Home

New 2RII Service manual - Superior Truck Equipment Inc.

1. Positive displacement gear type driven by the PTO from the truck transmission either aw ads ta Ge Pura 42 gpm 1200 rpm LEACH HYDRAULIC FLUID RECOMMENDATION All Leach hydraulic systems are factory filled with a high quality anti wear hydraulic fluid meeting an ISO 32 spec ification On units put into service where there are high ambient temperatures or sustained high duty cycles it may be desirable to change the fluid to an ISO 46 specification higher viscosity In colder climates or light duty an ISO 22 might be more appropriate The International Standards Organization assigns specification numbers so that a consumer receives the same product from various suppliers GRADE 1 50 5 22 32 46 NO Lad gus 1 Gravity i cei es karte RR EROR 33 31 31 Flash F osi he ade eee eee ee 375 380 390 POUR POINT seii as is Pep n em cen 20 20 20 Viscosity SSU 100 E redia per RE REG Rd eb Ra 112 158 228 SSU Q 210 E css cete eee 40 44 48 OSLO 40 C leidas Ria peur qoa Pesto 21 30 5 44 CSE 100 Ci iz s 4 1 5 2 6 5 Viscosity Index e kk pee ero IR 98 99 99 ASTM Oxidation Test Hours to 2 0 Neut No 2500 2500 2500 ASTM Rust Test amp Foai TO
2. 6 7 Contamination 6 7 Commercial Hydraulic Fluid Testing 6 7 In House Fluid Testing 6 7 Preventive Maintenance Requirements 6 8 Daily Preventive Maintenance 6 8 Weekly Preventive Maintenance 6 9 Yearly Preventive Maintenance 6 10 SECTION 7 CHECK OUT General coa ds REN NOR aca 7 1 Check Hydraulic Tank Fluid Level 7 1 Check Engine Solenoid Switch 7 2 Check Engine Speed Up Switches 7 2 Check Packing Cycle Time 7 3 Check Pressures 7 3 Check Main Line Pressure 7 4 Check Packer and Carrier Panel Shifting Pressure 7 5 Check Resistance Cartridge Pressure 7 6 Check Pushout Shoes and Wear Blocks 7 7 Power Take Off 7 7 SECTION 8 TROUBLESHOOTING Geh ral asig ue Ras 8 1 Compaction 8 1 Dieseling in Hydraulic Systems 8 2 Operation is 8 3 Pump Noise is 8 3 Engine Will Not Speed Up When Carrier Panel Lever or Speed UP Button is Engaged 8 4 Engine Speed Will Not Return to Normal When Packing Cycle is Completed or Speed Up Button is Released 8 4 SECTION 8 TROUBLESHOOTING continued Packer Panel Valve
3. 9 23 SECTION 9 SERVICE AND REPAIR INTERRUPTED CYCLE POSITION CARRIER PANEL REMOVAL OF THE MAIN CONTROL VALVE 1 Place the packer and carrier panels in the interrupted cycle position PACKER PANEL 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 PACKER PANEL LEVER 3 Turn off the engine remove the keys CARRIER PANEL 4 Disconnect the shift linkage 5 Disconnect and cap all hydraulic lines and hoses PACKER PANEL 6 Plug all open ports on the valve to prevent contamina tion NOTE MAIN CONTROL VALVE MCV The main Control Valve MCV assembly and bracket weigh approximately 100 lbs Use appropriate lifting pro cedures and techniques when handling this assembly 7 Remove the capscrews washers and nuts holding the valve bracket to the tailgate 9 24 SECTION 9 SERVICE AND REPAIR DISASSEMBLY AND INSPECTION OF MAIN CONTROL VALVE 1 Wash the valve body with solvent to prevent conta mination NOTE Before disassembly it is suggested that each work section be marked numerically to avoid incorrect assembly 2 To separate valve sections from inlet or outlet cov ers remove the four 4 tie bolts which secure the valve sections and overs Separate carefully
4. CEA This unit conforms to all American HYDRAULIC National Standards Institute safety requirements Z 245 1 in effect on SPEED UP FLU ONLY the date of manufacture 4 LEACH FILTER ELEMENT CHANGE To ensure oil cleanliness and longer machine life change the element at intervals of 20hrs 50hrs and at EJECTION 250hr intervals thereafter EJECTION EJECTION ADD HYDRAULIC FLUID DO NOT FILL BEYOND THIS LINE DRIVER SIGNAL FE RANGE LL CYLS RETRACTED WARNING Youm SERVICE THIS vil You a g and experien n Stand clear when tailgate is in motion amp during unloading cycle TAILGATE not stand or Cees raised TA l LGATE TAILGATE A WARNING SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL PACKER PACKER PACKER CONTAINER DUMP CONTROL HYDRAULIC FLUID ONLY ENGINE _ SPEED UP This unit conforms to all American National Standards Institute safety requirements Z 245 1 in effect on DRIVER SIGNAL the date of manufacture Both container latch arms must be in place and latched before raising container FILTER ELEMENT CHANGE To ensure oil cleanliness and longer machine life change the element at intervals of 20hrs 50hrs and at 250hr intervals thereafter 7 NO STEP 9 CARRIER 10 emis CARRIER HYD PUSH BAR ME x CARRIER HYD PUSH BAR SEN HYD PUSH B
5. HANDLE TIE BOLT m OUTLET PUSHOUT NOTE Do not remove the spool from the valve body as the seals can be replaced externally 9 20 SECTION 9 SERVICE AND REPAIR Remove retainer plate retainer plate washer and o ring seal Thoroughly clean center bore To remove the bonnet remove two 2 capscrews securing the bonnet to the work section The spool positions is now exposed for inspection and repair Remove the capscrew securing the spring collar to the valve spool Remove the spring collar and spring to expose the retainer plate retainer plate washer and o ring seal Thoroughly clean counterbore The removal of the resistance cartridge is accom plished in two 2 steps First unscrew the adjust ment cartridge care should be taken as there are loose parts within the cartridge body Since the resistance cartridge consists of two 2 pieces the piston and seat components remain internal in the work section To remove the piston and seat remove the load check plug on the opposite side of the resistance cartridge With the plug removed the piston and seat can be tapped out with a Y drift It would not be necessary to use force to remove the piston and seat RETAINER PLATE RESISTANCE CARTRIDGE REASSEMBLY OF FRONT CONTROL VALVE With all o ring seals removed and counterbores thoroughly clean lightly oil the new seals Slide over spools and cartridges and insert the seal
6. SERVICE AND REPAIR DISASSEMBLY OF HYDRAULIC PUMP 307451 01 1 After removal thoroughly clean and dry the pump 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 2 Carefully place the pump body in a vise and gears 4 pressure plate 3 and pressure balance remove capscrews 10 and washers 11 2 3 Lift the front housing 9 from the rear housing 1 and remove o ring 8 Be sure dowels 7 do not NOTE fall out Care should be taken not to bend or damage the pressure plates 6 Clean and dry all parts Inspect parts carefully for Be sure to wear eye protection LL REPLACING SEALS IN FRONT HOUSING 1 Remove the front housing 9 as described in steps 1 3 of the disassembly instructions 2 Remove both outer seals 12 snap rings 13 and both inner seals 12 3 Clean seal bores 4 Install both inner seals 12 and both snap rings 13 Seal lips are to be installed towards inside of pump 5 Pack grease into both seal bores to cover the inner seals 6 Install both outer seals 12 Pack grease into both seal bores to cover the seals Seal lips are to be installed towards inside of pump 9 42 SECTION 9 SERVICE AND REPAIR REASSEMBLY OF HYDRAULIC PUMP 307451 01 1 Place the rear housing 1 with the opening up and 6 Insta
7. 2RII PACKMASTER SERVICE MANUAL Over Serial Number 16000 BUILDING THE BEST WARRANTY LEACH C O NM P A N Y 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 the date of original sale under reasonable conditions of use and operation providing required planned maintenance services are performed Extended war ranty packages 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 replace ment of wear expendable components is not covered 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 LEGALITY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF ANY KIND OR NATURE THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL OR CON SEQUENTIAL DAMAGES OF ANY KIND OR NATURE OTHER THAN ITS LIMITED WAR RANTY OF REPLACEMENT HEREIN NO OTHER PERSON FIRM OR CORPORATION CAN BIND THE COMPANY TO ANY WARRANTY OTHER THAN HEREIN ABOVE STATED To validate the new unit w
8. 726 kg to the lower end of the carrier panel as shown This will support the carrier panel once the packer panel is removed NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains OPERATIONAL STATUS Truck Running PTO Engaged Speed 5 n Up 2 Move the packer panel operating lever inward to bring the packer panel up When the panel reach es a vertical position bring the packer panel con trol lever back to neutral This will take the pres sure off the rod eye when the pin is removed OPERATIONAL STATUS Truck Off PTO Disengaged Remove the capscrews 1 lockwashers 2 and pivot pin covers 3 from the rod end Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin PACKER PANEL LEVER OOO sz 9 35 3 Attach a chain connected to a suitable lifting device capable of lifting 1600 Ibs 726 kg to the packer panel as shown Operate the lifting device to support the weight of the packer panel without causing strain on the bearing and roller assemblies 4 Remove the inside bearing assemblies as described earlier in this section 5 Remove the roller assemblies as described earlier in this section 6 Remove the outside bearing assemblies as described earlier in this section 7 With the bearing assemblies removed carefully oper ate the
9. Open gate valve Check fluid level Check hydraulic fluid filter and tank Check for obstruction in suction lines hoses Bring fluid to normal operating temperature Change hydraulic fluid to proper grade for Repair replace and or balance all parts Replace pump Replace with proper grade of hydraulic fluid kinked or collapsed 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 SECTION 8 TROUBLESHOOTING SPEED UP BUTTON IS ENGAGED ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR POSSIBLE CAUSE REMEDY 1 Short in electrical wiring 2 Blown fuse on speed up relay 3 Relay solenoid or switch is defective 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 4 Solenoid to carburetor or governor cable is broken Replace cable Check all ground connections for corrosion or Repair replace or adjust as required Be s
10. Compaction Cycle Operation Operating Procedures Pre operating Walk around Inspection Walk around Inspection Checklist Start Up Operating Instructions Positioning Pushout Panel SECTION 3 OPERATION continued Loading the 3 13 Attaching a Container to the Packer 3 13 Using a Winch or Container Lift Cylinder 3 14 Using a Container Push Bar 3 15 Packing the 3 15 Pushout Panel Operation During Packing Telescopic 3 16 Disconnecting the Container 3 16 Unloading at Dumpsite 3 17 Lifting the Tailgate 3 17 Ejecting the 3 18 Lowering the Tailgate 3 18 Shut DOWN serari E Ree E REA ER 3 19 SECTION 4 GENERAL REPAIR PRACTICES Preparation for 4 1 Replacement 4 1 Service Bulletins 4 1 Safety 5 4 2 Prior to Performing Any Service or Repair 4 2 Safety During Service and Repair 4 2 Welding 5 4 2 Electric 5 4 2 Oxy Acetylene Torches 4 3 Removal Disassembly and Repair 4 3 Reassembly
11. Main Control Valve shifts automatically HYDRAULIC SEQUENCE Fluid flows from the MCV Main Control Valve to the case end of the carrier panel cylinders The cylinders extend moving the carrier and packer panels up pack ing refuse against the pushout panel When the pres sure reaches 1800 PSI 125 BAR the MCV Main Con trol Valve shifts into neutral and the packing cycle is completed As the carrier cylinders apply force to com pact refuse the pressure of the trapped fluid in the TAILGATE LIFT CYLINDER CARRIER CYLINDER PACKER wa CYLINDER Da ome S CYLINDER TELESCOPIC packer cylinders will increase Should this pressure reach 3500 PSI 242 BAR a relief valve will open reducing the pressure by allowing some trapped fluid to escape and return to the hydraulic tank PRESSURE RETURN TRAPPED FLUID OPERATING VALVE HYDRAULIC FLUID TANK VALVE N TAILGATE LIFT CYLINDER 8 14 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RAISING TAILGATE OPERATOR ACTION 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 ENGINE SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the tailgate lift lever rearward shifts a spool in the FCV Front Control Valve causing flow to the tailga
12. When checking the fluid level in the hydraulic tank also note any frequent or sudden loss of fluid This may indicate leakage which must be traced and corrected to avert equipment failure and possible damage to other components If low fill the hydraulic tank to the NORMAL FILL LEVEL with hydraulic fluid as specified in Sec 4 SPECIFICA TIONS according to operating and weather conditions CLEAN TANK BREATHER WEEKLY Clean the air breather 2 every week Replace a breather that cannot be cleaned adequately CHECK REPLACE RETURN LINE FILTER ELEMENT The return line filter is a vital component of the hydraulic system Without proper filtration problems are bound to occur among the hydraulic system compo nents Stick to the strict maintenance schedule for this item Time Lapse Recommendations for Element Replacement 1 After the first 20 hours of hydraulic pump operation 2 After the next 50 hours of hydraulic pump operation 3 Thereafter every 250 hours of hydraulic pump oper ation or sooner if so indicated by the filter replace ment indicator 3 The condition of the filter element must be checked weekly by looking at the 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
13. described in Sec 3 OPERATION Leave all hydraulic cylinders in the retracted position and shut down unit 6 Recheck the fluid level and add fluid as necessary to bring level to the NORMAL FILL LEVEL on the sight gauge NOTE Refer to Sec 9 SERVICE amp REPAIR for detailed instructions pertaining to those items requiring repair or replacement 6 6 LEACH 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 Mayfair Rd Milwaukee WI 53222 Samples should be taken from the center of the reser voir when the fluid is at operating temperature and placed in a clean dry glass bottle with a nonshedding screw on cap The bottle shoul
14. ing device place a sign on the steering wheel indicating the unit is inoperative Proper servicing requires specialized tools and pro cedures Service must be performed by authorized personnel only following procedures in the 2RIl Service manual 5 10 11 Walk completely around the vehicle to make sure all persons and obstructions are clear before start ing the unit The container handling system is a critical compo nent of the unit use only the proper replacement parts Inspect all hooks chains and cables daily to ensure serviceable condition Replace damaged or worn parts See Section 5 Preventive Maintenance Before operating the vehicle the driver must be thoroughly familiar with the employer s safety pro gram concerning traffic rules warning devices and hand signals Be sure to know where to get assistance in the event of an emergency Know your machine Know the location and func tion of all controls gauges instruments and pro tective devices Should the height of a refuse collection vehicle be altered by 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 13 14 15 It is the operators responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operators manual and in accordance with
15. noting the loca tion of o ring seals 3 Thoroughly clean the o ring counter bores and ground surfaces of each section TIE ROD INLET T1 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 33 8Nm 3 Torque the 3500 lb relief cartridge load check and blanking plugs to 20 ft Ibs 27 Nm BONNET KNOCKOUT POSITIONER OUTLET COVER le H CARRIER SECTION 9 25 SECTION 9 SERVICE AND REPAIR DISASSEMBLY AND INSPECTION OF KNOCKOUT POSITIONER Remove bonnet screws 1 and bonnet 2 2 Loosen locknut 3 and remove adjustment screw 4 Count and record the number of turns needed to remove 6 3 Remove spool collar 5 If the control rod is not installed on the opposite spool end it may be nec 7 essary to insert a rod through the spool clevis to keep the spool from rotating 8 Remove spring guide 15 and needle roller 16 Remove back up ring and o ring 17 Remove 9 ACAUTION back up rings and o ring 18 10 Clean and inspect parts for excessive wear or scor The spool collar is under spring tension and ing Clean the o ring counter bores Servicing of caution should be use
