sure solenoid is mounted firmly and Repair or replace as required Check for proper grade of fluid See Sec 6 Check fluid level Add fluid if necessary Test for leaking cylinders See Sec 9 Service Repair replace or realign damaged linkage and Repair mounting does not flex Preventive Maintenance and Repair Bring
77. d Symbol are used to alert the operator and mechanics to special instructions concerning a particular operation or service that may be hazardous if performed incorrectly or carelessly DANGER Immediate hazards which WILL result in severe personal injury or death AWARNING A CAUTION WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION Hazards or unsafe practices which could result in minor personal injury or prop erty or product damage Strict compliance to these safety alerts combined with common sense operations are important accident pre vention measures The word NOTE is also used throughout the manual It precedes information that provides special emphasis or clar ification on a specific operation or procedure 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 wa
78. d maintenance of the return filter are probably the two most vital areas of preventive maintenance required The objective of preventive mainte nance is to anticipate and pre vent operational difficulties before they require extended shut down for costly repairs r 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 6 1 SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART 5 ICE BAF 999 10 e e j In below freezing climates all grease and fluids should have a cold test rating of at least 20 F INSTRUCTIONS Grease weekly every 40 hrs of operation with MOBILUX EPI SERVICE grease or equivalent E Cil weekly every 40 hrs of operation with SAE 10 or equivalent ILLUS
79. d 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 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 COMPACTION Before troubleshooting a unit it is important to remem ber that the compaction may vary with the following conditions 1 Type of refuse Tree branches dry 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 refus
80. 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 REDUCTION FROM NORMAL DIAMETER EVIDENCE OF HEAT DAMAGE OF MORE FROM ANY CAUSE THAN a KINKING Y CRUSHING OR DISTORTION OF ROPE STRUCTURE WIRE ROPE CHART REAR ANY ONE LAY OR 3 BROKEN WIRES IN ONE MORE THAN 1 STRAND IN BROKEN WIRE AT XN UNY A DEAD END WEAR GREATER THAN CONNECTION DIAMETER OF OUT SIDE INDIVIDUAL WIRES LEACH 6 8 SECTION 6 PREVENTIVE MAINTENANCE MAINTENANCE RECOMMENDATIONS The packer carrier assembly should be visually inspect ed every forty 40 hours of operation for cracked or fatigued welds loose or broken fasteners worn bear ings pin hubs or pins HYDRAULIC SYSTEM LIFTING HOOK a Once a month remove 4 A thorough inspection of any container lifting hook and clean the 5 should be completed once a month consisting of check hydraulic tank fluid 9 v ing for distortion cracks nicks wear latch engagement strainer as described and secure end connections Maximum distortion in HYDRAULIC SYS SS 1 allowable is an 8 percent increase in the throat dimen TEM SERVICE in this sion or a 10 degree twist
81. ditional valve sec tions depending on the installation of options 9 31 9 SERVICE AND REPAIR REMOVAL OF THE MAIN CONTROL VALVE 1 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 valve assembly and bracket weigh approxi mately 100 Ibs Use appropriate lifting procedures and techniques when handling this assembly 7 Remove the capscrews washers and nuts holding the valve bracket to the tailgate CARRIER PANEL PACKER PANEL INTERRUPTED CYCLE CARRIER PANEL LEVER PUSHOUT PLATE MAIN CONTROL VALVE 9 32 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
82. e 6 Winch assembly 7 Container attachment 8 Bump bar Lid guard CONTAINER LIFTING CYLINDER CLC Control lever Engine speed up button Roller guide Hook Hook safety latch Cable Lifting cylinder assembly Container attachment Bump bar Lid guard CONTAINER PUSH 1 Control lever 2 Push bar 3 Lift pad 4 Container dumping cylinder 5 Bump bar 6 Container attachment 2 6 SECTION 2 INTRODUCTION 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 DUMP DISCONNECT When the container is empty it is lowered to the ground the latch arms released and the truck is moved forward DISCONNECT P 2 7 SECTION 2 INTRODUCTION LEACH SECTION OPERATION GENERAL This section will provide all of the instructions neces sary to operate the Alpha Beta and Delta However prior to
83. e PTO and turn the sole noid switch on 3 Unlatch both tailgate clamps 4 Depress speed up button Move the tailgate control lever to the rear to fully raise the tailgate NOTE The tailgate lift time is 24 to 28 seconds Move the pushout control lever to the rear to fully extend the pushout cylinder While continuing to hold the pushout control lever observe the reading on the gauge The pressure should be at 1950 PSI 135 BAR plus or minus 100 PSI 7 BAR IF NOT 9 Perform TEST FOR LEAKING Pushout CYLIN DER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again check gauge for correct pressure IF NOT 10 Replace the two stage workport relief MAIN RELIEF TEST COUPLER PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 1950 PSI TWO STAGE WORKPORT RELIEF ai Hill Mill 7 Q y MAIN RELIEF M 7 5 SECTION 7 CHECK OUT CHECK RESISTANCE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 1 Move pushout control lever to fully extend the pushout cylinder OPERATIONAL STATUS Truck Off PTO Disengaged 2 Connect a porta power with a gauge to the work port relief test coupler 3 Slowly pump the porta power and read the gauge to see what pressure the two stage workport relief cracks open at
84. e is not moving the directional valve 6 Repair the linkage 7 Lifting motor or cylinder s by passing hydraulic 7 Repair or replace the defective component fluid 8 Shear pin or key broken between winch shaft 8 Replace the key or pin and drum WINCH MOTOR LEAKING POSSIBLE CAUSE REMEDY 1 Shaft seal damaged 1 Replace shaft seal 2 Motor worn internally 2 Replace motor CONTAINER RAISES VERY SLOWLY POSSIBLE CAUSE REMEDY 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 handling systems System following procedures in service manual LEACH 8 8 SECTION 8 TROUBLESHOOTING DESCRIPTION OF HYDRAULIC SYS TEM The following is a description with flow diagrams of what happens in the hydraulic system during the load ing packing and unloading operations of the unit Operator action is presented and then a description of the 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 LIFT CYLINDER HYDRAULIC FLUID TANK PUSHOUT 4 CYLINDER CYLINDER K gt TAILGATE LIFT CYLINDER PACKER CYLINDER 8 9
85. e 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 4 Preventive maintenance A properly maintained unit will achieve higher compaction rates than one that is poorly maintained The condition of the hydraulic system pump main relief setting and the condition of the 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 8 TROUBLESHOOTING DIESELING IN HYDRAULIC SYSTEMS Any hydraulic system should be a sealed environment free o
86. eak If the cylinder does not leak excessively continue test OPERATIONAL STATUS PACKER PANEL CARRIER PANEL LEVER LEVER Truck Off PTO Disengaged 5 Reconnect the hydraulic lines to the end of cylin ders Repeat steps 3 5 for the other cylinder OBSERVE FLUID FLOW OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 6 Shift the packer panel lever inward to retract the packer panel cylinder to the interrupted cycle position OPERATIONAL STATUS Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent Truck Off PTO Disengaged movement of components 7 Disconnect and cap the hydraulic lines which con nect to the case end of a packer panel cylinder 9 3 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 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 If the cylinder does not leak r
87. ece oe athe le Ok Quart ath eos cach 2 in Length dd E T RR ies 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 jc TT D O F Double Branch Oblong link Foundry Hook sl OI bb tr cha deta one EI 2 in ODIONGANINGS 2 xc meer cr s mie urs RAO IE pex sia nite Ae sae ons 7b in 4 5 SECTION 4 GENERAL REPAIR PRACTICES CAPSCREW MARKING AND TORQUE VALUES Much Used Used at Times Used at Times Capscrew Diameter To 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 6 or7 CAPSCREW HEAD MARKINGS Manufacturer s marks may vary These are all SAE Grade 5 3 line 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 P 2 oN A w w a a a SSEBBAASSSSSRAREALZSUSO 120 16 60 amp NONMDONNAANMNH 167 23 10 A
88. eck gauge for correct pressure IF NOT 10 Replace the two stage workport relief PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 1950 PSI TWO STAGE WORKPORT RELIEF MAIN RELIEF TEST COUPLER MAIN RELIEF 7 21 SECTION 7 CHECK OUT CHECK RESISTANCE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 1 Move pushout control lever to fully extend the pushout cylinder OPERATIONAL STATUS Truck Off PTO Disengaged 2 Connect a porta power with a gauge to the work port relief test coupler 3 Slowly pump the porta power and read the gauge to see what pressure the two stage workport relief cracks open at The pressure should be 300 PSI 21 BAR IF NOT 4 Verify all pressure in the signal line is relieved by moving the tailgate control lever forward to relieve any pressure in the circuit Repeat step 3 IF NOT 5 Disconnect signal line at the two stage workport relief 6 Loosen locknut and adjust the relief If reading was below 300 PSI 21 BAR turn adjustment clock wise If reading was over 300 PSI 21 BAR turn adjustment counter clockwise 7 Secure locknut connect signal line and confirm resistance pressure reading PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 300 PSI TWO STAGE WORKPORT RELI