16. 15 Disassembly of Hydraulic P 9 42 of Hydraulic Pump Removal of Tailgate Lift Cylinders 9 16 Replacing Shaft Seal the Hydraulic P 9 42 Disassembly of Tailgate Lift Cylinder 9 17 AR SUE eect EE t MUSS Inspection and Replacement of Reassembly of 307451 01 Hydraulic Pump 9 43 Tailgate Lift 9 17 Description of Electrical System 9 44 Reassembly and Installation of Tailgate Testing weet ae eet nee me 9 44 Lift 9 17 9 44 Description of Tailgate Assembly 9 18 Inspection 9 44 Removal of the Tailgate Assembly 9 18 Grounding the Electrical System 9 44 Inspection of Tailgate 9 19 Reassembly and Installation of Tailgate 9 19 Front Control 9 20 Removal of Front Control Valve 9 20 Disassembly and Inspection of Front Control Valve 9 20 Reassembly of Front Control Valve 9 21 Reinstallation of Front Control Valve 9 22 Main Control Valve MCV General 9 23 Removal of the Main Control Valve 9 24 Disassembly and Inspection of the Main Control 9 25 Reassembly of Main Control Valve 9 25 Disassembly and Inspection of the Knockout Positioner 9 26 Reassembly
17. PUSH BUTTONS 8 These two push buttons one located on each side of the tailgate are connected to a buzzer mounted under the drivers seat or under the dash in the chassis cab The operator depresses one of these push buttons to signal the driver when the loading operation is completed and the truck is ready to be moved PACKER AND CARRIER PANEL OPERATIONAL LEVERS 9 10 A Packer panel lever 9 The packer panel operational control lever is lo cated on the right curb side of the tailgate It is used by the operator 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 B Carrier panel lever 10 The carrier panel operational control lever is lo cated on the right curb side of the tailgate It is used by the operator 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 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
18. Section Shifts too Soon 8 4 Carrier Panel Valve Section Shifts to Neutral too Soon 8 5 Packer Panel Valve Section Will Not Shift 8 5 Carrier Panel Valve Section Will Not Shift To 8 5 Packer Panel Does Not Deliver Full Force to in House Hydraulic Fluid Testing 8 5 Loud Squealing Noise When Manually Retracting Telescopic Cylinder 8 6 Load Will Not Push Out 8 6 Pushout Panel Slides Forward Too Fast While Packing Refuse 8 6 Pushout Panel Will Not Slide Forward 8 6 Carrier and Packer Panel Stop Short of Home Position After Each Cycle 8 6 Pushout Panel Returns When Pushout Cylinder is Retracted 8 7 Pushout Cylinder Will Not Extend to Push Out Load iiis ker eme 8 7 Load Will Not Push Out 8 7 Packer Panel Drifts Open While Packing Load Into 8 7 Cycle Time is Too 0 8 7 Tailgate Will Not 8 7 Container Won t Lift 8 8 Winch Motor 8 8 Container Raises Very Slowly 8 8 Description of Hydraulic SysteM 8 9 Hydraulic system sequence Neutral 8 10 Packer panel sweeps back over load 8 11 Carrier and Packer panels move to interrupted cy
19. all applicable codes including Occupational Safety and Health Act OSHA and American National Standards Institute ANSI reg ulations Do not attempt to operate this equipment without proper training Move the vehicle as slowly as possible without stalling when traveling in reverse Always make sure the area behind the unit is clear before traveling in reverse Do not travel in reverse for distances greater than those dictated by local ordinances If reverse trav el exceeds 10 feet use a spotter or move the vehicle in 10 foot increments only and then check to make sure the area behind the unit is clear between increments Do not attempt to dislodge any material above waist level unless wearing eye protection such as approved side shielded safety glasses or a full face shield Never use the unit to push or tow another vehicle Never unload uphill or against a pile of refuse or into the bank of a hill Never place head body fingers or any limbs into a scissors point or pinch point on the equipment Before operating the vehicle the driver must be 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 manufact
20. and Installation 4 4 Electrical Testing 4 4 Checking for Voltage 4 4 Checking Continuity 4 4 Welding o suus Il circa a ees 4 4 Lifting Instructions ooooooooo o 4 5 Capacity of Lifting Device Required for Removal 4 5 Sling Strap Specificati0nS 4 5 Chain and Hardware Specifications 4 5 Capscrew Marking and Torque Values 4 6 SECTION 5 SPECIFICATIONS Body Dimension Illustration 5 1 Lubricants eee eee eee 5 2 Hydraulic 5 2 Capacity eR Rm 5 2 Total System 5 2 PUMP 5 2 Leach Hydraulic Fluid Recommendation 5 2 Hydraulic Fluid 02 0000 ee 5 2 TABLE OF CONTENTS SECTION 6 PREVENTIVE MAINTENANCE General rca dd ed 6 1 Operating and Maintenance Records 6 1 Lubrication 6 2 Hydraulic System 6 5 Checking Fluid Level Daily 6 5 Clean Tank Breather Weekly 6 5 Check Replace Return Line Filter Element 6 5 Replacement of Filter Element 6 5 Cleaning Hydraulic Strainer Monthly 6 5 Flushing Hydraulic System Yearly 6 6 Hydraulic System Service
21. and lifting chains 2 Disconnect the hydraulic line 1 at the cylinder port in the piston rod and cap the line 3 Remove the capscrew 2 washer 3 and cover 4 from the cylinder end 4 Remove capscrew 5 lockwashers 6 cover 7 and pin 8 from the rod end 9 16 SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF TAILGATE LIFT CYLINDER 1 Wash the outside of the cylinder assembly com pletely to prevent contamination and or damage to the cylinder components Secure the case end of the cylinder to a workbench or floor mount and the rod end to an overhead lift ing device with a minimum lifting capacity of 500 Ibs Remove the plug from the port and drain all fluid Remove the 1 4 socket head setscrew from side of the cylinder case and discard Remove the bleeder screw and gasket from the end of the cylinder rod Save these for reassembly Unscrew the head gland from the cylinder case completely Slide the head gland off of the the rod Using the overhead lifting device carefully extend the cylinder rod approximately 1 2 way out of the case Apply a 6 piece of 1 masking tape to the chrome 10 11 12 13 surface of the exposed section of the cylinder rod about 1 2 way up the cylinder rod The tape should be applied in a diagonal fashion on the rod Push the rod back into the case then again using the overhead lifting device extend the rod 1 2 way out The cylinder packing shou
22. 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 refuse loaded into the body will increase the compaction rate 3 Operation of the equipment As with the operation of any type of heavy equipment one machine can yield different results with different operators Operating a rear loader is a skill Placement of items in the hopper not over loading the hopper and releasing the pushout plate clamp at the right time are all learned skills that will affect the com paction rate of a unit 4 Preventive maintenance A properly
23. 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 walk 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
24. curb side of the tailgate directly above the packer and carrier panel control levers Arefuse vehicle may have none one or two control levers de pending on the configuration of the unit 3 5 SECTION 3 OPERATION oo OJ DRIVER SIGNAL PUSH BUTTONS CARRIER PANEL LEVER PACKER PANEL 7 LEVER COMPACTION CYCLE OPERATION Both the packer panel lever and the carrier panel lever are shifted simultaneously 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 shifted the engine speed up automatically engages The packing cycle may be stopped at any point by moving both oper ating levers to neutral The packer or carrier panel can be moved independently CONTAINER HANDLING CONTROL LEVERS UN SECTION 3 OPERATION OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the 2RII Packmaster including specific instructions for loading packing and unloading the unit NOTE It is important that operators and mechanics understand these procedures PRE OPERATING WALK AROUND INSPECTION Each day before starting the unit perform the following walk around inspection 1 Refer to the decal location illustration in Section 1 SAFETY of this manual and make sure all decal
25. is above the appropriate setting loosen the lock nut on the relief cartridge and using an allen wrench turn the adjusting screw out rotate counter clockwise After readjusting retighten the lock nut Repeat steps 4 and 5 IF NOT 8 Perform TEST FOR LEAKING Tailgate CYLINDER SEAL as described in Section9 SERVICE AND RE PAIR Start truck repeat steps 4 and 5 and again check gauge for correct pressure 7 4 TAILGATE LIFT LEVER ENGINE SPEED UP BUTTON 20 25 yd 31 33 yd 2o 27 J sel L 6 0 Lom TAILGATE RAISED CHECK PACKER AND CARRIER PANEL SHIFTING PRESSURES There are two methods to determine accurate pressure settings OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 1 Use an electronic pressure gauge that maintains and records maximum system pressures 2 If an electronic gauge is unavailable and a mechani cal gauge must be used the following procedure is recommended a Install a 0 4000 PSI 0 276 BAR pressure gauge at the quick disconnect coupler on the two spool directional valve at the 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 1000 PSI 69 BAR OPERATIONAL STATUS Truck Off PTO Disengaged c Remove the button plug from the end of the Main Control Valve bonnet using a screwdriver the shift the Main
26. know 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 2 5 SECTION 2 INTRODUCTION WINCH 1 Control lever 2 Engine speed up button 3 Cable 4 Winch assembly 5 Container attachment 6 Stop bar Lid guard CONTAINER LIFTING CYLINDER CLC 1 Control lever 2 Engine speed up button 3 Roller guide 4 Cable 5 Lifting cylinder assembly 6 Container attachment 7 Stop bar Lid guard 3 9 OJ CONTAINER PUSH BAR CPB 1 Control lever 2 Push bar 3 Lift roller 4 Container dumping cylinder 5 Stop bar Lid guard 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 DISCONNECT When the container is empty it is lowered to the ground the latch arms released and the truck is moved forward DISCONNECT 2 7 GENERAL This s
27. lever forward ENGINE SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever forward shifts a spool in the FCV Front Control Valve causing flow to the telescopic cylinder As the cylinder retracts the pushout panel is positioned near the front of the body PRESSURE OPERATING RETURN M VALVE NA SEGS HYDRAULIC TAILGATE FLUID TANK LIFT CYLINDER FRONT c VALVE TELESCOPIC CARRIER CYLINDER CYLINDER Q X PACKER CYLINDER 9 CARRIER P D CYLINDER a TAILGATE LIFT CYLINDER 8 17 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM LOWERING TAILGATE OPERATOR ACTION Operator moves the tailgate lift lever forward HYDRAULIC SEQUENCE Moving the tailgate lift lever forward shifts a spool in the FCV Front Control Valve allowing fluid in the tailgate lift cylinders to drain back to tank The weight of the tail gate forces fluid out of the cylinders the cylinders re tract and the tailgate lowers TAILGATE LIFT CYLINDER CARRIER CYLINDER PACKER CYLINDER CARRIER CYLINDER OPERATING VALVE a aS EI FRONT ER 5103 VALVE TELESCOPIC CYLINDER 9 ER E vs TAILGATE LIFT CYLINDER TAILGATE LIFT LEVER PRESSURE ON RETURN HYDRAULIC FLUID TANK 8 18 SECTION 9 SERVICE AND REPAIR GENERAL This section contains the instructions nece
28. of Motor Carrier Safety 2 Never use lighted smoking materials open flame or sparks around when working with flammable mate rials such as fuel tanks or storage batteries 3 Never have an open flame as a light source 4 Never load ashes or other materials which might be smoldering These materials could ignite refuse in the packer body HOUSEKEEPING Good housekeeping habits are a major factor in acci dent prevention 1 Keep handrails and steps clean and free of grease or debris 3 Rubbish scrap paper and litter are highly com 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 1 Put all controls in neutral 2 Set parking brake 3 Disengage PTO 4 Shut off engine 5 Shut off solenoid dashboard switch 6 Remove key 7 Lock vehicle SECTION 1 SAFETY PRECAUTIONS 00 A My LLA Sys 5 2 9 CONTAINER DUMP CONTROL EN G INE PACKER 7 SPEED UP DOWN on a NOTE Both container latch arms must be in place and latched before raising container CARRIER CARRIER CARRIER A DANGER Le Stand clear when container dumping mechanism is in motion
29. packer 4 CAUTION panel cylinder to the interrupted cycle position Loosen the hydraulic fittings slowly to release any OPERATIONAL STATUS trapped pressure Watch for inadvertent movement of components Truck Off PTO Disengaged 7 Disconnect and plug the hydraulic lines which con nect to the case end of a packer panel cylinder PLUG OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 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 9 If the cylinder does not leak reconnect the hydrau lic lines to the cylinder Repeat steps 7 9 for the other cylinder TEST FOR LEAKING CARRIER PANEL CYLINDERS NOTE Before testing any cylinder make sure the main line pressure is correct as described under MAIN LINE PRES SURE CHECK Sec 7 CHECK OUT PROCEDURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top covers over the operating cylinders for better accessibility during testing SECTION 9 SERVICE AND REPAIR j PACKER PANEL OBSERVE FLUID LEVER
30. refuse and into the hopper structure Anytime a repaired area has a repeat failure suspect that the core problem whether it is mechanical or oper ator has not been adequately addressed REMOVAL OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove top sheet supports for better accessibility 2 Remove the packer panel as previously described 3 Remove the operating cylinders as previously described 4 Remove the tubing to the operating valve Cap the lines and plug the ports in the valve to prevent con tamination 5 Remove the carrier panel REMOVE TOP SHEETS CARRIER PANEL 9 38 SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot bearing and roller sur faces for excessive or uneven wear scoring or damage 2 Check the panel for broken welds bent edges or warpage 3 Inspect the track bar for excessive wear or damage 4 Replace parts as necessary INSTALLATION OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the carrier panel in the approximate reverse order of disassembly Pay particular attention to the installation of roller and bearing assemblies as described earlier in this section PACKER PANEL TRACK BAR REPLACEMENT OPERATIONAL STATUS Truck Off PTO Disenga
31. the closed position and tighten securely NOTE The tailgate open light backup lights and backup alarm should be off after closing the tailgate SECTION 3 OPERATION SHUT DOWN 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 of solenoid dashboard switch 7 Remove key 8 Lock truck 3 19 Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these ser vice 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 accord ingly anyone who uses a service procedure or tool 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 quickly as possible and reduce the incidenc
32. the hydraulic line to the cylinder port Cap the hydraulic lines and the cylinder to prevent contamination of the hydraulic system 8 Remove the cylinder end case pin PUSHOUT LEVER NOTE For more information about lifting devices and slings refer to Sec 4 General Repair Attach a sling connected to a suitable lifting device with a minimum lifting capacity of 750 Ibs 341 kg Operate the lifting device slowly and guide the cylinder out of the body through the side access door Take care during removal to avoid damaging the surrounding components or hydraulic lines 9 27 SECTION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER PACKING REPLACEMENT ROD END 1 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to prevent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up 2 Remove the setscrew 1 and plastic plug 2 from the head nut 3 Remove the smallest head nut 3 using a strap or chain wrench If the tube turns with the head nut tighten the next head nut slightly 4 Repeat steps 2 and 3 to remove each head nut TELESCOPIC 5 Using a suitable lifting device attached to the rod CYLINDER eye 5 pull up on the tube The packing 4 should come out as the tube is raised If it does not clean off a section of the tube and wrap masking tape around
33. thoroughly satisfy himself that neither his nor the operator s safety will be jeopardized by the service methods selected Any person who modi fies their equipment must do so in accordance with American National Standards Institute Z245 1 1992 It is important to note that deviating from these pro cedures could cause damage to the unit or render it unsafe However please remember that these procedures are not all inclusive a Original Factory Parts 4 1 SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR 1 Set the parking brake 2 Put the vehicle in park or if equipped with a manu al transmission put the unit in gear and remove the 5 ignition key 3 Place an OSHA approved chock block in front of and behind the front tire 4 If steel supports 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 the PTO turn off the ignition and remove the keys befor
34. 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 hinge Tailgate i iesus emi eed ne Packer plate ii 31234004 ra EE 5 Use ER 70S 6 wire for all locations ARA AA eae E6010 E6011 E6013 DTE E7018 Wok song nd deh eae denne EE E6010 E6011 E6013 hh WORN Dies De cie c Rt E6010 E6011 ioi GE Rig E RUE E7018 LEACH SECTION 4 GEN
35. 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 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 installing new rings the ends should be positioned on opposite sides of the tube to prevent leakage After the tubes have been installed back into the case the retaining rings 6 should be installed packings 4 replaced and the head nuts 3 rein stalled ROD END CASE END 9 29 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PUSHOUT PANEL PUSHOUT PANEL Refuse is compacted against and ejected from the body by the Pushout Panel The telescopic system uses ge one multi stage cylinder that is attached to the pushout panel approximately half way up the pushout panel During its movement through the body the pushout panel rides in a trough The panel ride
36. 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 customer TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS General si ew cea rarae ir Danger Warning and Caution Decals Prior To Start Up Operation E Rs Hydraulics seus he RR RS Fire Housekeeping Shutddos uisa e ed EG RR Decal lt SECTION 2 INTRODUCTION Terms You Will Need To Know Loading 5 cx RR TREE XR Compaction Unloadirig eue bs Container Container Handling Systems General Terms You Need to KnoW OOK eects eras ra a Comae s aoa caca pes state e Container Attachment WINC saaan en e e Eo A hes Container Lifting Cylinder CLC Container Push Basic Attach 4 lt SECTION 3 OPERATION Description of Operating Controls Location Of Operating Controls
37. 00 Ibs 227 kg Operate the hoist to make the lifting cable snug without applying strain on the cylinder OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 3 Shift the packer panel lever inward to partially retract the packer panel cylinders Disengage the lever when the panel is vertical This relieves the weight of the panel from the cylinder rod end PACKER PANEL LEVER CYLINDER OPERATIONAL STATUS Truck Off PTO Disengaged 4 Remove the capscrews 1 lockwashers 2 and pivot pin cover 3 from the rod end 9 7 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 5 Make sure the cylinder weight is securely support ed by the hoist and carefully remove the pivot pin PIVOT PIN OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up Shift the packer panel lever inward to completely retract the cylinder OPERATIONAL STATUS Truck Off PTO Disengaged ACAUTION Disconnect both the case end 1 and rod end 2 Loosen the hydraulic fittings slowly to release pressure tubes Immediately cap or plug the pres any trapped pressure Watch for inadvertent sure tubes and cylinder ports to keep fluid in and movement of components dirt out 10 Remove the pivot pin by using special packer pin Remove capscrew 1 lockwashers 2 an
38. 1 6 SECTION 1 SAFETY PRECAUTIONS 0 i ES AN 5 gt 22 SEK 12 000 LB CAPACITY be in 0 Both container latch arms must place and latched before raising container gt iY 9 WARNING 1 A SECTION 1 SAFETY PRECAUTIONS PACKER PACKER D ENGINE PACKER SPEED UP 2 DRIVER SIGNAL ON OFF 9 CARRIER AWARNING CARRIER CARRIER Rotating power take off sh k Do noi chassis unless engi is stopped and key d A CAUTION Serious pump damage will result if vehicle is operated at highway speed with pump 2 B engaged Move unit with pump engaged run dry Disconnect pump drive to run engine work only as required to perform its function as if tank valve is required to be closed or if oil faclurers operator a refuse Shear erat al ap vehicle at tank is not at proper fill level Serious pump damage will result if pump is 0 rules all governmental regulations and and safety manuals relative to this machines safe use AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY speeds less than 10 mph 1 8 SECTION 1 SAFETY PRECAUTIONS A DANGER A WARNING To prevent possible serious injury or uh death do not use this refuse collection ay v
39. 8 7 SECTION 8 TROUBLESHOOTING CONTAINER WON T LIFT POSSIBLE CAUSE 1 Insufficient hydraulic pressure Cable broken Cable loose from the lifting device drum cylinder Container overload Container frozen to the ground oR WP Control linkage is not moving the directional valve Lifting motor or cylinder s by passing hydraulic fluid 8 Shear pin or key broken between winch shaft and drum NO REMEDY 1 Check hydraulic pressure following proce dures in service manual Replace cable Secure cable to lifting device Reduce weight of material in container Do not use lifting device to break container loose from the ground Repair the linkage Repair or replace the defective component aR WP Al O 8 Replace the key or pin WINCH MOTOR LEAKING POSSIBLE CAUSE REMEDY 1 Shaft seal damaged 2 Motor worn internally 1 Replace shaft seal 2 Replace motor CONTAINER RAISES VERY SLOWLY POSSIBLE CAUSE REMEDY 1 Winch motor by passing 2 Rear loader hydraulic system not providing sufficient flow rate or pressure for container handling systems 1 Repair or replace motor 2 Check and repair rear loader hydraulic system following procedures in service manual 8 8 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM DESCRIPTION OF HYDRAULIC SYSTEM The following is a description with flow diagrams of w
40. 9 Solenoid or wiring defective 10 Defective governor diesel engine Set engine RPM to achieve 32 to 36 second Fill to proper level See Sec 6 Preventive Service filter See Sec 6 Preventive Service breather See Sec 6 Preventive Replace pump See Sec 9 Service and Perform test for leaking operating cylinder Refill with proper grade of hydraulic fluid Remount solenoid securely on engine if pos Repair or replace as required See Electrical Diesel engine must have a full variable speed cycle time Must be done by authorized dealer Maintenance Maintenance Maintenance Repair seals and repair as required See Sec 5 Specifications sible System Sec 9 Service and Repair governor to properly operate packer TAILGATE WILL NOT RAISE POSSIBLE CAUSE REMEDY Tailgate clamps still engaged Insufficient hydraulic pressure Hydraulic pump is defective N Relief section of 2 spool directional valve out of adjustment or broken Tailgate lift cylinders leaking or defective Restriction in tailgate cylinder hose oo hb wha Disconnect clamps and swing free of tailgate Check main pressure See Sec 7 Check out Replace pump See Sec 9 Service and Adjust or replace spring as necessary See Repair or replace as required Remove and clean hose Repair Sec 9 Service and Repair LEACH
41. AIR 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 If you suspect a leak in the system perform a leak test using an approved leak detection system DO NOT USE HOUSEHOLD OR LAUNDRY SOAP BECAUSE OF THE DANGER OF OXYGEN COMBINING WITH IT AND EXPLODING When preparing to use the torch make certain that the regulator valves are all the way out to the off position before the main tank valves are opened to protect the regulators from sudden impact of tank pressure When opening the tank valves stand alongside of the regulators out of the way in case they blow out Backfiring or machine gunning at the torch is very dangerous and can lead to a major explo sion Welding should b
42. ANSI regulations should be used in conjuction with Leach Container Handling Systems ARM LATCH ARMS CONTAINER HANDLING SYSTEMS To lift or dump a container several systems are avail able A hydraulically operated container push bar is available to handle containers of 1 to 3 cubic yard capacity The handling of containers with capacities of four 4 or more cubic yards requires the use of a drum winch or roof mounted container lifting cylinder Drum winches are rated at various pounds of pull Leach Company offers winches with 8 000 12 000 and heavy duty 12 000 Ib ratings The Leach container lift cylinder is rated at 12 000 pounds NO TE Leach bodies are capab le of being equipped with more than one container handling system CYLINDER LIFTING 2 4 SECTION 2 INTRODUCTION GENERAL The main purpose of a refuse body is to load compact transport and unload refuse To assist in loading of 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 TERMS YOU NEED TO KNOW Before going further become familiar with the contain er handling terms you will need to
43. AR LEACH COMPANY OSHKOSH WI TA WARNING Rotating power take off shaft hazard Do not enter under chassis unless engine is stopped and key removed DO NOT FILL BEYOND THIS LINE A A EJECTION EJECTION ADD HYDRAULIC FLUID EJECTION 12 000 LB CAPACITY 17 SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW TAILGATE ASSEMBLY HOPPER L Al 2 2 2 AIC uj 1 300 VA 000 Z 9 EC LOADING CC j h CL Om EDGE CARRIER PUSHOUT PANEL PANEL ER a PACKER HYDRAULIC OR RV PANEL TANK 4 ec eiu SES Re ars E E H E tr SECTION 2 INTRODUCTION The main purpose of the 2RIl Packmaster is to safely and effi ciently load compact transport and unload refuse The following describes how the unit performs those tasks in the most basic terms For a more detailed description of the unit and its com p ponents read the complete 2RII PACKMASTER SERVICE MANUAL Before going further look at the accompanying i full page illustration of the 2RII Packmaster and become familiar with the terms you will need to know CARRIER LOADING PANEL Refuse is first loaded into the hopper of the tailgate assembly The carrier and packer p
44. Control Valve linkage to the detented poer position and release leaving the valve spool in the detented position OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up d While observing the pressure gauge slowly increase the main relief valve setting The pressure indicator will increase until the knockout pressure setting is reached and the Main Control Valve spool returns to neutral Revised 3 15 02 ref TSA 02 R01 SECTION 7 CHECK OUT PACKER LEVER ADJUSTING SCREW PACKER PANEL CARRIER PANEL SECTION SECTION CARRIER LEVER e The knockout pressures should be set at 1500 PSI 10 BAR for the packer panel section and 1800 PSI 125 BAR for the carrier panel section If the knockout pressure setting requires adjust ment it may be changed by turning knockout pressure adjustment screw located inside the bonnet clockwise to increase the knockout pres sure setting or counter clockwise to decrease the setting Once the proper knockout setting has been attained reinstall the button plug to seal the Main Control Valve f Return the main relief valve pressure setting to its specified value as described previously 7 5 SECTION 7 CHECK OUT CHECK RESISTANCE CARTRIDGE PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture part number 605018 and test as shown on illustration ATTACH PORT A POWER WITH 0 3000 PSI GAUGE 1 4 NPTF POR
45. D UP BUTTON 3 Push the pushout lever rearward until the pushout cylinder is fully extended NOTE On units with a telescopic pushout cylinder the pushout panel is now in position for loading 4 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed 5 Repeat steps 2 3 and 4 until the pushout panel is as far back as it will go and then pull forward on the pushout lever to fully retract the pushout cylinder Now extend the cylinder a few inches to reset the clamp SPEED UP BUTTON PUSHOUT LEVER 3 12 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 hop per 3 Do not load refuse higher than the loading edge Always follow proper loading procedures SECTION 3 OPERATION uni 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 the latch arms open until the container trunnion bar is between the guide ears and within the latch assembly Center the container on the attachment A
46. EDY 1 Cylinder bypassing 2 Resistance setting too low 1 Perform test for leaking cylinder 2 Adjust resistance cartridge 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 AFTER EACH CYCLE CARRIER AND PACKER PANEL STOP SHORT OF HOME POSITION 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 SECTION 8 TROUBLESHOOTING PACKER PANEL DRIFTS OPEN WHILE PACKING LOAD INTO BODY POSSIBLE CAUSE 1 Packer panel cylinder seal leaking 2 Packer panel valve section pressure too high Perform test for leaking cylinder See Sec 9 Perform pressure test as described in Sec 7 REMEDY Service and Repair Check out CYCLE TIME TOO SLOW POSSIBLE CAUSE REMEDY Engine RPM too low 2 Hydraulic fluid level too low 3 Hydraulic fluid filter needs servicing 4 Hydraulic tank breather dirty 5 Hydraulic pump worn or defective 6 Operating cylinder piston seals leaking 7 Incorrect grade of hydraulic fluid for current operating conditions 8 Solenoid mounting loose or broken
47. ERAL 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 OVIIn ders 2 Re a aa e e hee EA 500 lbs 227 kg Telescopic Pushout Cylinders llis 1000 Ibs 454 kg Carrier Panel oo oe ewes ba eee a a uS E nd PERS ERR 1600 Ibs 726 kg Packer Panel ese casts siste xri 1600 Ibs 726 kg Pushout Panel s222ice0sseeee22 fees e GS Lg Ree Chew bah Ped cessus es 2800 Ibs 1270 kg T EET 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 loco curar ps ar Aer AA AE A AEN y 4800 lbs 2177 kg lacras aran aran a 3600 Ibs 1633 kg Basket lift zs siege Sea aeo eee wie Pee a See FG ewe ad 9600 Ibs 4354 kg WIG ee rer 2 in LONO eggs gees eee ee eee qux eR depends on type of lifting device used CHAIN AND HARDWARE SPECIFICATIONS Chains should be used to lift and or support th
48. ESCOPIC ye TAILGATE LIFT CYLINDER NO PRESSURE RETURN HYDRAULIC FLUID TANK Ss 05 PUMP SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PANEL SWEEPS BACK OVER LOAD OPERATOR ACTION The operator moves the control levers inward to start the compaction cycle HYDRAULIC SEQUENCE Operator action causes the MCV Main Control 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 Re turn fluid flow from the cylinder is back to the tank Aa PRESSURE 2 OPERATING eee RETURN 1 VALVE T SO m TAILGATE 1 FLUID TANK LIFT CYLINDER VALVE el TELESCOPIC CYLINDER CARRIER CYLINDER JN PACKER CYLINDER f By oe CARRIER CYLINDER TAILGATE LIFT CYLINDER 8 11 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM CARRIER amp PACKER PANELS MOVE DOWN TO INTERRUPTED CYCLE POSITION OPERATOR ACTION None MCV Main Control Valve shifts automatically HYDRAULIC SEQUENCE At the end of the packer cylinder stroke pressure builds to 1200 PSI 83 BAR causing the MCV Main Control Valve to shift diverting flow to the rod end of the carrier cylinders The cylinders retract moving the carrier and packer panels down to the interrupted cycle position
49. EVER NOTE Additional speed up control buttons may be installed with optional winches and container FRONT attachments CONTROL VALVE FRONT CONTROL VALVE The front control valve is located behind the access door TAILGATE on the front left hand side of the body The control levers LIFT LEVER for this valve extend out through a cutout in the door This valve controls the ejection pushout panel and the lifting of the tailgate PUSHOUT LEVER 5 The upper lever controls the movement of the pushout panel Moving the control lever rearward toward the tail gate will move the pushout panel to the rear Moving 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 Mov ing the lever forward toward the cab will lower the tail gate 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 position TAILGATE CLAMPS 3 4 DRIVER SIGNAL
50. FLOW CARRIER PANEL CYLINDERS 9 4 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS STATUS Truck Running PTO Engaged CARRIER PANEL 2 Shift the carrier panel lever outward to fully extend the LEVER carrier panel cylinders home position OPERATIONAL STATUS 3 Disconnect and plug the lines that connect to the rod end of one cylinder Loosen the hydraulic fittings slowly to release Truck Running PTO Engaged Speed trapped pressure Watch for inadvertent movement of components 4 Shift the carrier panel lever outward to apply hydraulic pressure to the case end of the carrier cylinders Hold the lever and observe the fluid flow from the open port on the rod end The flow of hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces indicates an excessive piston seal leak If the cylinder does not leak excessively continue test OPERATIONAL STATUS CARRIER PANEL LEVER 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 OBSERVE FLUID FLOW 9 5 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS STATUS Truck Running PTO Engaged CARRIER PANEL LEVER Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components 6 Shift t