89. econnect the hydraulic lines to the cylinder Repeat steps 7 9 for the other cylinder PACKER PANEL LEVER CARRIER PANEL LEVER Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components TEST FOR LEAKING CARRIER PANEL CYLINDERS NOTE Before testing any cylinder make sure the main line 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 ga CARRIER PANEL CYLINDERS 9 4 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 2 Shift the carrier panel lever outward to fully extend the carrier panel cylinders home position PACKER CARRIER PANEL __ X 6 PANEL LEVER LEVER OPERATIONAL STATUS Truck Off PTO Disengaged 3 Disconnect and cap the lines that connect to the rod end of one cylinder OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 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
90. eight of a refuse collection vehicle be altered by installing a container handling system be sure the overall height is rechecked and overall height plus 3 inches is noted on the decals LEACH SECTION 1 SAFETY PRECAUTIONS OPERATION GENERAL It is the operators responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operator s 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 eq
91. er in this section 9 24 9 SERVICE AND REPAIR DESCRIPTION OF PUSHOUT PANEL The pushout panel is connected to and controlled by the pushout cylinder Refuse is packed against the pushout panel during loading During unloading the pushout panel ejects the load as the pushout cylinder is extended The pushout panel will travel the entire length of the body At the end of the extension stroke the load is com pletely ejected During its movement through the body the pushout panel rides in a trough Its sideways movement is mini mized by replaceable wear blocks PUSHOUT PANEL INSPECTION AND REPLACEMENT OF WEAR BLOCKS OPERATIONAL STATUS Truck Off Keys Removed 1 Inspect the wear blocks for wear Replace worn parts SHIMMING WEAR BLOCKS WITH PANEL IN PLACE Shims can be added to the wear blocks without remov ing the pushout panel as follows OPERATIONAL STATUS Truck Off Keys Removed Remove attachment bolts and pins for wear blocks Pry pushout panel to one side Add shims behind the wear block Repeat procedure for other side Install attachment bolts and pins Tighten securely RON REMOVAL OF PUSHOUT PANEL OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Remove the pushout lever and position the pushout panel at the extreme rear of the body 2 Pull the tailgate lift lever to r
92. er one mile empty com pletely retract the cylinder When packing is about to resume extend the cylinder and start packing PUSHOUT PANEL MOVES REARWARD EJECTING LOAD PUSHOUT PANEL 2 3 SECTION 2 INTRODUCTION CONTAINER ATTACHMENT The Leach Container Attachment system consists of a loading edge with a latch assembly and a guide ear ear on each side of the packer tailgate The standard container for use with the Leach rear loader must have an ANSI Standard 174 1 diameter trunnion bar which is between 777 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 Institute ANSI regulations should be used in conjunction with Leach Container Handling Systems ly S990 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
93. es ATTACHING A CONTAINER TO THE PACKER Place the container on a flat level surface For large 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 trunnion bar is between the guide ears and within the latch assem bly Center the contain er on the attachment OR N EA f m ATTACHING CONTAINER E After setting the vehicle parking brake the right and left PU container latch arms must be engaged Lifting a container without both latch arms secured can allow the container to swing away LATCH ARMS from the unit and cause severe injury or death NOTE ATTACHED If the container is equipped with wheels it should be rolled into position only after the vehicle parking brake has been set Even small containers must use the latch arms to secure them to the packer 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 ope
94. ess 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 OO ENGINE SPEED UP DRIVER SIGNAL EJECTION EJECTION EJECTION WARNING YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS You are qualified by training and experience in the safe operation of this machine Training includes complete knowledge of your employer s work rules all governmental regulations and manufacturer s operator and safely manuals relative to this machines safe use AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY AWARNING 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 riding steps HYDRAULIC FLUID ONLY This unit conforms all American National Standards Institute safety requirements Z 245 1 in effect on the date of manufacture FILTER ELEMENT CHANGE
95. est knockout pressure OPERATIONAL STATUS 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 Truck Running PTO Engaged Sol Sw 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 0 3000 PSI GAUGE PACKER PANEL SECTION INLET COVER SCREW ACCESSORY SECTION OUTLET COVER CARRIER LEVER e The knockout pressures should be set at 1800 PSI 124 BAR for the packer panel section and 2000 PSI 138 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 7 SECTION 7 CHECK OUT CHECK WEAR BLOCKS OPERATIONAL STATUS Truck Off PTO D
96. f 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 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 Where does the air come from The answer is that the air comes out of the fluid itself Hydraulic fluid can con tain 1096 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 sy
97. fluid to operating temperature Check for proper grade of hydraulic fluid See Sec 5 Specifications PUMP NOISE IS EXCESSIVE NOTE ALL PUMPS MAKE A CERTAIN AMOUNT OF NOISE POSSIBLE CAUSE REMEDY 1 Pump starving for fluid 2 Hydraulic fluid too cold 3 PTO driveshaft and or u joints badly worn or out of balance 4 Pump gears end plates bearings etc badly worn 5 Improper grade of hydraulic fluid fluid foaming 6 Air entering the system 2a 2b 6a 6b 6c 6d 6e ef Open gate valve 1b 1c 1d Repair replace and or balance all parts Replace pump Replace with proper grade of hydraulic fluid Check fluid level Check hydraulic fluid filter and tank Check for obstruction in suction lines hoses kinked or collapsed Bring fluid to normal operating temperature Change hydraulic fluid to proper grade for operating conditions See Sec 5 Specifica tions See Section 5 Specifications 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 8 3 8 TROUBLESHOOTING ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR SPEED UP BUTTON IS ENGAGED POSSIBLE CAUSE 1 Short in electrical wiring 2 Blown fuse on speed up relay 3 Relay solenoid or switch is defecti
98. g 17 Remove 9 ACAUTION back up rings and o ring 18 Clean and inspect parts for excessive wear or scor o The spool collar is under spring tension and ing Clean the o ring counter bores Servicing of the caution should be used when removing detent assembly is limited to o ring and back up 4 Remove spring collars 7 and centering spring 6 washer replacement 12 BACK UP 17 amp 18 9 FOLLOWER RING O RING DETENT BALLS 4 7 10 14 ADJUSTMENT SPRING SPRING KNOCKOUT 0 SCREW COLLARS GUIDE PLUNGER eee 999 b OD 3201 N SPOOL P 2 3 BONNET LOCK NUT 2 O BACK UP DETENT RING BALLS 3 Q 18 9 INNER SPRING NEEDLE SPOOL CENTERING OUTER SPRING SLEEVE GUIDE ROLLER 13 8 15 16 SCREW COLLAR SPRING SPRING 1 5 6 11 REASSEMBLY OF KNOCKOUT POSITIONER 1 Lightly oil and install 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 Ibs 7 Nm sleeve 8 over the spool and into place 3 Install knockout plunger 14 inner spring 13 if 6 Install spring collars 7 and centering spring 6 used fol
99. gaged Sol On Sw 1 Position the packer panel at the interrupted cycle position 2 Move the packer panel lever upward until the pack er plate reaches a vertical position This will take the pressure off the rod eye when the pin is removed CARRIER PANEL LEVER PACKER PANEL __ LEVER OPERATIONAL STATUS Truck Off Keys Removed 3 Remove the locknut and capscrew from the rod end of both packer cylinders 4 Secure nylon sling around the cylinder and attach to a suitable lifting device with a minimum 500 Ib lifting capacity Make sure the cylinder weight is securely supported and carefully remove the cylin der rod pin 5 After both cylinders have been disconnected attach a chain connected to a suitable lifting device with a minimum lifting capacity of 1600 Ibs to the packer panel as shown Operate the lifting device to support the weight of the packer panel without causing strain on the bearing or roller assemblies 6 Remove the roll pins and washers from the packer panel pivot pins Remain clear of packer panel when removing pivot pins 7 Remove the pivot pins 8 With the pivot pins removed carefully operate the hoist and lift the packer panel out of the hopper Use care to avoid damaging the hopper NYLON SLING NOTE See Sec 4 GENERAL HEPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 9 19
100. he cylinder in the approximate reverse order of assembly NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from entering the cylinder NOTE Special tools listed in Section 10 SERVICE TOOLS may be necessary to properly reassemble the cylinder PISTON SEALS d BUSHING PISTON 9 9 SERVICE AND REPAIR A L P H A DISASSEMBLY OF INSPECTION AND REPLACEMENT CARRIER PANEL CYLINDERS 1 Carefully and thoroughly inspect the bore of the cylinder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices f ing to di le th linder dL Md 2 A new rod wiper rod seal O rings and piston seals must be installed anytime the cylinder is disassem bled Pay particular attention to me way the parts are positioned before disassembly 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 device with a minimum lifting capacity of 500 Ibs REASSEMBLY AND INSTALLATION he Reassemble and install the cylinder in the approximate reverse order of assembly 5 Remove the gland NOTE If the cylinder is not to be installed immedia