51. Hydraulic System Illustration Remove filter cover 4 Remove o ring 5 Remove element 6 and discard Install a new element 6 Qv X9 Coat a new o ring 5 with fresh hydraulic fluid and install in filter cover 4 6 Install the cover and secure to the bowl with the attaching hardware 7 Checkthe fluid level and replenish with fresh fluid as described earlier in this section under CHECK ING FLUID LEVEL Extended operation of the unit without proper filtration will result in reduced service life of hydraulic system components CLEANING HYDRAULIC STRAINER MONTHLY 1 Remove cover 7 and gasket 8 2 Unscrew and remove strainer 9 3 Clean strainer thoroughly in a suitable cleaning sol vent 4 Reinstall strainer 5 Remove clean and reinstall magnetic ring 10 6 Inspect the gasket 8 and replace if necessary 7 Align the gasket carefully and secure the cover 7 to the tank with the attaching hardware 6 5 SECTION 6 PREVENTIVE MAINTENANCE FLUSHING HYDRAULIC SYSTEM YEARLY 1 Drain all fluid from the hydraulic tank into a suitable container Dispose of it 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
52. IR ENGINE SPEED UP SYSTEM CHECK ENGINE SPEED UP SWITCHES OPERATIONAL STATUS Truck Running PTO Engaged Speed n Up 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 SPEED UP BUTTON CARRIER LEVER Ew Q SECTION 7 CHECK OUT CHECK PACKING CYCLE TIME OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 1 Activate both the packer panel lever and carrier panel lever Using a stopwatch time a complete cycle A complete cycle should take 32 to 34 sec onds IF NOT 2 The engine ECU Electronic Control Unit may have be programmed by an authorized chassis dealer NOTE It is important the the cycle time is correct before performing the following pressure checks CARRIER LEVER 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
53. LOADING At the dumpsite the unit is unloaded in two easy steps First the tailgate is raised by the operator Second the pushout panel is moved to the rear of the body pushing out the load After unloading on telescopic units the tailgate is low ered and latched to the body On clamp style units the the pushout cylinder is retract ed and then the clamp is set by extending the cylinder a couple of inches The tailgate is then lowered and latched to the body X TAILGATE TAILGATE RAISED TAILGATE PUSHOUT _ PANEL PUSHOUT PANEL MOVES REARWARD EJECTING THE LOAD 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 latches and ears are installed to accomodate containers from one 1 to ten 10 cubic yard capacity The standard container for use with the Leach rear loader must have an ANSI Standard 114 134 diameter trunnion bar which is between 771 2 and 78 end to end This trun nion bar length will center the container between the ears and prevent the container from moving side ways The latch arms must be manually raised and secured by the arm latch The container arms when properly latched together with the guide ears will secure the container to the packer Only containers that meet the American National Standards Institue
54. OSSIBLE CAUSE 1 Carrier panel valve section pressure too low REMEDY 1 Perform pressure check as described in Sec 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 1 Perform test for leaking cylinder See Sec 9 Service and Repair 2 Perform pressure check as described in Sec 7 Check out 3 Inspect and free linkage as necessary 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 1 Perform test for leaking cylinder See Sec 9 Service and Repair 2 Perform pressure check as described in Sec 7 Check out 3 Inspect and free linkage as necessary 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 hydrauli
55. R 16000 105549 2RII SERVICE 8993 9718 _ ALPHA BETA DELTA 105567 2RII PARTS 6972 8993 105284 PARTS OVER 3500 105544 2RII SERVICE 6972 8993 105282 SERVICE OVER 3500 105600 2RII PARTS 0001 6972 105283 OPERATORS OVER 3500 105601 2RII SERVICE 0001 6972 _ 951134 5 ALPHA COLOR SPECIFICATIONS 9511134 8 BETA COLOR SPECIFICATIONS 105557 ALPHA PARTS 2140 3500 _ 9511134 7 DELTA COLOR SPECIFICATIONS 105556 ALPHA SERVICE 2140 3500 9603134 2 AL BE SUGGESTED SPECS 105565 BETA PARTS 0001 2139 9603134 3 DELTA SUGGESTED SPECS 105563 BETA SERVICE 0001 2139 Other Publications 105295 MILLENIUM PARTS 105305 2 LEACH BINDER 105297 MILLENIUM SERVICE 105309 REARLOADER PRE OP GUIDELINE 105296 MILLENIUM OPERATORS 105308 ALL REARLOADER PARTS SERVICE 105616 FL 104 SERIES B PARTS AND OPERATORS CD ROM 105596 FL 104 SERIES B SERVICE 42495293 PAINT COLOR CHART 961134 5 LEACH COLOR SPECIFICATIONS 105590 SAFETY BOOKLET S 9603134 1 LEACH SUGGESTED SPECIFICATIONS LSAFE SAFETY WALL POSTERS 6 PER SET 105286 REARLOADER MOUNTING MANUAL 105321 REARLOADER CONTAINER HANDLING SYSTEMS 105605 CHASSIS REQUIREMENTS MANUAL Send this form by Fax or Mail to Leach Company Attention Service Department P O Box 2608 Oshkosh WI 54903 2608 Fax 920 231 2712 REWARD 2RII PACKMASTER PARTS MANUAL Over Serial Number 16000 BUILDING THE BEST 2RII PACKMASTER SERVICE MANUAL Over Serial Number 16000 BUILDING THE BEST 2RIl PACKMASTER OPERA
56. R PRACTICES for detailed information about the correct use of slings and lifting chains 4 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 7 500 Ibs 3402 kg to the tailgate as shown Operate the lifting device no more than necessary to support the weight of the tailgate SECTION 9 SERVICE AND REPAIR Remove cap screw 1 and locknut 2 to remove retainer 3 and hinge pin 4 Operate the lifting device and or move the truck forward to free the tailgate from the body Position the tailgate on the supports as needed to facilitate repairs The supports must be capable of supporting 7 500 Ibs 3402 kg INSPECTION OF TAILGATE 1 Inspect all the sheet metal for bends dents or tears Check the hardware holes for enlargement or breaks in the metal Check threaded holes for stripped or otherwise damaged threads Check the tailgate seal for any sign of deterioration Check handles for looseness 2 Replace any defective or worn part Follow all safe ty precautions pertaining to welding described in Sec 1 SAFETY 3 See Sec 4 GENERAL REPAIR INSTRUCTIONS for information pertaining to welding repairs REASSEMBLY AND INSTALLATION OF TAILGATE Reassemble and install the tailgate in the approximate reverse order of disassem bly and removal SEC
57. RS 1 Remove the grease fittings clean parts drain fluid and follow all other applicable guidelines for disas sembly provided in Sec 4 GENERAL REPAIR PRACTICES before proceeding to disassemble the cylinder 2 Secure the case end of the cylinder to the floor or workbench 3 Secure the rod end of the cylinder to an overhead hoist or other suitable lifting mechanism with a min Se imum lifting capacity of 500 Ibs 4 Remove the six nylock screws 1 and three lock segments 2 securing the head gland 3 to the cylinder 5 Slowly operate the hoist to carefully pull the piston rod assembly out of the cylinder 6 Disassemble the cylinder and install replacement part s NOTE e During disassembly note the condition of each part as it is removed to aid in diagnosing Note the position of ET each part as it is removed to aid in reassembly INSPECTION AND REPLACEMENT OF OPERATING CYLINDERS 1 Carefully and thoroughly inspect the inside of the cylinder for cracks scoring or uneven wear Check all parts for damage 2 Use electric drill with an internal grinding wheel to remove burrs from the internal groove on the cylinder case 6 3 A new rod wiper 1 rod seal 2 o ring 3 seal 4 and wear rings 5 must be installed any time the cylinder is disassembled Pay particular atten tion to the way parts are positioned for correct assembly Parts that must be replaced together are available as a repa
58. St eiii ori rra ie Re Vickers Vane Pump Test Pass Pass Pass Dielectric Strength ASTM 877 EC O 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 FLUID To serve its purpose and give long and satisfactory service hydraulic fluid must possess desirable physical and chemical characteristics Stability over a wide range of temperatures and under agitation is very important Premium hydraulic fluids should be used in Leach hydraulic systems In addition to the above characteristics select ed additives should be incorporated to provide additional resistance to wear corrosion oxidation decomposition and foaming All additive blending should be done by the lubricant supplier so that they are compatible with each other A reputable lubricant supplier backed by a reputable oil company is great assurance of obtaining high quality prod ucts and generally speaking higher quality is worth the higher initial cost LEACH 5 2 SECTION 6 PREVENTIVE MAINTENANCE GENERAL The 2RII Packmaster has been designed for long peri ods of efficient uninterrupted operation Careful attention to proper preventive maintenance as described in this secti
59. T P INSTALL RESISTANCE CARTRIDGE wes 20 LBS FT SOME DRAINAGE DURING TESTING MAY OCCURAT THIS POINT WHEN THE ADJUSTED PRESSURE IS REACHED FLUID WILL EXIT FROM THIS DRAIN PORT 1600 PSI ADJUSTING LOCKING SCREW NUT 7 6 SECTION 7 CHECK OUT CHECK PUSH OUT SHOES AND WEAR BLOCKS OPERATIONAL STATUS 1 Visually inspect all pushout shoes and wear blocks for excessive wear These items must be replaced before there is metal to metal contact 2 Shim or replace warn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL WEAR BLOCKS POWER TAKE OFF P T O OPERATIONAL STATUS 1 Periodically re torque the mounting bolts or studs as outlined in the P T O manufacturers service manual 7 7 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 experienced opera tors a thorough understanding of the information in this manual and accurate maintenance records are the best troubleshooting tools available Occasionally it may be best for a service person who is trying to isolate a problem to go on the route or consult with operators to determine how the unit is acting under actual work ing conditions For the most part problems with the unit will be limited to hydraulic and electrical system component malfunc tion or
60. T LEVER 1 Depress and hold engine speed up button push the pushout lever rearward and hold until the pushout panel stops PX NOIE SPEED UP On units with a telescopic pushout cylinder this will BUTTON eject the entire load go on to step 4 2 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed AWARNING 3 Repeat steps 1 and 2 until the pushout panel is as far back as it will go completely ejecting the load Never drive the unit more than 10 feet with the tailgate in a raised position 4 Slowly pull the unit ahead to clear the refuse pile when the tailgate is lowered 6 Pull the pushout lever forward to completely retract the pushout cylinder Now push the pushout lever 5 Clear debris from the edges with a pole while stand rearward extending the pushout cylinder a few inches ing clear off to one side thus clamping the bar to the pushout panel With the telescopic circuit the pushout cylinder remains fully extended If the unit is going to travel over one mile empty completely retract the cylinder When packing is about to resume extend the cylinder and start packing PUSHOUT LEVER LOWERING THE TAILGATE 1 Pull forward on the tailgate lift lever slowly and in small increments to lower the tailgate a little at a time AVOID SLAMMING SHUT the tailgate TAILGATE LIFT 2 Place the tailgate clamps in
61. TION 3 OPERATION 10 Move both the packer panel lever and carrier panel CARRIER PANEL lever inward and let go Check for the following LEVER a Engaging the carrier panel lever will activate an engine speed up switch you should hear PACKER PANEL the engine speed up LEVER gt b Observe the carrier and packer panel move ment it should be smooth The panels should stop automatically at the interrupted cycle position mm Il LI 11 Move both the packer panel lever and carrier panel lever outward and let go Observe the carrier and packer panel movement it should be smooth The panels should stop automatically at the home position 12 Depress the two driver signal push buttons located on both sides of the tialgate to make sure that the au dible alarm located in the cab is working 8 DRIVER SIGNAL PUSH BUTTONS BOTH SIDES OF TAILGATE 13 Back the unit up a few feet to ensure that the back up alarm is working properly TAILGATE 14 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 3 9 SECTION 3 OPERATION Do not operate a unit that is in need of service or repair 15 Report any problems found during the pre opera tion walk around inspection to the maintenance supervisor for service or rep
62. TION 9 SERVICE AND REPAIR FRONT CONTROL VALVE The front control valve is located behind the access door in the front left hand side of the body It is manu ally activated and controls the raising and lowering of the tailgate and the operation of the pushout panel This valve also contains the main pressure relief for the hydraulic system REMOVAL OF FRONT CONTROL VALVE Truck Off PTO Disengaged OPERATIONAL STATUS 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 Remove the capscrews lockwashers nuts and remove the valve FRONT CONTROL DISASSEMBLY AND INSPECTION OF FRONT CONTROL VALVE 1 Wash the valve body with solvent to prevent conta mination NOTE Service should be limited to seal replacement car tridges and individual valve sections Field repairs of the spool assemblies are not recommended 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 Thoroughly clean the o ring counter bores and ground surfaces of each section To remove handle bracket remove the two cap Screws securing the bracket to the work section
63. TORS MANUAL Over Serial Number 16000 BUILDING THE BEST One genuine Leach hat to the first person to notify us of an error in any of our publications If you find what you believe to be an error in any of our publications please complete the requested information an return the form to us by fax or mail If you are the first you will receive a hat by return mail believe found an error In the Part No Page s It should say Name Address City State ZIP Code Thanks for your help manual Return this form to Leach Company Service Department P O Box 2608 Oshkosh WI 54903 2608 Fax 920 231 2712 LEACH C P A Y 2737 Harrison Street Oshkosh Wisconsin 54901 920 231 2770 920 231 2712 FAX Please visit our website www LeachUSA com PRINTED IN U S A April 30 2001 Part Number 105318
64. air 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 manufacturers instructions 9 All operating and running lights functioning 10 Engine speed up buttons operational 11 Packing cycle operates properly 12 Driver signal alarm can be heard 13 Back up alarm and tailgate ajar light are operable 14 Report any problems to proper personnel LEACH 3 10 SECTION 3 OPERATION START UP OPERATING INSTRUCTIONS 1 Inspect and start the truck as described in the pre operational walk around inspection alr lr fa Nis 2 Engage the Pump PTO control to start the hydraulic pump 3 Place the engine speed up switch in the ON position ENGINE SPEED UP SYSTEM OFF 3 11 SECTION 3 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 SPEE
65. anels which sweep up and pack the refuse from the hopper will be in the home position PACKER PANEL HOME POSITION COMPACTION When the operator starts the packing cycle the carrier and packer panels move rearward over the load CARRIER amp PACKER PANELS MOVE OVER LOAD CARRIER Next the carrier and packer panel automatically PANEL stop at the interrupted cycle position PACKER PANEL 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 PACKER PANEL PUSHOUT PANEL CARRIER PANEL COMPACTION POSITION 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 On units with the standard clamp pushout system the operator must manually release the pushout panel clamping system to allow movement of the pushout panel Once the body is full the 2RII Packmaster can be moved to the dumpsite for unloading CARRIER PACKER PANEL PANEL PUSHOUT PANEL MOVES FORWARD UN
66. arranty an authorized Leach Distributor must have completed a pre delivery inspection before the unit is placed into service and the delivery report form signed by both the customer and the distributor must be submitted to the Leach Service Department Because Company products are engineered to work only with genuine Company parts this limited warranty will be void and of no effect if a Company products are modified other than as done at its factory or as authorized to be done by the factory in writing or b Parts or assem blies of any other manufacturer 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 components and assemblies at any time FOREWARD Leach Company has been a leader in the refuse industry for over 110 years Leach refuse bodies are the industry standard for both quality and performance Leach Company is justifi ably proud of the quality engineering material and workmanship that goes into each a