101. he 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 DUMPING WITH CPB 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 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 edge stop in the interrupted cycle position and the carrier panel lever will automatically shift to neutral SIGNAL PUSH BUTTON PACKER PANEL LEVER 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 s
102. hout 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 Ibs to the pushout cylinder 4 Remove the capscrews and bearing block halves connecting the pushout panel to the cylinder OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 5 Move the pushout lever to slowly retract the pushout cylinder until it is completely retracted OPERATIONAL STATUS Truck Off PTO Disengaged 6 Disconnect the hydraulic line to the cylinder port Cap the hydraulic lines and the cylinder to prevent contamination of the hydraulic system 7 Remove the cylinder end case pin 8 Using the lifting device lower the pushout cylinder until it is resting on the floor of the body PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON 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 LEACH
103. i tion 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 SIGNAL PUSH BUTTON Back the unit up a few feet to ensure that the back up alarm is working properly 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 TAILGATE CLAMPS 3 9 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 1 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
104. ial 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 of water contamination the source of which must be found and eliminated immediately Common sources are 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 addit
105. imming may damage tailgate walls or wear the track channels OPERATIONAL STATUS Truck Off Keys Removed 8 Remove the appropriate rollers and adjust the shims as required to obtain a smooth operating car rier panel This may require adding or removing shims and operating the packing lever several times until the correct alignment is achieved 9 Reinstall the track hole covers in the reverse order of removal 10 Once the alignment is correct lubricate each roller as described in the LUBRICATION CHART Sec 6 PREVENTIVE MAINTENANCE 9 22 SECTION 9 SERVICE AND REPAIR REMOVAL OF CARRIER PANEL NOTE Remove the packer panel and four operating cylinders as described earlier in this section OPERATIONAL STATUS Truck Off Keys Removed 1 Attach a chain connected to a suitable lifting device with a minimum lifting capacity of 1600 Ibs to the upper and lower end of the carrier plate as shown 2 Remove the rollers as described later in this sec tion 3 Lowerthe carrier panel into the tailgate hopper and disconnect the chains NOTE See Sec 4 GENERAL HEPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 4 Remove the tailgate as described earlier in this section Once the tailga
106. ion See Sec 9 Service and Repair Secure PACKER PANEL VALVE SECTION SHIFTS TOO SOON POSSIBLE CAUSE REMEDY 1 Object in hopper that the packer panel cannot move 2 Cycle time too fast 3 Packer panel valve section pressure too low Recycle unit Rearrange or remove refuse if Adjust speed up cable length Perform pressure checks as described in Sec necessary 7 Check out LEACH 8 4 SECTION 8 TROUBLESHOOTING CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON POSSIBLE CAUSE 1 Carrier panel valve section pressure too low 1 Perform pressure check as described in Sec REMEDY 7 Check out PACKER PANEL VALVE SECTION WILL NOT SHIFT POSSIBLE CAUSE REMEDY 1 Packer panel cylinder seal leaking 2 Packer panel valve section pressure too high 3 Linkage binding or restrictive Perform test for leaking cylinder See Sec 9 Perform pressure check as described in Sec Inspect and free linkage as necessary Service and Repair 7 Check out CARRIER PANEL VALVE SECTION WILL NOT SHIFT TO NEUTRAL POSSIBLE CAUSE REMEDY 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 Perform test for leaking cylinder See Sec 9 Perform pressure check as described in Sec Inspect and free linkage as nece
107. isengaged 1 Periodically re torque the mounting bolts or studs as outlined in the manufacturers service manual LEACH 7 16 DELTA CHECK OUT GENERAL The Alpha Beta and Delta have been designed to pro vide long periods of trouble free operation Performing the check out procedures below at regular weekly intervals 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 OPERATIONAL STATUS Truck Running PTO Engaged Sol B n Sw CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down and clamped securely 2 Move the carrier and packer panel levers to position the carrier and packer cylinders in the retract posi tion 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
108. isengaged 1 Visually inspect all wear blocks for excessive wear These items must be replaced before there is metal to metal contact 2 Shim or replace worn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL 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 manufacturers service manual LEACH 7 8 CHECK OUT GENERAL The Beta has been designed to provide long periods of trouble free operation Performing the check out proce dures below at regular weekly intervals will help to prevent unscheduled downtime Make sure you know and observe all safety precautions 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 OPERATIONAL STATUS Truck Running PTO Engaged Sol B n Sw CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down a
109. ive content C Ifthe sample shows distinct rings the fluid should be changed D If a distinct dark spot remains in the middle but a lighter colored fluid migrates outward in the blotter paper the fluid is about to dump or already has sludge or other by products into the system The time for replacement of this fluid has already passed Kits are available from your fluid supplier to test for acid content in much the same way you would test the con dition of swimming pool water A shift in acid content may indicate a breakdown in the fluid KEEP ACCURATE DATED RECORDS OF ALL PER TINENT INFORMATION GAINED FROM THESE LEACH 6 6 SECTION 6 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE 4 CONTAINER HANDLING Each day perform the following maintenance EQUIPMENT In addition to performing the daily vehicle and packer body pre operating inspection also check the container handling system Each day perform the following inspection 1 INSPECTION Perform the PRE OPERATIONAL INSPECTION described in Sec 3 OPERATION A 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
110. ken 8 Remount solenoid securely on engine if pos sible 9 Solenoid or wiring defective 9 Repair or replace as required See Electrical System Sec 9 Service and Repair 10 Defective governor diesel engine 10 Diesel engine must have a full variable speed governor to properly operate packer 8 7 8 TROUBLESHOOTING TAILGATE WILL NOT RAISE POSSIBLE CAUSE REMEDY 1 Tailgate clamps still engaged 1 Disconnect clamps and swing free of tailgate 2 Insufficient hydraulic pressure 2 Check main pressure See Sec 7 Check out 3 Hydraulic pump is defective 3 Replace pump See Sec 9 Service and Repair 4 Relief section of 2 spool directional valve out 4 Adjust or replace relief as necessary See of adjustment or broken Sec 9 Service and Repair 5 Tailgate lift cylinders leaking or defective 5 Repair or replace as required 6 Restriction in tailgate cylinder hose 6 Remove and clean hose CONTAINER WON T LIFT POSSIBLE CAUSE REMEDY 1 Insufficient hydraulic pressure 1 Check hydraulic pressure following proce dures in service manual 2 Cable broken 2 Replace cable 3 Cable loose from the lifting device drum cylinder 3 Secure cable to lifting device 4 Container overload 4 Reduce weight of material in container 5 Container frozen to the ground 5 Do not use lifting device to break container loose from the ground 6 Control linkag
111. laced 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 responsibility 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 TABLE OF CONTENTS ORDERING PARTS IFC SECTION 3 OPERATION continued PREFACE Tur cue Loading the 3 13 Attaching a Container to the Packer 3 13 WARRANTY Using a Winch or Container Lift Cylinder
112. lar The spool collar is under spring tension and caution should be used when removing NOTE It may be necessary to turn the pressure adjust ment screw 1 clockwise until it is recessed far enough to allow removal of the spool collar Remove outer spool collar 4 spool centering spring b and inner spool collar 7 Carefully slide the detent sleeve assembly 16 off the spool The detent balls 9 will be free to fall out when the sleeve is slid off Remove spring 17 KO ramp 15 dowel pin 8 piston 14 spring pad 13 inner spring 10 and KO poppet 12 Remove o ring from counter bore of valve body Remove the four 4 capscrews which secure the linkage side cover bracket to the valve body work section Remove retainer plate retainer plate washer and o ring seal Do not remove the valve spool as the seals can be replaced externally The removal of the 3500 Ib relief valve load check and blanking plug are taken off as assemblies and repairs are limited to o ring replacement or com plete cartridge assembly REASSEMBLY OF KNOCKOUT POSITIONER 1 With all o ring seals removed and counterbores thoroughly clean lightly oil the new seals Slide over the valve spools and insert in the seal coun terbores Replace all seals in the knockout position prior to reassembly Apply a liberal amount of general purpose grease to the spring pad 13 inner spring 10 and the KO poppet 12 and insert the