67. bounce the container Do not slam the container against the packer tail gate or bump bar Do not attach the hook to any lift point which will not be completely encircled by the hook with the safe ty latch closed Do not remove the hook safety latch Read and obey all container decals issued by the container manufacturer Read and follow container manufacturers informa tion on accepted use practices Do not attempt to lift overloaded containers Center the container on the attachment All containers should be inspected for serviceabili ty and repaired if not in a safe usable condition Do not use a non standard or damaged trunnion bar Never cross under a raised container Stand clear when dumping containers Before attempting to lift a container below 32 F 0 C make sure it is not frozen to the ground When using an eye type container attachment point the base of the hook must be positioned to lift on the inside of the eye Place the container on a flat level surface LEACH 1 4 SECTION 1 SAFETY PRECAUTIONS HYDRAULICS Hydraulic fluid operates under high temperatures Avoid contact with piping hoses or cylinders to prevent burns Never use hands to check for leaks Hydraulic fluid escaping under pressure may cause injury In case of injury seek proper medical treatment immediately FIRE PROTECTION Keep a fire extinguisher accessible at all times as recommended by the Bureau
68. c 2 before performing any of the following check out procedures Use extreme caution to avoid coming near any moving parts Never enter the body of the unit when the truck is running Make sure the unit is in the correct opera tional mode as indicated by the 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 Speed On Up CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down and clamped se curely 2 Position the packer panel to the INTERRUPTED CYCLE position 3 Pull the pushout lever to position the pushout cylin der in the retract position 4 The fluid level should be between the safe range marks on the sight gauge IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 5 Add hydraulic fluid for normal operating and weather conditions See Sec 6 PREVENTIVE MAINTE N ANCE for additional information about servicing the hydraulic tank SECTION 7 CHECK OUT 1 1 2 HO a i 7 1 SECTION 6 CHECK OUT CHECK ENGINE SOLENOID SWITCH OPERATIONAL STATUS Truck Running PTO Engaged Speed n Up 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 REPA
69. c lines 1 Perform checkout procedures through pres sure checks See Sec 7 Check out 2 Add fluid to correct level See Sec 6 Preventive Maintenance 3 Service system as described in Sec 6 Preventive Maintenance 4 Drain and refill with correct type of hydraulic fluid See Sec 5 Specifications 5 Adjust main relief setting on 2 spool valve See Sec 9 Service and Repair 6 Replace pump See Sec 9 Service and Repair 7 Perform test for leaking cylinder See Sec 9 Service and Repair 8 Perform pressure checks See Sec 7 Check out 9 Cycle packer 6 or 7 times to bleed air out of system 8 5 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM TELESCOPIC CYLINDER LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING POSSIBLE CAUSE REMEDY 1 Excessive fluid flow being forced through the main relief in the 2 spool valve 1a Release speed up button 1b Only partially pull feather the 2 spool valve control handle LOAD WILL NOT PUSH OUT POSSIBLE CAUSE REMEDY 1 Less than full pressure in telescopic 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 WHILE PACKING REFUSE PUSHOUT PANEL SLIDES FORWARD TOO FAST POSSIBLE CAUSE REM
70. check out proce dure Prior to performing pressure checks OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install a gauge capable of reading at least 3000 PSI 207 BAR on the test coupling 2 Start the unit engage the PTO and turn solenoid switch ON TEST COUPLING 7 3 SECTION 7 CHECK OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 1 Depress speed up button 2 Move pushout control lever to fully extend pushout cylinder 3 Hold lever and read gauge Pressure should be at least 1950 PSI but no more than 2000 PSI FNOT AWARNING Make sure the area above the tailgate is clear be fore raising the tailgate 4 Release the tailgate clamps Move the tailgate con trol lever rearward to completely raise the tailgate 5 Hold the lever and read the gauge On 20 and 25 yd units the pressure should be at least 1950 PSI 135 BAR but no more than 2000 PSI 138 BAR On 31 and 33 yd units the pressure should be at least 2200 PSI 152 BAR but no more than 2250 PSI 156 BAR 6 Lower tailgate to the lowered position Lower in small stages to avoid slamming the tailgate down 7 If the pressure is below the appropriate setting for your unit but is at least 1400 PSI 97 BAR loosen the lock nut on the relief cartridge and using an allen wrench turn the adjusting screw in rotate clock wise to reach the correct pressure If the pressure
71. cle position 8 12 Packer panel sweeps hopper 8 13 Packing 8 14 Raising tailgate 8 15 Ejecting 8 16 Retracting Pushout panel 8 17 Lowering Tailgate 8 18 SECTION 9 SERVICE AND REPAIR Generals 4234s nie ides 9 1 Description of Operating Cylinders 9 1 Test for Leaking Packer Panel Cylinders 9 2 Test for Leaking Carrier Panel Cylinders 9 4 Removal of Packer Panel Cylinders 9 7 Removal of Carrier Panel Cylinders 9 9 Disassembly of Operating Cylinders 9 11 Inspection and Replacement of Operating CylinderS 9 11 TABLE OF CONTENTS SECTION 9 SERVICE AND REPAIR continued SECTION 9 SERVICE AND REPAIR continued Reassembly and Installation of Installation of Carrier Panel 9 39 Operating Cylinders e ostras tasa ds 9 12 Track Bar Replacement 9 39 Description of the Packer Panel 9 12 Description of Leach Hydraulic Pump MR EE 9 40 Bearing Replacement petet c e e e n n nn 9 12 Removal of Hydraulic 9 40 Roller Replacement Shimming 9 13 Installation of Hydraulic Pump 9 41 Description of Tailgate Lift Cylinders 9 15 New Pump Preparation 9 44 Test for Leaking Tailgate Cylinder 9
72. copic cylinder pivot pins 6 2 1 In below freezing climates all grease and fluids should have a cold test rating of at least 20 F ILLUS LUBE POINT QTY NOTE NOTE The packer panel must be in the home position to lubricate the following lube points 6 Operating valve 4 1 control lever e Inside amp outside 3 bearing housing es Carrier panel cylinder 1 end 9 Packer panel cylinder 2 rod ends 10 Rollers 4 3 amp 4 m1 Optional control 2 lever s SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART NOTES 1 These parts require frequent inspection and lubrica tion as necessary to be in prime working condition 2 Remove the top cover for access to lube points 3 Move roller track access covers to grease roller 4 Rollers need lubrication roller tracks do not Grease on the tracks will cause the rollers to slide keep tracks clean and dry 6 3 2 kE O N PREVENTIVE MAINTENANCE 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 Place the carrier and packer panels in the interrupted cycle position and fully retract the pushout cylinder to check the fluid level 1
73. d 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 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
74. d be labeled with the date type of fluid model and serial number of the machine Two identical samples should be taken One for labora tory analysis and one for your own preliminary analysis while you are waiting for the lab report We recommend the use of commercial laboratory ser vices for analysis of routine fluid samples taken on a regularly scheduled basis The cost is about 20 to 30 per sample The most important analysis are particle count Spectro chemical analysis water content and viscosity IN HOUSE HYDRAULIC FLUID TEST ING After your sample has been allowed to stand for 20 to 30 minutes to eliminate air bubbles hold the bottle up to the light to check whether the fluid is clear or cloudy Any visible debris is an indication of a severe solid con tamination problem the source of which must be locat ed and corrected immediately Common sources of this kind of contamination may be component wear under sealed reservoir covers or dirty air breather filters If the sample is the least bit cloudy it is an indication 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 ind
75. d nut 3 securing the pivot pin retainer 4 and remove the retainer puller See Sec 10 SERVICE TOOLS Check for bent pivot pins and inspect pin hubs for broken welds and elongated holes SECTION 9 SERVICE AND REPAIR REMOVAL OF CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet to provide better accessibili ty Remove two capscrews 1 lockwashers 2 and spacer 3 securing the upper track hole cover 4 and remove the upper covers from each side of the tailgate OPERATIONAL STATUS Truck Running PTO Engaged Speed n Up 2 Shift the carrier panel lever and cycle the unit until the roller assembly on the upper end of the carrier panel is in line with the open upper track hole CARRIER PANEL LEVER 9 OPERATIONAL STATUS Truck Off PTO Disengaged NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 3 Secure chains or a sling to the upper and lower end of the carrier panel Attach the other end to a suitable lifting device with a minimum lifting capac ity of 1 600 Ibs 726 kg Adjust the hoist so that it will support the panel once the roller assembly and pivot pin are removed but not so tight that it changes the position of the carrier panel 9 9 SECTION 9 SERVICE AND REPAIR 4 Once
76. d spacers 3 secure the cover weldment 4 over the four track holes 22222 cm DESCRIPTION OF TAILGATE LIFT CYLINDERS These two hydraulically operated cylinders mounted on each side of the tailgate lift and lower the tailgate assembly The rod end is pinned to a pivot ear on the body frame near the discharge opening while the cylin der weldment pivot ear is bolted to a mounting hub on the tailgate TEST FOR LEAKING TAILGATE CYLINDER NOTE This check will require two people OPERATIONAL STATUS Truck Off PTO Disengaged 1 Loosen and release swing away the tailgate clamps CLAMPS 9 15 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed B n Up 2 Depress the speed up button and move the tailgate lift lever to raise the tailgate and hold 3 Visual inspection of the tailgate cylinders is the only leakage test necessary TAILGATE RAISED WN Sa 2Y wx Tir aa 1 REMOVAL OF TAILGATE LIFT CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 With the tailgate closed attach a sling connected to a suitable lifting device with a capacity of 500 lbs 227 kg to the tailgate lift cylinder NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings
77. d when removing the detent assembly is limited to o ring and back 4 Remove spring collars 7 and centering spring 6 up washer replacement Carefully slide detent sleeve 8 off the spool The four detent balls 9 will be free to fall out when the sleeve is removed Remove spring guide 10 outer spring 11 and follower 12 Remove inner spring 13 if used and the knock out plunger 14 12 BACK UP 17 amp 18 9 FOLLOWER RING O RING DET NT BALLS 4 7 10 14 ADJUSTMENT SPRING SPRING KNOCKOUT a a SCREW COLLARS GUIDE PLUNGER EA 99 2 3 Q9 BONNET LOCK 3 DN SPOOL NUT MAA qe BACK UP DETENT RING BALLS y T 18 9 gw INNER DETENT SPRING NEEDLE o SPRING SLEEVE GUIDE ROLLER 13 8 15 16 SPOOL CENTERING OUTER SCREW COLLAR SPRING SPRING 1 5 6 11 REASSEMBLY OF KNOCKOUT POSITIONER 1 Lightly oil and install backup rings and o rings 18 Install needle roller 16 Lightly oil and install the o ring amp backup ring 17 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 Install spring collars 7 and centering s
78. e 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 clothing LEACH 4 2 SECTION 4 GENERAL REP
79. e 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 TYPO ovat kaye bacageone woe eee dee nd Oh Eee D O F Double Branch Oblong link Foundry Hook lp ECT in Harmimerlocks iux uei Reg 5 Dawe E oe eee XR ee eee d Feng OS in Oblong WINGS sa xe DE cea nn cena sa them AS A RC Exe ERU ER ees in 4 5 SECTION 4 GENERAL REPAIR PRACTICES CAPSCREW MARKING AND TORQUE VALUES Much Used Used at Times Used at Times Capscrew Diameter To 120 000 140 000 150 000 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 8 1 11 0 1 38 7 2 35 9 2 63 1 4 29 34 4 70 5 4 84 9 6 78 55 7 61 5 7 61 5 10 37 85 11 76 5 11 76 0 15 21 120 16 60 120 150 170 270 295 395 435 590 660 1 y y 3 3 4 5 7 8 1 2 167 23 10 a 280 38 72 51 86 54 53 440 60 85 805 83 67 a E 660 91 28 EA 91 28 136 92 NOTES Always use the torque values listed above when specif
80. e 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 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 valve replace all seals and o rings that are disturbed during repair Th
81. e of misplaced tools and parts If the portion of the unit to be repaired is ex cessively dirty it should be cleaned before work starts The cleaning process may include the use of high pres sure 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 Interrupt ing a job to locate tools or parts is a needless delay Special tools required for a specific job are listed in Sec tion 11 REPLACEMENT PARTS Of growing concern to the Leach Company is the use of counterfeit will fit or substitute parts Leach Signature replacement parts are designed and manufactured to exacting standards The use of counterfeit will fit or sub stitute parts may effect 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 infor mation necessary for maintaining the refuse unit in a proper safe operating condition Check with your autho rized Leach distributor SECTION 4 GENERAL REPAIR PRACTICES which is not recommended by Leach Company must first
82. e 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 good ground and the probe at the point where the presence of voltage is
83. e to move the pushout panel toward the front ofthe body When the pushout panel has reached the front of the body neither the packer panel operat ing lever nor the carrier panel lever should be overrid den except to clear the final hopper load ENGINE 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 discon nected DISCONNECTED PUSHOUT LEVER 3 16 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 interrupted cycle position 2 Loosen both tailgate clamps and swing them out and forward as far as they will go LIFTING THE TAILGATE Stand clear when the tailgate is raised If you need to clean debris from the edges use a pole while standing to the side E gt WE x N N S gt ENS SSN 1 Depress and hold engine speed up button 2 Push the tailgate lift lever rearward and hold until the tailgate is fully raised TAILGATE LIFT ENGINE SPEED UP BUTTON 3 17 Sv SECTION 3 OPERATION The tailgate open light and backup lights should illuminate The backup alarm should also sound SECTION 3 OPERATION EJECTING THE LOAD PUSHOU
84. ection will provide all of the instructions necessary to operate the 2RII Packmaster However prior to attemting any operation of the unit make sure you are familiar with all of the safety information contained in Section 1 SAFETY PRECAUTIONS DESCRIPTION OF OPERATING CONTROLS The following information is for descriptive purposes only It is not to be misconstrued as operating in structions For operating instructions refer to OP ERATING PROCEDURES later in this section There are only a few controls required for the complete and efficient operation of the 2RII Packmaster It is im portant that you know the location and function of each control before attempting to operate the unit Refer to the accompanying illustrations for their location 3 1 SECTION 3 OPERATION SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS SECTION 3 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 chas sis style and control panel location The Pump PTO may be engaged by use of a lever rocker switch push pull cable toggle lever or positive control button dep