113. ld the pushout control lever observe the reading on the gauge 8 The pressure should be at 1950 PSI 135 BAR plus or minus 100 PSI 7 BAR IF NOT 9 Perform TEST FOR LEAKING Pushout CYLIN DER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again check gauge for correct pressure IF NOT 10 Replace the two stage workport relief PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 1950 PSI TWO STAGE WORKPORT RELIEF Hil MAIN RELIEF TEST COUPLER MAIN RELIEF 7 13 SECTION 7 CHECK OUT CHECK RESISTANCE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 1 Move pushout control lever to fully extend the pushout cylinder OPERATIONAL STATUS Truck Off PTO Disengaged 2 Connect a porta power with a gauge to the work port relief test coupler 3 Slowly pump the porta power and read the gauge to see what pressure the two stage workport relief cracks open at The pressure should be 1100 PSI 76 BAR IF NOT 4 Verify all pressure in the signal line is relieved by moving the tailgate control lever forward to relieve any pressure in the circuit Repeat step 3 IF NOT 5 Disconnect signal line at the two stage workport relief 6 Loosen locknut and adjust the relief If reading was below 1100 PSI
114. le OPERATIONAL STATUS Truck Running PTO Engaged Sol On Sw CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down and clamped securely 2 Move the carrier and packer panel levers to position the carrier and packer cylinders in the retract posi tion 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 7 1 7 CHECK OUT CHECK ENGINE SOLENOID SWITCH OPERATIONAL STATUS Truck Running PTO Engaged Sol 6 n Sw IF ENGINE SPEEDS UP OPERATIONAL STATUS Truck Off PTO Disengaged The system is grounded Locate the short and repair as described under ELECTRICAL SYSTEM in Sec 9 SERVICE AND REPAIR CHECK ENGINE SPEED UP SWITCHES OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Depress the engine speed up pushbutton The engine should speed up IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged
115. lection and Compaction Equipment Safety Requirements ANSI Z245 1 1992 Before operating this unit please read and understand the safety precautions found in Section 1 of the Service and Operators manual They are important and are provided to assist you in the safe operation of the unit This manual was produced with the intention of providing clear concise instructions for the prop er operation and servicing of your refuse packer It was produced with the latest information available at the time of publication We do however reserve the right to redesign and or dis continue the manufacture of parts components or assemblies at any time The Leach Company has an aggressive manual and product improvement program In any conversation or 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 reference We ask that if you have comments or suggestions concerning this manual please contact us at 920 231 2770 We are here to be of service to you our valued customers _LEACH Original Factory Parts LEACH WARRANTY LEACH SILVE
116. lk around inspection of the refuse packer in accordance with the 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 Service manual 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 h
117. ll 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 visual 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 REPLACEMENT OF FILTER ELEMENT See Hydraulic System Illustration Qr ON 0x Remove filter cover 4 Remove o ring 5 Remove element 6 and discard Install a new element 6 Coat a new o ring 5 with fresh hydraulic fluid and install in filter cover 4
118. lower 12 outer spring 11 and spring Install spool collar 5 and torque to 32 in Ibs 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 LEACH 9 38 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 manual ly activated and controls the raising and lowering of the tailgate and the operation of the pushout panel This valve 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 Workport Relief Test Coupler Main Relief Two Stage Test Coupler Workport Relief Main Relief Signal Line 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 a
119. luid when retracted great ly reducing the chances of damage by means of rust corrosion etc Visual inspection of the tailgate cylinders is the only leakage test necessary for this design cylinder Check the cylinder rods for damage such as scratches nicks etc If any external leakage is present repair the cylin der as described under the removal and disassembly guidelines REMOVAL OF TAILGATE LIFT CYLINDER OPERATIONAL STATUS Truck Off Keys Removed 1 With the tailgate closed attach a sling connected to a suitable lifting device with a minimum lifting capacity of 500 Ibs to the tailgate lift cylinder NOTE See Section 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 base and cap the line 3 Remove the adapter 2 restriction pin 3 and plug the cylinder port 4 Remove the capscrew 4 washer 5 and retainer 6 from the cylinder end 5 Remove the capscrew 7 lockwashers 8 retain er 9 and pin 10 9 SERVICE AND REPAIR DISASSEMBLY OF TAILGATE LIFT CYLINDER 1 Wash the outside of the cylinder assembly com surface of the exposed section of the cylinder rod pletely to prevent contamination and or damage to about 1 2 way up the cylinder rod The tape should the cylinder components be applied in a diagonal fashion on the rod 2 Secure the ca
120. m come on Never use controls or hoses for hand holds 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 Stand 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 pressure in 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
121. n solenoid switch ON ii M MAIN RELIEF TEST COUPLER SECTION 7 CHECK OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Depress speed up button 2 Move pushout control lever to fully retract pushout cylinder 3 Hold lever and read gauge Pressure should be at least 2300 PSI 157 BAR but no more than 2400 PSI 165 BAR IF NOT 4 Perform TEST FOR LEAKING Pushout CYLINDER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again check gauge for correct pressure PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 2300 PSI TWO STAGE WORKPORT S RELIEF 5 on eels N R NR SE MAIN RELIEF TEST COUPLER MAIN RELIEF LEACH 7 12 SECTION 7 CHECK OUT CHECK PUSHOUT PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Connect a gauge to the workport relief test coupler 2 Start the unit engage the PTO and turn the sole noid switch on 3 Unlatch both tailgate clamps 4 Depress speed up button 5 Move the tailgate control lever to the rear to fully raise the tailgate NOTE The tailgate lift time is 24 to 28 seconds 6 Move the pushout control lever to the rear to fully extend the pushout cylinder 7 While continuing to ho
122. n the retracted position to check the hydraulic fluid level TAILGATE CLAMPS 6 Make sure all operating levers are in the neutral position Check a Packer panel lever b Carrier panel lever c Pushout lever d Tailgate lift lever e Container handling levers Never operate the unit with any part of the con trol system or levers removed or serious dam age will result Never under any circumstances enter the body if the truck is running Open the packer panel and release any pressure in the pushout cylin der before entering the body Always make sure the truck engine is off and the keys are in your pocket before entering the body PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON SIGNAL PUSH BUTTON CONTAINER HANDLING CONTROL LEVERS PACKER PANEL LEVER 3 7 OPERATION 7 Look around the pushout panel area Clean out any refuse caught in this area that could possibly hamper the pushout panel operation Never under any circumstances enter the body if the truck is running Open the packer panel and release any pressure in the pushout cylinder 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 manufacturers instructions and while it is warming up continue the
123. n the ring and the groove in the cylinder Continue to use the screwdrivers as pry bars and hang the remaining clips The clips 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 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 case the retaining rings 6 should be installed packings 4 replaced and the head nuts 3 rein stalled 9 46 9 SERVICE AND REPAIR DESCRIPTION OF LEACH HYDRAULIC PUMP 203834 The pump which serves the complete hydraulic system is a gear type coupled to the PTO shaft through a yoke arrangement It is usually mounted under the body near the front end curb side The Leach pump can run in either direction clockwise or counterclockwise rota tion The locations of the suction and pressure hoses are determined by the direction of rotation it is there fore imperative to install hoses correctly PUMP REMOVAL OF HYDRAULIC PUMP 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
124. nd clamped securely 2 Move the carrier and packer panel levers to position the carrier and packer cylinders in the retract posi tion 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 7 9 SECTION 7 CHECK OUT CHECK ENGINE SOLENOID SWITCH OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw IF ENGINE SPEEDS UP OPERATIONAL STATUS Truck Off PTO Disengaged The system is grounded Locate the short and repair as described under ELECTRICAL SYSTEM in Sec 9 SERVICE AND REPAIR CHECK ENGINE SPEED UP SWITCHES OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 1 Depress the engine speed up pushbutton The 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 2 Activate carrier panel lever Engine should speed up IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or swi