85. ehicle to tow other equipment It is W e Stand clear when not intended designed or equipped tailgate is in for towing motion amp during unloading cycle Stand clear when not stand or packer panel is cross under raised in motion tailgate 2RII PACKING OPERATION INSTRUCTIONS This vehicle requires of overhead clearance as originally mounted Be sure all persons are clear of hopper opening before operating controls STROBE LIGHT ON OFF TAILGATE Do not transport container OPEN on lift mechanism e Transporting a container could result in personal injury or property damage 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 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 riding steps SOLENOID MUST BE OFF WHEN TRUCK IS PARKED ON OFF Do not operate vehicle in excess of 20 mph from the stand up position 1 9 SECTION 1 SAFETY PRECAUTIONS
86. ending on the style Be sure to read all safety decals associ ated with the Pump PTO before attempting operation K cone enra t 0 17 M bro SOLENOID ON OFF SWITCH 2 This switch energizes the engine speed up system Itis located on the cab control panel exact location depen dent on cab make and style NOTE The engine speed up system consists of the solenoid ON OFF switch a relay and solenoid air cylinder on electronic engines the relay is wired to the engine ECU 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 system 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 lights Operation of the unit with an illuminated or defec tive warning system can result in personal injury and or equipment damage 3 3 SECTION 3 OPERATION ENGINE SPEED UP PUSH BUTTON 4 When depressed this push button switch will cause the engine to speed up and supply more power to the hy draulic system Located on the lower front left side of the body it is depressed by the operator when operating either the pushout lever or tailgate lift lever PUSHOUT L
87. er any circumstances enter the body if the truck is running Open the packer panel and release the pushout panel clamp before entering the body Always make sure the truck engine is off and the keys are in your pocket before entering the body 3 7 PUSHOUT LEVER FRONT CONTROL VALVE TAILGATE LIFT LEVER ENGINE SPEED UP BUTTON CARRIER PANEL LEVER Ss PACKER PANEL LEVER SECTION 3 OPERATION 7 Start the truck according to the manufacturers instruc tions and while it is warming up continue the walk around inspection 8 Check all of the operating and running lights Make sure none are missing and that there are no burned out bulbs AWARNING The tailgate open warning light should be off Do not operate the unit if the light is illuminated Never place hands in or near the packer panel dur ing operation 9 With the engine running the speed up solenoid switch ON the PTO engaged and the transmission in neutral and the brakes applied depress the speed up push but ton on the forward left street side of the body You should hear the engine speed up LA 00 A ALO 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 PUSHOUT LEVER FRONT CONTROL VALVE ENGINE SPEED UP BUTTON 3 8 SEC
88. etween the carrier panel and the partition sheet to take the weight off of the roller assemblies If the bottom roller is removed support the carrier and packer panel assembly before removing the roller OPERATIONAL STATUS TRACK HOLES Truck Off PTO Disengaged 4 Remove one roller at a time 5 Replace any roller that is excessively worn cracked or out of round Inspect the condition of the track bar 6 Replacement rollers should be installed with the SHIMS original shims or the same amount of new shims A grease fitting should be installed in the replacement OPERATIONAL STATUS Truck Running PTO Engaged Speed Up a 7 Repeat step 1 to determine if additional shims are zt GREASE FITTING CAUTION Do not over shim rollers Excessive shimming may damage the tailgate walls or wear the track channels 9 14 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 8 Remove the appropriate rollers and add shims as required to obtain smooth operation of the packer and carrier panel This may require adding or removing shims and operating the packing lever several times until the correct alignment is achieved Once alignment is correct lubricate each roller as described in the LUBRICATION CHART Sec 6 PREVENTIVE MAINTENANCE 10 Using the cap screws 1 and lockwashers 2 an
89. fter setting the vehicle parking brake the right and left container latch arms must be engaged Lifting a container without both latch arms secured can allow the container to swing away from the unit and cause severe injury or death NOTE If the container is equipped with wheels it should be rolled into position only after the vehicle parking brake has been set Even small containers must use the latch arms to se cure them to the packer LATCH ARMS DISCONNECTED ATTACHED 3 13 SECTION 3 OPERATION USING A WINCH OR CONTAINER LIFT CYLINDER Once the container is secured within the latch assem bly the lifting cable should be attached Place the load in the base of the hook with the safety latch closing the throat opening It is important that hooks are used in a proper manner Proper use of a lifting hook not only includes placing the load in the base of the hook but also includes ensuring that the hook is lifting on the proper area of the attachment point The hook must completely encircle the attachment point Equally as important at the time load is applied to the base of the hook the positioning must be correct to prevent the hook from dislodging When using an eye type attachment point the base of the hook must be positioned to lift on the inside of the eye The diagrams show both correct and incorrect positioning of the hook For the safety of yourself as well as others alwa
90. ged Refer to Sec 4 GENERAL REPAIR INSTRUCTION for welding instructions 1 Remove the old track bar and make sure the track channel is smooth and clean 2 Weld a new track bar in place The surface of the track bar must be at 90j from the side of the tail gate so the roller will run true CAUTION The Leach track bar is made out of special alloy bar steel Do not substitute a different steel It may cause damage to the tailgate WRONG RIGHT GAP NO GAP 9 39 SECTION 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 OPERATIONAL STATUS Truck Off PTO Disengaged 1 Shut the gate valve at the underside of the hydraulic fluid tank GATE VALVE 2 Remove the hose clamp 3 Remove the pump suction line and allow the fluid to drain NOTE The pump suction line tube and hose will also be filled with hydraulic fluid The pump and line may be drained into an absolutely clean container and the fluid poured back into the tank 4 Disco
91. hat happens in the hydraulic system of the telescopic sys tem during the loading packing and unloading opera tions 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 proceed ing to the flow diagram refer to the illustration and be come familiar with the system component nomencla ture SYSTEM COMPONENT NOMENCLATURE OPERATING TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK TELESCOPIC CYLINDER CARRIER CYLINDER n PACKER CYLINDER CARRIER 5 CYLINDER TAILGATE LIFT CYLINDER 8 9 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM NEUTRAL with the packer panel in home position OPERATOR ACTION Operator starts the truck and engages the PTO and speed up system HYDRAULIC SEQUENCE Hydraulic fluid flows from the tank by gravity to the pump from there it is pumped to the FCV Front Control Valve Flow continues through the valve to and through the MCV Main Control 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 con trol valve back to tank AA TAILGATE LIFT CYLINDER CARRIER CYLINDER PACKER CYLINDER CARRIER CYLINDER QM N SS VALVE TEL
92. he carrier panel lever inward to retract the car rier panel cylinder OPERATIONAL STATUS 7 Disconnect and plug the hydraulic lines which con nect to the case end of the carrier panel cylinder PLUG OPERATIONAL STATUS STATUS Truck Running PTO Engaged 8 Shift the carrier panel lever inward to apply hydraulic pressure to the rod end of the carrier cylinder Hold the lever and observe the fluid flow from the port on the cylinder case end The flow of hydraulic fluid should be no more than 2 fluid ounces A flow greater than 2 ounces indicates an excessive piston seal leak Dis assemble the cylinder and replace the piston seal OPERATIONAL STATUS CARRIER PANEL LEVER Truck Off PTO Disengaged 9 If the cylinder does not leak reconnect the hydrau lic lines to the case end of the carrier panel cylin der OBSERVE FLUID FLOW 9 6 SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet to provide better accessibil ity to the packer panel PACKER PANEL CYLINDERS NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device with a capac ity of 5
93. hoist and lift the packer panel out of the hop per Use care to avoid damaging the hopper INSPECTION AND REPLACEMENT OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot bearing and roller surfaces for excessive or uneven wear scoring or other dam age 2 Check the panel for broken welds bent edges or warpage 3 Inspect the packer panel edge for damage Replace a badly worn edge as described below 4 Replace parts as necessary See Sec 4 GENERAL REPAIR PRACTICES SECTION 9 SERVICE AND REPAIR OO 203 00 225159 m TTD INSIDE BEARING ASSEMBLY OUTSIDE BEARING ASSEMBLY 9 36 SECTION 9 SERVICE AND REPAIR REPLACEMENT OF PACKER EDGE 1 Remove the old edge with an air arc to obtain a clean cut Grind smooth the packer panel where the new edge will be attached Weld a new edge in place NOTE Pay particular attention to the torque tube Ensure that it is perfectly straight INSTALLATION OF PACKER PANEL Truck Off PTO Disengaged OPERATIONAL STATUS Install the packer panel in the approximate reverse order of disassembly Pay particular attention to the installation of roller and bearing assemblies as described earlier in this section 9 37 SECTION 9 SERVICE AND REPAIR CARRIER PANEL The correct method of operation is tho
94. iagram TESTING To locate a defective component or break in the wiring perform a continuity check across the between sus pected components as described in Sec 4 GENERAL REPAIR REPAIR Repair of the electrical system is limited to the replace ment of burned out light bulbs and other defective parts or wiring INSPECTION 1 Operate all light switches and pushbutton controls to insure that they are operating normally 2 Check all wiring for breaks frayed or worn insula tion and loose terminal connections GROUNDING THE ELECTRICAL SYSTEM To insure a proper ground for the electrical system make sure an internal lockwasher is installed in the fol lowing areas 1 Buzzer System between the pushbutton and bracket 2 Speed Up System between the pushbutton and bracket 3 Back Up Alarm between the backup alarm and bracket 4 Taillight between the light and bracket The internal lockwasher will bite into the metal and ensure a positive ground TYPICAL EXAMPLE TOOTHED WASHER LEACH 9 44 LEACH Y CUSTOMER SUPPORT MANUAL LITERATURE ORDER FORM SHIP TO LEACH INTERNAL USE ONLY mS ORDERED BY NO TITLE QTY NO TITLE QTY Current Production Units Previous Production Units 2RII 105291 2RII PARTS 9719 16000 105313 2RII PARTS OVER 16000 105615 2RII SERVICE 9719 16000 105318 2RII SERVICE OVER 16000 105546 2RII PARTS 8993 9718 105319 2RII OPERATORS OVE
95. ic torque values are not available The above is based on use of clean dry threads Reduce torque by 10 when engine oil is used as a lubricant Reduce torque by 20 if new plated capscrews are used General Formula for calculating Torques is as follows Torque in Inch Lbs 2 x Nominal Diameter of Screw x Loads in Lbs where Load 80 of Yield Strength expressed in Lbs not pounds per square inch LEACH Colo 4 6 SECTION 5 SPECIFICATIONS 4 B als BODY DIMENSIONS 20 Cu yd 25 Cu yd 31 Cu yd 15m 19m 24m3 AF After Frame 52 Beam 50 50 50 1270mm 1270mm 1270mm B Overall Length 249 270 316 6325mm 6858mm 8026mm CA To Centerline of Trunion Note2 123 144 190 3124mm 3658mm 4826mm D Height Above Chassis Frame 97 97 97 2464mm 2464mm 2464mm 1 Body Outside Width 96 96 96 2439mm 2439mm 2439mm J Body Inside Width 90 90 90 2286mm 2286mm 2286mm Hopper Depth 17 17 17 432mm 432mm 432mm N Interference Point Above 4 4 4 102mm 102mm 102mm Chassis Frame P Top of Step Below Chassis Frame 14 17 19 19 483mm 483mm 483mm Q Hopper Bottom Below Chassis 22 22 22 559mm 559mm 559mm Frame R Hopper Opening Width 80 80 80 2032mm 2032mm 2032mm S Hopper Opening Height 56 56 56 1423mm 1423mm 1423mm T Hopper Inside Width 80 80 80 2032mm 2032mm 2032mm U Rear of Body to Rear of 74 74 74 1880mm 1880mm 1880mm Ta
96. ication that a more complete test may be necessary A If the blotter remains colorless or develops only a light yellow ring oxidation is under control B If color develops but is uniform throughout the fluid is still serviceable but should be checked for cor rect additive content C If the sample shows distinct rings the fluid should be changed D lf a distinct dark spot remains in the middle but a lighter colored fluid migrates outward in the blotter paper the fluid is about to dump or already has sludge or other by products into the system The time for replacement of this fluid has already passed Kits are available from your fluid supplier to test for acid content in much the same way you would test the con dition of swimming pool water A shift in acid content may indicate a breakdown in the fluid KEEP ACCURATE DATED RECORDS OF ALL PER TINENT INFORMATION GAINED FROM THESE TESTS 6 7 SECTION 6 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE Each day perform the following maintenance 4 INSPECTION 4 CONTAINER HANDLING EQUIPMENT Perform the PRE OPERATIONAL INSPECTION described in Sec 3 OPERATION Never go under the vehicle with the engine run ning Death or serious injury could result a When checking for hydraulic leaks pay particular attention to hose fittings and connections at the cyl inders and valves A build up of hydraulic fluid a
97. icle 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 pushout panel clamp or the telescopic ejection system cylinder is released PTO disengaged and ignition key removed and placed in your pocket Do not attempt to load refuse into the hopper after SECTION 1 SAFETY PRECAUTIONS 34 35 36 37 38 39 40 41 42 43 44 54 46 47 48 49 50 51 the packing cycle has begun The packer panel must be 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 engage
98. ilgate Closed m Height Above Chassis Frame 194 194 194 4928mm 4928mm 4928mm Tailgate Raised Loading Sill Below Chassis 5 5 5 127mm 127mm 127mm Frame Non Tag Axle Body m Center of Gravity Measured From 117 131 151 2972mm 3328mm 3836mm Front of Body Body Only Payload 94 103 120 2388mm 2617mm 3048mm Hopper cubic yards 3 5 cu yd 3 5 cu yd 3 5 cu yd 2 7m3 2 7m3 2 7m3 Approx Body Weight 14 495 Ibs 15 020 Ibs 16 125 Ibs 6575kg 6575kg 6575kg Min Truck GVWR Requirement 46 000 Ibs 52 000 Ibs 60 000 Ibs 20 862 9 23 583kg 27 211kg Note 1 Notes 1 Truck selected must be capable of carrying net weight of body plus weight of refuse to be collected 2 CA must be usable with no obstructions protruding above frame 5 1 SECTION 5 SPECIFICATIONS LUBRICANTS SAE 10 equivalent Grease Multiservice quality grade HYDRAULIC SYSTEM CAPACITY approximately EII nene ze A xu ask be ba Ge RUE aa hae RR RU eb ede a 45 gallons Total system System pressure settings Clamp 1650 PSI 114 BAR Tele 1950 PSI 135 BAR Type of fittings llle Steel tubing with brazed and flared fittings reinforced rubber hose with crimped full flow fittings o ring fittings alcune PPP Suction Reusable wire mesh type Return line Disposable filter element located on the return line to the tank PUMP 203834 Uds ecc PCT rc
99. ill automati cally shift to neutral 2 To finish the cycle move both the packer panel lever and the carrier panel lever outward away from the tail gate then let go The packer panel will sweep the hop per 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 packing cycle 3 Repeat steps 1 and 2 each time the hopper is filled to but not above the loading edge 3 15 SECTION 3 OPERATION CONTAINER CONTROL LEVER Releasing the CPB control handle when the container begins to tip will allow the container trunnion bar to lower within the latch slots with ease CARRIER PANEL LEVER N PACKER PANEL 7 LEVER CARRIER PANEL LEVER PACKER PANEL LEVER SECTION 3 OPERATION PUSHOUT PANEL OPERATION DURING PACKING TELESCOPIC PUSH OUT The 2RII Packmaster telescopic pushout cylinder will normally move toward the front of the body automati cally When the resistance circuit is adjusted to produce maximum load density it may become necessary to manually retract the telescopic pushout cylinder in order to allow the compacted refuse to move forward in the body Also ifthe packer panel stops short of the home position the carrier panel operating lever may need to be held overridden to allow the refus