125. nd 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 HANDLE TIE BOLT v m OUTLET PUSHOUT NOTE Do not remove the spool from the valve body as the seals can be replaced externally 9 39 9 SERVICE AND REPAIR 5 Remove retainer plate retainer plate washer and o RETAINER ring seal PLATE TWO STAGE WORKPORT 6 Thoroughly clean center bore RELIEF 7 To remove the bonnet remove two 2 capscrews securing the bonnet to the work section 8 The spool positions is now exposed for inspection and repair Remove the capscrew securing the x j SPOOL spring collar to the valve spool O S Ve 9 Remove the spring collar and spring to expose the lt i retainer plate retainer plate washer and o ring seal PA 10 Thoroughly clean counterbore MAIN RELIEF BONNET 11 The removal of the two stage workport relief is accomplished in two 2 steps First remove the
126. nd pressure plate 3 into rear housing 1 NOTE Pressure plates must be assembled with the traps opening to the outlet side of the pump 4 Carefully lower gears 4 into the rear housing 1 Install the gears one at a time 5 Install pressure plate 6 and pressure balance 2 6 T 8 9 10 11 Install o ring 8 into groove in rear housing 1 Lubricate the gear shaft extensions with grease to protect lip seals Install seals 12 and snap rings 13 into front housing 9 as described in steps 1 6 of the replac ing seals instructions Install dowels 7 into holes in rear housing 1 Carefully lower front housing 9 with seals installed onto rear housing 1 Insert washers 11 and capscrews 10 Tighten opposite and even to 80 ft Ibs 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 disassemble find the problem and carefully reassemble the pump Be sure to wear eye protection 9 53 9 SERVICE AND REPAIR INSTALLATION OF HYDRAULIC PUMP 307451 01 OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install pump in the reverse order of removal NOTE Fill pump with clean hydraulic oil up to the threads of the ports for the pressure and suction hoses Make sure the hoses are installed correctly 2 Be sure to reinstall any shaft
127. ng LEACH 4 2 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 10 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
128. ng seals 3 Thoroughly clean the o ring counter bores and ground surfaces of each section BONNET BONNET 3500 LB RELIEF KNOCKOUT POSITIONER O RINGS TIE BOLT 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 83 8Nm 3 Torque the 3500 Ib relief cartridge load check and blanking plugs to 20 ft Ibs 27 Nm ACCESSORY SECTIONS PACKER O RING SECTION OUTLET CARRIER COVER SECTION 9 37 SERVICE AND REPAIR D E LTA DISASSEMBLY AND INSPECTION OF KNOCKOUT POSITIONER 1 Remove bonnet screws 1 and bonnet 2 5 Carefully slide detent sleeve 8 off the spool The 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 Remove back up ring and o rin
129. ning 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 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
130. nsion stroke completed pressure builds to knock out setting causing the operating valve to shift TAILGATE LIFT CYLINDER SAS NESS CA T HYDRAULIC FLUID TANK hs ws FRONT CONTROL J VALVE CARRIER NA 4 AS PUSHOUT NI SP CYLINDER K PUMP 4 lt CARRIER CYLINDER TAILGATE LIFT CYLINDER PACKER CYLINDER 7 2 PRESSURE RETURN 8 13 8 TROUBLESHOOTING PACKING REFUSE OPERATOR ACTION None Operating Valve shifts automatically HYDRAULIC SEQUENCE Fluid flows from the operating valve to the rod end of the carrier panel cylinders The cylinders retract moving the carrier and packer panels up packing refuse against the pushout panel When the pressure reaches the knockout setting the operating valve shifts into neutral and the packing cycle is completed As the carrier cylinders apply force to compact refuse the pressure 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 pres sure by allowing some trapped fluid to escape and return to the hydraulic tank TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK NC PUSHOUT CYLINDER SHE CYLINDER A TAILGATE LIFT CYLINDER PACKER CYLINDER PRESSURE RETURN mam m TRAPPED LEACH 8 14
131. od 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 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 WELDING 1 Completely clean out an old weld before rewelding 2 When repairing a cracked weld the old weld should be completely removed before rewelding 3 When adding a part or attachment be sure the metal is clean before welding the part is properly located and the weld will not cause damage to adjacent parts 4 Use the following rods rod AWS number for welding Body except top hinge area Top hinge Tailgate x iux eim tds Be eS Carrier plate 5 Use ER 70S 6 wire for all locations MeO ne HOE Seah scr d a E6010 E6011 E6013 EET E7018 see d Y Neat eee tio a ox e s E6010 E6011 E6013 DUET EET E6010 E6011 immor uiu e quee UE Reed m E7018 LE
132. olled up lapped edge that adjoins the pressure plate Do not force or bend the pressure plate 8 Remove the bottom isolation plates 9 sealing strips 11 end separators 7 center separator 8 back up rings 5 and o rings 6 Clean all the internal parts with solvent and blow dry Inspect all parts carefully Be sure to wear eye protection REPLACING SHAFT SEALS ON THE HYDRAULIC PUMP N Oa PF ON Remove the flange cover 15 from pump as described in steps 1 4 of the Disassembly Instructions First drive out the old wiper 20 Remove snap ring 19 and then the seal 18 Clean the flange cover 15 in solvent and blow dry Press in a new seal 18 Install snap ring 19 and a new wiper 20 Install the flange cover 15 as described in steps 12 16 of the Reassembly Instructions 9 48 9 SERVICE AND REPAIR REASSEMBLY OF HYDRAULIC PUMP 203834 1 2 Place the body 1 so the scribe mark faces you For easier assembly use clean hydraulic fluid as a lubri cant Install o rings 6 and back up rings 5 on the protrud ing ends of the bearings at the bottom of the body Examine the four isolation plates Note that one pair is slightly different from the other pair Choose the two that have the rounded outer edges 9 and install them in their proper location at the bottom of the body bore with the rounded edges facing down Install end separators
133. out Cylinder Will Not Extend to Push Qut Loads Gores ane Sad 8 7 Packer Panel Drifts Open While Packing Load Into 8 7 Cycle Time is Too Slow 8 7 Tailgate Will Not Raise 8 8 Container Won t 8 8 Winch Motor 8 8 Container Raises Very Slowly 8 8 TABLE OF CONTENTS SECTION 8 TROUBLESHOOTING continued Description of Hydraulic System 8 9 System Component Nomenclature 8 9 System Flow 8 10 SECTION 9 SERVICE AND REPAIR General eue aimer is 9 1 Description of 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 8 ALPHA White Pages Disassembly of Packer Panel Cylinders 9 9 Inspection and Replacement 9 9 Reassembly and Installation 9 9 Disassembly of Carrier Panel Cylinders 9 10 Inspection and Replacement 9 10 Reassembly and Installation 9 10 BETA Blue Pages Disassembly of Packer Panel Cylinders 9 11 Inspection and Replacement 9 11 Reassembly and Installation 9 11 Disassembly of Carrier Panel Cylinders
134. peed up button 1b Only partially pull feather the 2 spool valve control handle POSSIBLE CAUSE REMEDY 1 Less than full pressure in pushout cylinder 2 The operator is trying to push the load out against a pile of refuse dirt or bank of a hill 1a Perform test for leaking cylinder and repair 1b Adjust main relief pressure See Sec 9 Service and Repair 2 Move the unit forward to finish unloading PUSHOUT PANEL SLIDES FORWARD TOO FAST WHILE PACKING REFUSE POSSIBLE CAUSE 1 Oylinder bypassing 2 Resistance setting too low REMEDY 1 Perform test for leaking cylinder 2 Adjust resistance setting PUSHOUT PANEL WILL NOT SLIDE FORWARD AUTOMATICALLY POSSIBLE CAUSE REMEDY 1 Resistance setting too high 2 Packer panel not applying full force to move pushout panel forward 1 Reduce resistance setting 2a Check pressures 2b Check pump CARRIER AND PACKER PANEL STOP SHORT OF HOME POSITION AFTER EACH CYCLE POSSIBLE CAUSE REMEDY 1 Unit full 2 Resistance too high 3 Packer panel does not deliver full force 1 Empty unit 2 Reduce resistance setting 3 See Section 8 Troubleshooting LEACH 8 6 SECTION 8 TROUBLESHOOTING PUSHOUT CYLINDER WILL NOT EXTEND TO PUSH OUT LOAD PACKER PANEL DRIFTS OPEN WHILE PACKING LOAD INTO BODY POSSIBLE CAUSE Operator trying to push load out against pile of refuse dirt or
135. ption of Operating Controls 3 1 Lubricants 2 ead PIE dees 5 1 Location of Operating Controls 3 2 Operating Procedures 3 6 Pre operating Walk around Inspection 3 6 Walk around Inspection Checklist 3 10 SECTION 6 PREVENTIVE MAINTENANCE Start Up Operating Instructions 3 11 General hoy geste eles Rd excede ea 6 1 Positioning Pushout Panel 3 12 Operating and Maintenance Records 6 1 LEACH TABLE OF CONTENTS SECTION 6 PREVENTIVE MAINTENANCE continued Lubrication Chart 6 2 Hydraulic System Service 6 4 Checking Fluid Level Daily 6 4 Clean Tank Breather Weekly 6 4 Check Replace Return Line Filter Element 6 4 Replacement of Filter Element 6 4 Cleaning Hydraulic Strainer Monthly 6 4 Flushing Hydraulic System Yearly 6 5 Hydraulic System Service 6 6 Contamination 6 6 Commercial Hydraulic Fluid Testing 6 6 In House Fluid Testing 6 6 Preventive Maintenance Requirements 6 7 Daily Preventive Maintenance 6 7 Weekly Preventive Maintenance 6 8 Yearly Preventive Maintenance 6 9 SECTION 7 CHECK OUT ALPHA White Pages General soe attri b oen 7 1 Check Hydraulic Tank Fluid Level
136. r panel lever inward to completely retract the cylinder PACKER CARRIER PANEL X 6 PANEL LEVER LEVER CAPSCREW NUN 9 7 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off Keys Removed 7 Disconnect both the case end and rod end hoses Immediately cap or plug the hoses and cylinder ports to keep fluid in and dirt out 8 Remove capscrew from the case end 9 Remove the pivot pin by using pin puller See Sec 10 SERVICE TOOLS 10 Check for pivot pin or pin hub wear PLUG REMOVAL OF CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off Keys Removed 1 Remove the topsheets to provide better accessibil ity NOTE See Sec 4 GENERAL HEPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Secure a chain to the lower end of the carrier panel Attach the other end to a suitable lifting device with a minimum lifting capacity of 1 600 Ibs Adjust the hoist so that it will support the panel once the carrier cylinders are removed 3 Once the carrier panel has been securely support ed secure a nylon sling around the carrier cylinder and attach to a lifting device with a minimum lifting capacity of 500 Ibs Operate the hoist to snug the lifting sling without applying strain to the cylinder 4 Remove the capscrew from the rod end Carefully remove the pivot
137. r the operator s safety will be jeopardized by the service methods selected Any person who modifies their equipment must do so in accordance 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 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
138. r to fully retract pushout cylinder 3 Hold lever and read gauge Pressure should be at least 2300 PSI 157 BAR but no more than 2350 PSI 162 BAR IF NOT 4 Perform TEST FOR LEAKING Pushout CYLIN DER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again check gauge for correct pressure PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON WORKPORT RELIEF TEST COUPLER 2300 PSI TWO STAGE 773 WORKPORT S RELIEF T E MAIN RELIEF TEST COUPLER MAIN RELIEF LEACH 7 20 DELTA SECTION 7 CHECK OUT CHECK PUSHOUT PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Connect a gauge to the workport relief test coupler 2 Start the unit engage the PTO and turn the sole noid switch on 3 Unlatch both tailgate clamps 4 Depress speed up button 5 Move the tailgate control lever to the rear to fully raise the tailgate NOTE The tailgate lowering time is 24 to 28 seconds 6 Move the pushout control lever to the rear to fully extend the pushout cylinder 7 While continuing to hold the pushout control lever observe the reading on the gauge 8 The pressure should be at 1950 PSI 135 BAR plus or minus 100 PSI 7 BAR IF NOT 9 Perform TEST FOR LEAKING Pushout CYLIN DER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again ch
139. rdware 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 replaced as described in Sec 9 SERVICE AND REPAIR CHECK OUT PROCEDURES Each week perform the CHECK OUT PROCE DURES listed in Sec 7 of this manual CONTAINER HANDLING SYSTEM HARDWARE Check all container handling system hardware to make sure that no damage exists and that all fas teners are secure PIVOT POINTS Check all pivot points for wear and smooth opera tion 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
140. re adjust ment screw 1 clockwise until it is recessed far enough to allow removal of the spool collar Remove outer spool collar 4 spool centering spring b and inner spool collar 7 Carefully slide the detent sleeve assembly 16 off the spool The detent balls 9 will be free to fall out when the sleeve is slid off Remove spring 17 KO ramp 15 dowel pin 8 piston 14 spring pad 13 inner spring 10 and KO poppet 12 Remove o ring from counter bore of valve body Remove the four 4 capscrews which secure the linkage side cover bracket to the valve body work section Remove retainer plate retainer plate washer and o ring seal Do not remove the valve spool as the seals can be replaced externally The removal of the 3500 Ib relief valve load check and blanking plug are taken off as assemblies and repairs are limited to o ring replacement or com plete cartridge assembly REASSEMBLY OF KNOCKOUT POSITIONER 1 With all o ring seals removed and counterbores thoroughly clean lightly oil the new seals Slide over the valve spools and insert in the seal coun terbores Replace all seals in the knockout position prior to reassembly Apply a liberal amount of general purpose grease to the spring pad 13 inner spring 10 and the KO poppet 12 and insert these parts into the piston 14 Slide this assembly into the end of the valve spool and push into place Insert the dowel pin 8 and slide
141. se end of the cylinder to a workbench 9 Push the rod back into the case then again using or floor mount and the rod end to an overhead lift the overhead lifting device extend the rod 1 2 way ing device with a minimum lifting capacity of 500 out The cylinder packing should slide out with the Ibs taped section of the rod If not repeat until the 3 Remove the plug from the port and drain all fluid packing slides out Slide the packing off of the rod 4 Remove the 1 4 socket head setscrew from side of and discard the cylinder case and discard 10 Using a long screwdriver or pick remove the retain 5 Remove the bleeder screw and gasket from the ing ring from the inside of the cylinder between the end of the cylinder rod Save these for reassembly case and the rod Use care to avoid damage to the 6 Unscrew the head gland from the cylinder case case or rod surfaces Slide the retaining ring off of completely Slide the head gland off of the the rod the rod and discard 7 Using the overhead lifting device carefully extend 11 Slide the rod assembly out of the case the cylinder rod approximately 1 2 way out of the 12 Remove the wear ring from the bottom of the cylin case der rod and discard 8 Apply a 6 piece of 1 masking tape to the chrome 13 Remove the wiper from the head gland INSPECTION REASSEMBLY AND INSTALLATION 1 Thoroughly check all components of the cylinder for is not to be installed immediately keep the port cr
142. se is first loaded into the Delta The tailgate is raised for unloading and lowered by the tail gate lift cylinders which are actuated by the tailgate lift lever 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 Keys Removed 1 Release the tailgate clamps Disconnect and remove the tailgate lift cylinders as described earlier in this section 3 Disconnect and cap the hydraulic lines 4 Disconnect the electrical conduit and wires from the junction box on the tailgate NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains CHAINS 5 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 7 500 Ibs to the tailgate as shown Operate the lifting device no more than necessary to support the weight of the tailgate 6 Remove the capscrew 1 lockwasher 2 retainer 3 and hinge pin 4 7 Operate the lifting device and or move the truck to free the tailgate from the body 8 Position the tailgate on supports if needed to facili tate repairs Supports must be capable of support ing a minimum of 7 500 Ibs
143. se parts into the piston 14 Slide this assembly into the end of the valve spool and push into place Insert the dowel pin 8 and slide 17 over end of the KO ramp 15 Insert this assembly into the end of the valve spool and push into place Apply a liberal amount of general purpose grease into the detent ball holes 9 in the valve spool and push into place 6 10 11 Insert one detent ball 9 into each hole and care fully slide the detent sleeve assembly 16 includ ing the seals and retainers over the valve spool into place next to the valve housing Insert the adjustment screw 1 into the spool collar 6 from the inside and turn a few revolutions Do not turn the adjustment screws in too far or it will interfere with installation of the spool collar Slide inner spring collar 7 centering spring 5 and outer spring collar 4 onto end of valve spool While holding in place screw the spool collar 6 into the spool end Torque the spool collar 6 to 10 12 ft Ibs 13 6 16 3 Nm Reassemble parts in reverse order of disassembly Torque the bonnet screws and linkage end bracket to 60 in Ibs 6 75 Nm LEACH 9 30 SERVICE AND REPAIR MAIN CONTROL VALVE MAIN CONTROL VALVE The main control valve is located on the tailgate above the packer and carrier panels The valve controls the operation of the packer and carrier panels through the entire packing cycle It may have ad
144. semble the cylinder PISTON SEALS ROD WIPERS SEALS O RINGS o CASE BUSHING PISTON ROD GLAND RETAINER BUSHING LEACH 9 14 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF THE TAILGATE LIFT CYLINDERS These two 2 hydraulically operated cylinders mount ed 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 der weldment pivot ear is attached to a mounting hub on the tailgate The cylinders raise the tailgate by means of hydraulic fluid flowing through a port on the case end of the cylin der extending the cylinder The tailgate is lowered by the weight of the tailgate forcing oil from the cylinder ue E CHECK FOR LEAKING TAILGATE LIFT CYLINDER The tailgate lift cylinder utilizes a design that does not incorporate a cylinder piston such as a typical cylinder would This cylinder incorporates a hollow piston rod to allow the hydraulic fluid to extend the rod by applying pressure to the inside of the rod The rod is ported to allow hydraulic fluid to pass from the area between the rod and the case to inside the case When the cylinder is being retracted fluid is then allowed to pass through this porting from the inside of the rod to the area between the rod and the case Therefore the cylinder rod is protected in hydraulic f