100. inders for better accessibility during testing OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 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 A CAUTION 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 plug the lines to the rod end of one cylinder at a time SECTION 9 SERVICE AND REPAIR PACKER PANEL CYLINDERS PACKER PANEL LEVER 9 2 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 4 Shift the packer panel lever outward to apply hydrau lic pressure to the case end of the packer panel cylin ders Hold the lever and observe the fluid flow from the open port on the rod end The flow of hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces indicates an excessive piston seal leak If the cylinder does not leak exces sively continue test OPERATIONAL STATUS PACKER PANEL LEVER OBSERVE FLUID FLOW Truck Off PTO Disengaged 5 Reconnect the hydraulic lines to the end of cylinders Repeat steps 3 5 for the other cylinder OPERATIONAL STATUS Truck Running PTO Engaged Speed On Up 6 Shift the packer panel lever inward to retract the
101. ir kit from your authorized Leach distributor 9 11 SECTION 9 SERVICE AND REPAIR REASSEMBLY AND INSTALLATION OF OPERATING CYLINDERS Reassemble and install the operating cylinders in the approximate reverse order of dissassembly DESCRIPTION OF THE PACKER PANEL The packer panel works in conjunction with the carrier panel and four operating cylinders to make up the com paction mechanism The packer panel is hinged to the carrier panel and is controlled by the operating cylin ders Rollers supporting the two panels move along a track inside the tailgate The packer panel sweeps forward through the hopper picking up the refuse and together with the carrier panel moves the refuse forward into the body where it is compacted against the pushout panel BEARING REPLACEMENT OPERATIONAL STATUS Truck Running PTO Engaged Speed B E n Up 1 Move the packer panel lever outward to fully PACKER PANEL extend the packer panel cylinders and put the LEVER panel into the home position 2 Raise the tailgate for access to the bearing ha Ws through bolts Support the tailgate with stands prior Ss 1 72 to loosening through bolts 57 BEARING HOUSINGS HW SS 9 12 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 3 Remove the nuts 2 and through bolts 1 Remove the bearing assembly 3 Inspect the bearing s
102. it Lower the wrapped section of tube down into the packing and then lift the tube once again 6 When removing the packing from succeeding larg er stages replace the head nut 3 on the stage directly above the section you need access to Wrap a strap under the head nut and use it to lift the tube 7 Prior to installing new packing 4 clean the area thoroughly and lubricate the new packing set inside and out with an all purpose grease CASE END 8 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 9 Replace all of the head nuts 3 being careful not to overtighten 10 Replace the plastic plug 2 and setscrew 3 Al 9 28 SECTION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER DISASSEMBLY Prior to disassembling the cylinder first make four clips from thin steel These clips should be approx imately 020 thick U 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 prevent 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
103. ld slide out with the taped section of the rod If not repeat until the packing slides out Slide the packing off of the rod and discard Using a long screwdriver or pick remove the retain ing ring from the inside of the cylinder between the case and the rod Use care to avoid damage to the case or rod surfaces Slide the retaining ring off of the rod and discard Slide the rod assembly out of the case Remove the wear ring from the bottom of the cylin der rod and discard Remove the wiper from the head gland INSPECTION REASSEMBLY AND INSTALLATION T Thoroughly check all components of the cylinder for cracks scoring or uneven wear Parts that must be replaced together such as seals and wear rings are available as a repair kit from your authorized Leach dealer Liberally coat all seals and wear rings with clean fresh hydraulic fluid before installation Assembly of the tailgate lift cylinder is in approxi mate reverse order of disassembly Install the packing into the cylinder using a flat punch to push it in place Tighten the head gland only enough to prevent leakage from the cylinder Check all cylinder mounting components for cracks or excessive wear before installation If the cylinder PACKING RETAINING RING ET SCREW GLAND scd PISTON WEAR RINGS SEALS is not to be installed immediately keep the port sealed to prevent contamination After installation of the cylinder is complete clamp the tailga
104. ll o ring 8 into groove in rear housing 1 the scribe mark visible 7 Lubricate the gear shaft extensions with grease to 2 For easier assembly use clean hydraulic fluid as a protect lip seals lubricant 8 Install seals 12 and snap rings 13 into front 3 Install pressure balance 2 and pressure plate 3 housing 9 as described in steps 1 6 of the replac into rear housing 1 ing seals instructions NOTE 9 Install dowels 7 into holes in rear housing 1 Pressure plates must be assembled with the traps opening to the outlet side of the pump 10 Carefully lower front housing 9 with seals installed onto rear housing 1 Insert washers 11 4 Carefully lower gears 4 into the rear housing 1 and capscrews 10 Tighten opposite and even to Install the gears one at a time 80 ft Ibs 5 Install pressure plate 6 and pressure balance 2 11 Test the pump by turning on one gear shaft The pump should turn with a maximum of 10 ft lbs of torque If shaft does not turn properly disassem ble find the problem and carefully reassemble the pump AWARNING Be sure to wear eye protection 9 43 SECTION 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 d
105. 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 SECTION 8 TROUBLESHOOTING DIESELING IN HYDRAULIC SYSTEMS Any hydraulic system should be a sealed environment free of foreign material including air Unlike solid conta mination air is compressible and contains oxygen It is these two 2 properties of air contamination that pro vide the elements needed to support the phenomenon known as dieseling Dieseling can only occur when the elements of fuel oxygen and heat are all present at the same time In the hydraulic system the hydraulic fluid is the fuel The presence of air provides not only the oxy gen to support combustion but also the mea
106. nd dirt indicates a small leak that can probably be corrected by tightening the fitting or connection c b Checkthe visual indicator to determine the condition of the return line element c Inspect the mounting sills and mounting hardware The springs should be compressed to 3 1 2 inches 1 8 inch The mounting bolts should torqued to 700 ft lbs and inspected daily 2 CLEANING Hose the entire unit inside and out with clean wa ter Make sure no refuse is lodged in the body through or behind the pushout panel especially near the telescopic push out cylinder area or rear of the tank 3 LUBRICATION Frequent inspection of grease points will indicate when lubrication is needed LATCHES 6 8 In addition to performing the daily vehicle and packer body pre operating inspection also check the con tainer handling system Each day perform the fol lowing inspection Check the condition and operation of the container latch assemblies If the latch arms will not latch se curely in the assembly do not use the unit Avisual inspection of the wire rope cable should identify any broken wires or obvious damage A vis ual inspection of the chains should identify any dam aged or elongated links Make a visual inspection of the hook for obvious damage Make sure that the hook latch is working properly Check the operation of the container handling sys tem The lifting mechanism should move smoothly with no je
107. nd every packer we produce This commitment to quality extends to the best parts service and distribu tor organization in the industry One area of great importance to us is your safety This unit was built in accordance with the American National Standards Institute ANSI standard for Mobile Refuse Collection and Com paction Equipment Safety Requirements ANSI Z245 1 1992 Before operating this unit please read and understand the safety precautions found in Section 2 of this manual They are important and are provided to assist you in the safe operation of the unit This manual was produced with the intention of providing clear concise instructions for the proper operation maintenance and service of your 2RII 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 discontinue the manufacture of parts components or assemblies at any time Leach Company has an aggressive manual and product improvement program In any conver sation or correspondence dealing with the information provided in any Leach manual please refer to the part number of that manual The manuals provided with the unit are considered a permanent part of the unit and should be included in the event of a re sale 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
108. nnect the pressure hose at the pump and cap the end CAP 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 SECTION 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 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 8 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 41 SECTION 9
109. ns 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 occur Where does the air come from The answer is that the air comes out of the fluid itself Hydraulic fluid can con tain 10 air by volume As the pressure on the fluid increases the amount of air that can be absorbed also increases Now we know that the air is most likely present in the fluid but the next question is How does the air get out of the fluid The air while it is in suspension will pose no problem to the operation of the hydraulic system But once it is separated into bubbles then all the factors are present to support combustion The air in suspension can be separated when the fluid is subjected to a neg ative pressure vacuum of as little as 3 5 psi This can occur when the fluid is squeezed through a restriction or an orifice The resulting pressure decrease can be sufficient to allow trapped air to separate from the fluid A good example may be a front mounted pump dry valve system In the dry mode of
110. of Knockout Positioner 9 26 Removal of Telescopic Pushout Cylinder 9 27 Telescopic Cylinder Packing Replacement 9 28 Telescopic Cylinder Disassembly 9 29 Description of Pushout Panel 9 30 Front Wear Block Replacement 9 30 Rear Wear Block Replacement Telescopic 9 31 Shimming Upper Wear Blocks with Panel in Place 9 31 Removal of Pushout Panel 9 32 Installation of Pushout Panel 9 33 Description of Carrier and Packer Panels 9 34 Removal of Packer 9 35 Inspection and Replacement of Packer Panel 9 36 Replacement of Packer Edge 9 37 Installation of Packer Panel 9 37 Carrier Panel 9 38 Removal of Carrier Panel 9 38 Inspection and Replacement of Carrier Panel 9 39 VI SECTION 1 SAFETY PRECAUTIONS GENERAL The 2RII Packmaster has been designed with the oper ator in mind However as with any industrial machinery especially those that are large and apply forces through hydraulic pressures the ultimate responsibility for safe ty rests with you the user An alert conscientious attitude and observance of all known safe operating practices are the best ways to prevent accidents Before operating the unit it is the operator s responsibil ity to be thoroughly familiar with
111. oid potential problems thoroughly bleed all hydraulic systems and ensure that all inlet connections are tight and not ingesting air LEACH SECTION 8 TROUBLESHOOTING OPERATION IS ERRATIC POSSIBLE CAUSE 1 Solenoid receiving erratic electrical current 2 Solenoid flexing at mounting point 3 Engine motor mounts defective 4 Hydraulic fluid too hot 5 Hydraulic fluid level too low 6 Bypass in cylinders 7 Hydraulic fluid too cold 8 Operating linkage bent or binding 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 REMEDY and Repair mounting does not flex Preventive Maintenance and Repair Bring 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 6a 6b 6c 6d 6e 6f
112. on will ensure and extend trouble free operation of the unit Particular attention to correct lubrication of the unit and maintenance of the return filter are probably the two most vital areas of preventive maintenance required The objective of preventive maintenance is to anticipate and prevent operational difficulties before they require extended shut down for costly repairs OPERATING AND MAINTENANCE RECORDS Prepare and adhere to a maintenance schedule Keep detailed records of all maintenance performed Regu larly inspect operating and maintenance records for de viations from normal operating conditions Analyze the records for indications of potential trouble NOTE Occasionally distributors wall receive Service Bulletins from Leach Company concerning updated maintenance information Keep those bulletins with this manual and make notes at the appropriate places in the manual ref erencing the updated information 6 1 SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART INSTRUCTIONS O Grease weekly every 40 hrs of operation with MOBILUX EPI SERVICE grease or equivalent Oil weekly every 40 hrs of operation with SAE 10 or equivalent ILLUS LUBE POINT QTY NOTE m7 Control levers e PTO shaft 3 Tailgate lift cylinder top and bottom 4 Tailgate clamps 5 Operating cylinders top pivots Not Shown Teles
113. 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 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 av
114. pring 6 used follower 12 outer spring 11 and spring guide 10 The centering spring will have to be com pressed during assembly by applying pressure to the spool collar Caution should be used Install spool collar 5 and torque to 32 in Ibs 3 6 Nm Install adjustment screw 4 and turn the number of turns recorded during disassembly Install and tighten lock nut 3 Install bonnet 2 and screws 1 Torque screws to 10 ft Ibs 13 6 Nm 9 26 SECTION 9 SERVICE AND REPAIR REMOVAL OF TELESCOPIC CYLINDER OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 1 Move the pushout lever to position the pushout panel approximately midway in the body 2 Weld a lifting eye to the roof of the body PUSHOUT LEVER OPERATIONAL STATUS Truck Off PTO Disengaged 3 Attach a sling connected to a lifting device capable of lifting 750 165 to the telescopic cylinder 4 Remove the capscrews and bearing block halves connecting the pushout panel to the cylinder OPERATIONAL STATUS Truck Running PTO Engaged Sol n Sw 5 Move the pushout lever to slowly retract the tele scopic cylinder until it is completely retracted OPERATIONAL STATUS Truck Off PTO Disengaged 6 Using the lifting device lower the telescopic cylin der until it is resting on the floor of the body 7 Disconnect
115. rkiness or binding N SECTION 6 PREVENTIVE MAINTENANCE WEEKLY PREVENTIVE MAINTENANCE 1 CLEANING Clean and paint exposed metal surfaces to remove and prevent the formation of rust 2 INSPECTION a In addition to the body mounting hardware which is checked daily inspect all other acces sible mounting hardware and fittings for tight ness Refer to the CAPSCREW MARKING AND TORQUE VALUE CHART provided in Sec 4 GENERAL REPAIR PRACTICES b Check electrical wiring and insulation for frays breaks and loose connections 3 LUBRICATION Refer to the LUBRICATION CHART in this section and service those items which require weekly lubri cation 4 HYDRAULIC SYSTEM a The return line filter element is vital to the ser vice life of the hydraulic system Check the replacement indicator on the filter assembly weekly Refer to HYDRAULIC SYSTEM SER VICE for more detailed information about this 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 include