145. shboard switch 6 Remove key 7 Lock vehicle 1 5 SECTION 1 SAFETY PRECAUTIONS BOY J AD S 2 2d St PACKER Temm PACKER m SPEED UP Both container latch arms must be in place and latched before raising container CARRIER CARRIER CARRIER Stand clear when container dumping mechanism is in motion SECTION 1 SAFETY PRECAUTIONS 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 Both container latch arms must be in place and latched before raising container SECTION 1 SAFETY PRECAUTIONS BEACON LIGHT DRIVER SIGNAL on OFF 3 Oo PACKER PACKER PACKER ENGINE SPEED UP AWARNING CAR RI R Rotating power take oa e off shaft hazard CARRIER a 4 Do not enter under CARRIER chassis unless engine is stopped and key removed A CAUTION Serious pump damage will result if pump is 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 me WARNING YOU MUST si
146. sition 3 4 SECTION OPERATION DRIVER SIGNAL PUSH BUTTONS 8 These two push buttons one located on each side of the tailgate are connected to a buzzer mounted under the dri vers seat or under the dash in the chassis cab The oper ator depresses one of these push buttons to signal the dri ver when the loading operation is completed and the truck is ready to be moved DRIVER SIGNAL PUSH BUTTON 227 e oh e PACKER AND CARRIER PANEL OPERATIONAL LEVERS 9 10 The packer panel operational control lever is located on the right curb side of the tailgate It is used by the oper ator to position the packer panel open or closed during the compaction cycle operation NOTE The engine speed up system does not engage if only the packer panel lever is shifted The carrier panel lever must also be shifted to engage the engine speed up system The carrier panel operational control lever is located on the right curb side of the tailgate It is used by the oper ator to position the carrier panel up or down during the compaction cycle NOTE The engine speed up system automatically engages any time the carrier panel lever is shifted SIGNAL PUSH BUTTON CONTAINER HANDLING CONTROL LEVERS PACKER PANEL LEVER COMPACTION CYCLE OPERATION Both the packer panel lever and the carrier panel lever are shifted simult
147. ssary Service and Repair 7 Check out POSSIBLE CAUSE REMEDY 1 Hydraulic pressure incorrect 2 Hydraulic fluid in tank is low 3 Tank strainer screen is dirty this condition will starve pump and cause noise in the system 4 Wrong type of hydraulic fluid in system 5 Main relief section of 2 spool directional valve opens too soon 6 Hydraulic pump is defective and will not deliver full pressure 7 Operating cylinder piston seal is leaking 8 Operating valve pressures are too low 9 Air in hydraulic lines Perform checkout procedures through pres Add fluid to correct level See Sec 6 Service system as described in Sec 6 Drain and refill with correct type of hydraulic Adjust main relief setting on 2 spool valve Replace pump See Sec 9 Service and Perform test for leaking cylinder See Sec 9 Perform pressure checks See Sec 7 Check Cycle packer 6 or 7 times to bleed air out of sure checks See Sec 7 Check out Preventive Maintenance Preventive Maintenance fluid See Sec 5 Specifications See Sec 9 Service and Repair Repair Service and Repair out system 8 5 8 TROUBLESHOOTING LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING PUSHOUT CYLINDER POSSIBLE CAUSE 1 Excessive fluid flow being forced through the main relief in the 2 spool valve LOAD WILL NOT PUSH OUT REMEDY 1a Release s
148. stem 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 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 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
149. t FL104 9 405 638 Carrier Cylinder Remove install fittings 2RII Fitting Wrench 10 2 LEACH
150. t to over tighten Replace the plastic plug 1 and setscrew 2 SINGLE STAGE PUSHOUT CYLINDER DISASSEMBLY 1 Prior to disassembling the cylinder first make four clips from thin steel These clips should be approx imately 020 thick 7 2 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 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to pre vent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up 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 pry bars and hang the remaining clips The clips 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 Clean inspect and replace the guide and piston rings 7 as necessary When ins
151. ta and Delta have been designed with the operator in mind However as with any industrial machinery especially those that are large and apply forces through hydraulic pressures the ultimate responsibility for safety rests with you the 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 Operator s Manual 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 WARNING AND CAUTION DECALS See the accompanying illustration for the location and label content of all safety decals 1 These decals must be obeyed at all times 2 These decals must be in place at all times Report any damaged or missing decals to the proper authority at once 3 Replacement decals can be ordered free of charge from your local authorized Leach distributor DANGER AWARNING A CAUTION DANGER WARNING AND CAUTION Throughout this manual DANGER WARNING and CAUTION notations accompanied by the International amp Hazar
152. tallation of Pushout Panel ALPHA White Pages Main Control Valve MCV Removal of the Main Control Valve MCV Disassembly and Inspection of the Main Control Valve MCV Reassembly of Main Control Valve MCV Disassembly and Inspection of the Knockout Positioner Reassembly of Knockout Positioner BETA Blue Pages Main Control Valve MCV Removal of the Main Control Valve MCV Disassembly and Inspection of the Main Control Valve MCV Reassembly of Main Control Valve MCV Disassembly and Inspection of the Knockout Positioner Reassembly of Knockout Positioner DELTA Pink Pages Main Control Valve MCV Removal of the Main Control Valve MCV Disassembly and Inspection of the Main Control Valve MCV Reassembly of Main Control Valve MCV Disassembly and Inspection of the Knockout Positioner Reassembly of Knockout Positioner Front Control Valve Removal of Front Control Valve FCV Disassembly and Inspection of Front Control Valve FCV Reassembly of Front Control Valve FCV Reinstallation of Front Control Valve FCV Removal of Pushout Cylinder Single Stage Pushout Cylinder Single Stage Pushout Cylinder Packing Single Stage Pushout Cylinder Disassembly Telescopic Cylinder Packing Replacement
153. talling new rings the ends should be positioned on opposite sides of the tube to prevent leakage After the tube has been installed back into the case the retaining ring 6 should be installed packings 4 replaced and the head nut 3 rein stalled LEACH 9 44 9 SERVICE AND REPAIR TELESCOPIC CYLINDER PACKING ROD END REPLACEMENT 1 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to pre vent 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 to remove each head nut 5 Using a suitable lifting device attached to the rod 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
154. tch and repair See Sec 9 SERVICE AND REPAIR ELECTRICAL SYSTEM PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON SIGNAL PUSH BUTTON CONTAINER HANDLING CONTROL LEVERS 7 10 SECTION 7 CHECK OUT CHECK PACKING CYCLE TIME OPERATIONAL STATUS Truck Running PTO Engaged Sol 6 n Sw 1 Activate both the packer panel lever and carrier panel lever Using a stopwatch time a complete cycle A complete cycle should take 29 to 31 sec onds IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 2 Adjust the cable length between the solenoid or air cylinder and throttle linkage as needed to obtain the correct cycle time NOTE It is important the the cycle time is correct before performing the following pressure checks SOLENOID SIGNAL PUSH BUTTON PACKER PANEL LEVER LENGTHEN FOR LONGER CYCLE SHORTEN FOR SHORTER CYCLE lt gt CHECK PRESSURES The pressure checks provided below will indicate the operating condition of the hydraulic system Detailed adjustment procedures are provided later in this section and are referenced at the appropriate 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 main relief test coupling 2 Start the unit engage the PTO and tur
155. te is removed the carrier panel can be supported ore removed as necessary for repair ROLLERS TRACK BAR REPLACEMENT Refer to Sec 4 GENERAL REPAIR INSTRUCTIONS for welding instructions 1 Remove the old track bar and make sure the track channel is smooth and clean 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 2 Weld the new track bar into place The surface of the track bar must be 90 from the side of the tail gate so the roller will run true WRONG gt THIS ANGLE MUST BE 90 15 5 RIGHT FLAT NO GAP 9 23 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CARRIER PANEL 3 Inspect the tailgate channel track bars for exces OPERATIONAL STATUS sive wear or damage 4 Replace parts as necessary Truck Off Keys Removed 5 The roller shaft bushings may be removed using a pin puller See Sec 10 SERVICE TOOLS which screws in the bushing plug 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 NO BUSHING O Cp BUSHING PLUG INSTALLATION OF CARRIER PANEL Install the carrier panel in the approximate reverse order of disassembly Pay particular attention to the installation of the roller and bearing assemblies as described earli
156. tely keep the ports sealed to prevent contamination NOTE from entering the cylinder 6 Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder Use an electric drill with an internal grinding wheel NOTE from the int th Special tools listed in Section 10 SERVICE li Otherwise the cyli diffi Dee ee EEEE TOOLS be necessary to properly reassemble cult to take apart the cylinder PISTON SEALS ROD WIPERS SEALS O RINGS CASE BUSHING PISTON ROD BUSHING LEACH 9 10 9 SERVICE AND REPAIR DISASSEMBLY OF PACKER PANEL CYLINDERS Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Section 4 General Repair Practices before proceeding to disassemble the cylinder Secure the case end of the cylinder to the floor or workbench Secure the rod end of the cylinder to an overhead hoist device with a minimum lifting capacity of 500 Ibs Remove the setscrew from the gland retainer Remove the gland retainer Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder NOTE Use an electric drill with an internal grinding wheel to remove any burrs from the internal groove on the cylinder case Otherwise the cylinder may be diffi cult to take apart ROD WIPERS SEALS O RINGS
157. teps 1 and 2 each time the hopper is filled to but not above the loading edge SIGNAL PUSH BUTTON PACKER PANEL LEVER 3 15 OPERATION PUSHOUT PANEL OPERATION DURING PACKING 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 necessary to manually retract the pushout cylin der in order to allow the compacted refuse to move for ward in 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 PUSHOUT LEVER TAILGATE LIFT LEVER SPEED UP BUTTON DISCONNECTING THE CONTAINER Once the container is empty it should be lowered to the ground the latch arms released and the cable disconnected il DISCONNECTED Lo d o 3 16 SECTION OPERATION UNLOADING AT DUMPSITE Do not unload uphill or against a pile of refuse 1 Apply the 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
158. 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 When it becomes necessary to raise the tailgate for maintenance or repair do not enter the area beneath the tailgate unless the proper bracing has first been applied All bracing and supports must be able to support 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 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 a well venti lated area 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 clothi
159. this section and are referenced at the appropriate check out proce dure Prior to performing pressure checks OPERATIONAL STATUS Truck Off PTO Disengaged Install a gauge capable of reading at least 3000 PSI 207 BAR on the main relief test coupling Start the unit engage the PTO and turn solenoid switch ON MAIN RELIEF TEST COUPLER LD DE ci y MM 7 3 CHECK OUT ALPHA CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Sol PUSHOUT en LEVER W TAILGATE LIFT LEVER 1 Depress speed up button 2 Move pushout control lever to fully retract pushout cylinder Hold lever and read gauge Pressure should be at SPEED UP least 2150 PSI 148 BAR but no more than 2200 BUTTON PSI 152 BAR IF NOT 4 Perform TEST FOR LEAKING Pushout CYLIN DER SEAL as described in Section 9 SERVICE AND REPAIR Start truck repeat steps 2 and 3 and again check gauge for correct pressure C 2080 gt 1000 30007 WORKPORT RELIEF TEST COUPLER 2150 PSI TWO STAGE 773 WORKPORT S RELIEF T E MAIN RELIEF TEST COUPLER MAIN RELIEF LEACH 7 4 ALPHA 7 CHECK OUT CHECK PUSHOUT PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged Connect a gauge to the workport relief test coupler Start the unit engage th
160. thoroughly and lubricate the new packing set inside and out with an all purpose grease 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 being careful not to overtighten 10 Replace the plastic plug 2 and setscrew 3 9 45 9 SERVICE AND REPAIR TELESCOPIC CYLINDER DISASSEMBLY ROD END 1 Prior to disassembling the cylinder first make four clips from thin steel These clips should be approx imately 020 thick 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 pre vent 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 betwee
161. uipment Before operating the vehicle the driver must be thoroughly familiar with the employer s safety pro gram concerning traffic rules warning devices and hand signals Know where to get assistance in the event of an emergency Know your machine Know the location and func tion of all controls gauges instruments and pro tective devices Wear your seat belt Start the engine following the manufacturer s rec ommended procedure Always set the parking brake before leaving the cab Turn on appropriate warning lights put on a safety 17 18 19 20 21 22 2 24 25 26 27 28 29 30 31 32 33 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 Ride 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 0 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 Stop the vehicle immediately if warning lights for the TAILGATE AJAR syste
162. ulic lines to the case end of the carrier panel cylinder PACKER CARRIER PANEL LEVER Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components PACKER CARRIER PANEL PANEL LEVER LEVER OBSERVE FLOW 9 6 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL CYLINDERS OPERATIONAL STATUS Truck Off Keys Removed 1 Position the packer panel to the interrupted cycle position and then sweep the packer plate to the vertical position OPERATIONAL STATUS Truck Running PTO Engaged Sol Sw 2 Remove the topsheets to provide better accessibil ity to the packer panel NOTE See Sec 4 GENERAL HEPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 3 Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device with a mini mum lifting capacity of 500 Ibs 227 kg Operate the hoist to make the lifting cable snug without applying strain on the cylinder OPERATIONAL STATUS Truck Off Keys Removed 4 Remove the capscrew from the rod end pin retain er 5 Make sure the cylinder weight is securely support ed by the hoist and carefully remove the pivot pin Check for pivot pin or pin hub wear OPERATIONAL STATUS Truck Running PTO Engaged Sol Off Sw 6 Slowly operate the packe
163. ump 4 Remove pressure balance 2 and pressure plate Scribe the rear housing 1 and the front housing 6 9 so they are marked for reassembly 5 Remove keys 5 from the gears 4 Remove gears 2 Carefully place the pump body in a vise and 4 pressure plate 3 and pressure balance 2 remove capscrews 10 and washers 11 3 Lift the front housing 9 from the rear housing 1 NOTE and remove o ring 8 Be sure dowels 7 do not Care should be taken not to bend or damage the fall out pressure plates 6 Clean and dry all parts Inspect parts carefully for Be sure to wear eye protection 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 LEACH 9 52 9 SERVICE AND REPAIR REASSEMBLY OF HYDRAULIC PUMP 307451 01 1 Place the rear housing 1 with the opening up and the scribe mark visible 2 For easier assembly use clean hydraulic fluid as a lubricant 3 Install pressure balance 2 a
164. ve 4 Solenoid to carburetor or governor cable is broken 5 Electrical system not grounded properly 6 Carrier panel lever speed up switch or linkage defective 7 Solenoid mounting loose broken or incorrect 8 Truck engine mounts loose worn broken or missing Repair broken wire See Electrical System Replace fuse and check electrical system for Check for and replace defective parts as Replace cable Check all ground connections for corrosion or Repair replace or adjust as required Be sure solenoid mounting is correct and Repair or replace engine mounts as required REMEDY Sec 9 Service and Repair shorts See Electrical System Sec 9 Service and Repair described in the Electrical System Section See Sec 9 Service and Repair breaks Clean or repair as described in the Electrical System Section See Sec 9 Service and Repair Secure ENGINE SPEED WILL NOT RETURN TO NORMAL WHEN PACKING CYCLE IS COMPLETED OR SPEED UP BUTTON IS RELEASED POSSIBLE CAUSE 1 Short circuit in electrical system 2 Carrier panel lever speed up switch is defective 3 Solenoid mounting loose broken or incorrect 4 Truck engine mounts loose worn broken or missing Check for and repair short in system as Repair replace or adjust as required Be sure solenoid mounting is correct and Repair or replace engine mounts as required REMEDY described in Electrical Sect
165. walk around inspection 9 Check all of the operating and running lights Make sure none are missing and that there are no burned out bulbs A WARNING 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 PUSHOUT LEVER 10 With the engine running the speed up solenoid TAILGATE switch ON the PTO engaged and the transmission in LIFT LEVER neutral and the brakes applied depress the speed up push button on the forward left street side of the body You should hear the engine speed up ACAUTION BUTTONS 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 LEACH 3 8 SECTION OPERATION 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 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 pos
166. will be in the home position COMPACTION When the operator starts the packing cycle the packer panel opens and the carrier and packer panels auto matically move rearward over the load PACKER PANEL MOVES OVER LOAD Next the carrier and packer panels automatically stop at the interrupted cycle position INTERRUPTED CYCLE 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 packer panels are back into the home position and the hopper is cleared for more refuse COMPACTION CYCLE Also during the compaction cycle considerable 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 As loading and compaction continues the pushout panel gradually moves forward until the body is full Once the body is full the unit can be moved to the dumpsite for unloading PUSHOUT PANEL MOVES FORWARD UNLOADING At the dumpsite the unit is unloaded in two easy steps First the tailgate is raised by the operator TAILGATE RAISED Second the pushout panel is moved to the rear of the body pushing out the load If the unit is going to travel ov

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