116. roughly described in the 2RII Operator s Manual Our policy is not to describe the many different ways in which a unit might be incorrectly operated however in an attempt to provide maintenance personnel with clues that may assist in the diagnosing of a reoccurring carrier packer panel concern that might be operator induced we offer the following Skimming is a result of the operator interrupting the movement of the packer panel and stopping the pack er panel before it rotates perpendicular 901 to the car rier plate When the packer panel is not allowed to fully rotate and the carrier is then moved toward the home position a shear load is induced to the lower channel of the carrier panel The carrier panel lower channel is designed for compression or tension not shear loads If the lower channel on the carrier panel cracks or the center bearing straps consistently break suspect that the unit is being skimmed Short cycling is when the carrier panel is stopped before it completely lowers The operator then attempts to penetrate down through the refuse that is in the hop per with the packer panel This incorrect method of operation results in much the same kind of failures as skimming because the torque tube and lower carrier channel are put into a shear situation This incorrect method of operation will also adversely affect the hop per bottom because the force of the packer panel cylin ders is being dissipated down through the
117. s 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 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 bro ken or excessively worn parts Check capscrews and fasteners for looseness visible welds for cracks and control levers for each movement SPRINGS 3 6 SECTION 3 OPERATION 4 Make sure the tailgate clamps are in the closed posi tion 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 tail gate down the carrier and packer panels in the inter rupted cycle position to check the hydraulic fluid level TAILGATE CLAMPS 6 Make sure all operating levers are in the neutral posi tion Check a packer panel lever b Carrier panel lever c Pushout lever d Tailgate lift lever Never operate the 2RII Packmaster with any part of the control system or levers removed or serious damage will result Never und
118. s checking the wire rope for damage dete rioration and secure end connections Damage or deterioration requiring replacement of wire rope is indicated by broken wires excessive wear heat damage corrosion stretching or distortion as shown in the wire rope illustration below NOTE important item A lay of rope is that length of rope in which one strand of wire makes a complete revolution about the core 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 REDUCTION FROM EVIDENCE OF HEAT DAM NORMAL AGE FROM ANY CAUSE DIAMETER OF MORE THAN 764 WIRE ROPE CHART MORE THAN 1 WEAR GREATER BROKEN WIRE AT THAN DIAMETER ee OF OUTSIDE CONNECTION INDIVIDUAL WIRES KINKING CRUSHING OR us DISTORTION OF ROPE STRUCTURE 6 BROKEN WIRES IN ANY ONE LAY OR 3 BROKEN WIRES IN ONE STRAND IN ANY LAY 6 9 SECTION 6 PREVENTIVE MAINTENANCE MAINTENANCE RECOMMENDATIONS CARRIER The packer carrier assembly should be visually inspect ed every forty 40 hours of operation for cracked or fatigued welds loose or broken fasteners worn bear ings pin hubs or pins The four 4 torque tube bearing straps should be lubricated a minimum of every forty 40 hours of opera
119. s in the counterbores Reassemble parts in reverse order of disassembly Torque the spool collar to 10 ft Ibs 13 6 Nm Torque the bonnet and handle bracket capscrews to 10 ft Ibs 13 6 Nm 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 TIE BOLT SPOOL COLLAR RO CAPSCREW 9 21 SECTION 9 SERVICE AND REPAIR 6 Torque tie bolts evenly to 32 ft Ibs 43 Nm If tie bolts are not tightened to the proper torque valve spools may bind or stick or cause section seals to extrude 7 Torque value of the resistance main relief cartridge and load checks will be 20 ft Ibs 27 2 Nm RESISTANCE MAIN RELIEF CARTRIDGE REINSTALLATION OF FRONT CON TROL VALVE 1 Secure the valve to the mounting bracket with the appropriate hardware 2 Remove plugs and caps then attach hydraulic lines E FRONT CONTROL VALVE 9 22 SECTION 9 SERVICE AND REPAIR MAIN CONTROL VALVE MCV The Main Control Valve valve is located on the tailgate above the packer and carrier panels It controls the operation of the packer and carrier panels through the entire pack ing cycle It may have either 2 3 or 4 individual valve sec tions depending on the installation of options The standard valve will have 2 sections MAIN CONTROL VALVE MCV
120. s on replaceable plastic wear blocks that control its movement in the trough and reduce friction WEAR SHOES OUTER SHOES FRONT WEAR BLOCK REPLACEMENT The wear blocks should be replaced before there is metal to metal contact between the pushout panel and trough floor OPERATIONAL STATUS Truck Off PTO Disengaged 1 Raise the front of the pushout panel enough to take the weight off the wear blocks one side at a time Use a hydraulic jack wedge or pry bar Support the pushout panel and remove the two 2 capscrews on the wear block holder retainer 2 Slide the upper and lower wear blocks out and replace 3 Reinstall the wear block holder retainer and tighten the two 2 capscrews 4 Lower the pushout panel SHIMS pe 5 Repeat this procedure for the other side WEAR SHOES SECTION 9 SERVICE AND REPAIR REAR WEAR BLOCK REPLACEMENT TELESCOPIC SYSTEM The wear blocks should be replaced before there is metal to metal contact between the pushout panel and the trough floor 1 Move the pushout control lever rearward and posi tion the pushout panel at the rear of the body 2 Move the tailgate lift control lever rearward to raise the tailgate allowing access to the pushout panel OPERATIONAL STATUS Truck Off PTO Disengaged 3 Support the tailgate with support jacks capable of supporting at least 7500 Ibs 8402 kg 4 Raise one side of the pushou
121. ssary for the repair and replacement of the main components of the unit Before attempting any repair of the unit become throughly 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 There are some procedures in this section that will require that the truck is running In these instances the operational status will be indicated Otherwise make sure that the truck is shut off and the keys are removed The pressure of the hydraulic system and resulting movement of the units parts can cause serious injury or death DESCRIPTION OF OPERATING CYLINDERS CARRIER AND PACKER PANEL The four double acting hydraulic cylinders that control movement of the carrier and packer panels during the compaction cycle are called the operating cylinders All four cylinders are the same except for tag axle units The two packer panel cylinders mount in the opposite direction of the carrier panel cylinders and the pivot mountings are different CARRIER PANEL CYLINDERS 9 1 PACKER PANEL TEST FOR LEAKING PACKER PANEL CYLINDERS NOTE Before testing any cylinder make sure the main system pressure is correct as described under MAIN LINE PRES SURE CHECK Sec 7 CHECK OUT PROCEDURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top covers over the operating cyl
122. t panel slightly with a pry bar or wedge Support the panel in this position and remove the access cover Remove the cap screws from the wear block retainer Slide the upper and lower wear blocks out and replace 5 Reinstall the wear block retainer and tighten the capscrews Lower the pushout panel and replace the access cover 6 Repeat this procedure for the other side SUPPORT JACKS ACCESS COVER SHIMMING UPPER WEAR BLOCKS WITH PANEL IN PLACE Shims can be added to the upper wear blocks in the front without removing the pushout panel as follows OPERATIONAL STATUS Truck Off PTO Disengaged 1 Loosen the friction brake adjusting bolt 2 Pry the panel at the forward nearest cab end to one side 3 Add shims behind wear block 4 Repeat the procedure for the other side ACCESS COVER WEAR SHOES 5 Tighten the friction brake adjusting bolt until the panel does not move when stopping or starting 9 31 SECTION 9 SERVICE AND REPAIR REMOVAL OF PUSHOUT PANEL OPERATIONAL STATUS PUSHOUT LEVER Truck Running PTO Engaged Sol On Sw 1 Move the pushout lever rearward and position the pushout panel at the extreme rear of the body TAILGATE LIFT LEVER 2 Remove the tailgate lift cylinders as described earlier in this section OPERATIONAL STATUS Truck Off PTO Disengaged 3 S
123. t this process until the container is empty LOWER TO GROUND LEACH 3 14 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 in struction decal to raise the container When raiseing a container with the push bar it is normal for the container to first lift upward within the container latch assembly 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 persons are standing clear lower the container to check the load condition of the container and the hopper Lower the con tainer enough to see between the container and the tail gate while standing on the ground without placing your self between them PACKING THE LOAD NOTE The compaction cycle can be stopped at any time by moving both the packer panel lever and the carrier 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 automati cally shift to neutral The carrier panel will then move down to above the loding edge stop in the interrupted cycle position and the carrier panel lever w
124. te in the down position and remove the bleeder screw from the cylinder rod Operate the control lever until oil flows from e bleeder port Install the bleeder screw Fully extend and retract the cylinder twice clamp the tailgate in the down position and once again remove the bleeder screw Operate the control lever After all air has exited the cylinder install the bleeder screw Check for any external leaks on the cylinder and connecting fittings FITTING 9 17 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF THE TAILGATE ASSEMBLY The tailgate assembly consists of the operating cylin ders carrier and packer panels and the hopper where refuse is first loaded into the unit The tailgate is lifted for unloading and lowered by the tailgate lift cylinders which are actuated by the tailgate lift lever located at the front of the body The need to remove the tailgate is rare and limited to repair of the hopper area and removal of the carrier panel Procedures for carrier panel removal are differ ent and are covered under REMOVAL OF CARRIER PANEL REMOVAL OF THE TAILGATE ASSEMBLY OPERATIONAL STATUS Truck Off PTO Disengaged EU i 2m I 1 Release the tailgate clamps and swing away 2 Disconnect and remove the tailgate lift cylinders as described earlier in this section 3 Disconnect and cap the hydraulic lines NOTE See Sec 4 GENERAL REPAI
125. te lift cylinders The cylinders extend causing the tailgate to raise Excess fluid flow from the FCV Front Control Valve returns back to tank PRESSURE OPERATING ce RETURN m VALVE ELT SS ES siege HYDRAULIC TAILGATE FLUID TANK LIFT CYLINDER FRONT__ ASA VALVE Y TELESCOPIC CARRIER N CYLINDER CYLINDER PACKER CYLINDER CARRIER CYLINDER D a TAILGATE LIFT CYLINDER 8 15 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM EJECTING LOAD OPERATOR ACTION PUSHOUT Operator depresses speed up button and moves pushout LEVER lever rearward ENGINE SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever rearward shifts a spool in the FCV Front Control Valve causing flow to the telescopic cylinder As the cylinders extends the load is ejected from the body PRESSURE OPERATING RETURN M VALVE a eee Sipe HYDRAULIC TAILGATE FLUID TANK LIFT CYLINDER FRONT__ VALVE TELESCOPIC CARRIER CYLINDER CYLINDER O u CHECK VALVE PACKER CYLINDER m CARRIER ae CYLINDER TAILGATE LIFT CYLINDER SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RETRACTING PUSHOUT PANEL OPERATOR ACTION PUSHOUT Operator releases speed up button LEVER NOTE Speed up may have to be used to retract pushout panel if engine RPM drops too far Operator moves the pushout
126. the carrier panel has been securely supported remove the roller assemblies 1 from each side of the tailgate through the open upper track holes Remove the split pin that retains the roller pivot 2 and remove the roller shaft bushings 5 Secure a nylon sling around the cylinder and attach to a lifting device with a lifting capacity of 500 lbs 227 kg Operate the hoist to snug the lifting cable without applying strain to the cylinder OPERATIONAL STATUS Truck Running PTO Engaged Speed 5 n Up 6 Slowly operate the carrier panel lever inward to completely retract the carrier cylinder piston rod This will provide enough clearance to remove the cylinder CARRIER PANEL LEVER OPERATIONAL STATUS Truck Off PTO Disengaged 7 Disconnect both the case end 1 and rod end 2 pressure tubes from the carrier cylinder Immediately plug the pressure tubes and cap the cylinder ports to keep fluid in and dirt out 8 Remove capscrew 1 nut 2 and lockwashers 3 securing the cylinder pivot pin retainer 4 and remove retainer 9 Carefully remove the pivot pin and lift out the cylin der assembly 10 Check for bent pivot pins and inspect pin hubs for broken welds and elongated holes NOTE If the cylinder is not to be installed immediately keep ports sealed to prevent dirt from entering SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF OPERATING CYLINDE
127. 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 tor s 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 Hazard 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 AWARNING A CAUTION DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION Hazards or unsafe practices which
128. tion PACKER PANEL TORQUE TUBE MONTHLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM LIFTING HOOK a Once a month remove f and clean the hydraulic tank fluid strainer as described in HYDRAULIC SYS TEM SERVICE in this section A thorough inspection of any container lifting hook should be completed once a month consisting of check ing for distortion cracks nicks wear latch engagement and secure end connections Maximum distortion allowable is an 8 percent increase in the throat dimen sion or a 10 degree twist in the hook Cracks nicks and wear must not exceed 10 percent of any dimension b Each month check the tailgate lift cylinder air breather If plugged Visually inspect before each use for obvious damage replace it with a new LATCH breather THROAT OPENING P d 4 POINT BACK T A HEEL V BASE YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a year drain flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SERVICE in this section b Once a year replace the hydraulic tank air breather c Once a year replace the fibrous tailgate lift cylinders air breathers 6 10 GENERAL The 2RII Packmaster has been designed to provide 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 Se
129. trapped fluid keeps the packer panel cylinders retracted At the end of the carrier cylinder retraction stroke pres sure builds to 1800 PSI 125 BAR causing the MCV Main Control Valve to shift to neutral TAILGATE LIFT CYLINDER CARRIER _ CYLINDER PACKER CYLINDER CARRIER CYLINDER VALVE FRONT__ HN VALVE Tarps TELESCOPIC CYLINDER a TAILGATE LIFT CYLINDER PRESSURE RETURN TRAPPED FLUID HYDRAULIC FLUID TANK a J amp Sus gt 5 PUMP 8 12 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PANEL SWEEPS HOPPER OPERATOR ACTION Operator shifts the control levers outward to start com paction HYDRAULIC SEQUENCE Fluid flow is through the MCV Main Control Valve packer section to the case end of the packer panel cylinders As the cylinders extend the packer panel sweeps the load forward in the hopper As the packer cylinder exten sion stroke continues pressure builds to 1200 PSI 83 BAR causing the operating valve to shift _ PRESSURE 2 ee OPERATING wees RETURN y A VALVE A E Valk HYDRAULIC TAILGATE i FLUID TANK LIFT CYLINDER VALVE _ S TELESCOPIC 1 fs CARRIER CYLINDER ar PACKER SN CYLINDER 9 PUMP CARRIER Y CYLINDER e TAILGATE LIFT CYLINDER 8 13 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKING REFUSE OPERATOR ACTION None MCV
130. unit to sweep the refuse from the hopper and to pack it against the pushout panel Their movement through the different cycles is controlled by the operating cylinders The two panels are connected together and pivot on the inside and outside bearing assemblies Movement of the pan els within the body is kept in alignment by the roller assemblies located at the upper corners of each panel The rollers ride inside a roller track on each side of the hopper CARRIER PANEL CYLINDERS PACKER PANEL This section focuses on some factors that need to be taken into consideration when performing packer carrier repairs The packer carrier assemblies and interrelated components are designed for relatively trouble free use however they are subject to reduced service life due to the lack of or ineffective maintenance Methods of op eration other than for which the unit was designed can also affect the longevity of these components PACKER PANEL CYLINDERS CARRIER PANEL 9 34 SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 IF THE CARRIER PANEL IS ALSO TO BE REMOVED remove all four operating cylinders as described earlier in this section and proceed to step 3 below OR OPERATIONAL STATUS Truck Off PTO Disengaged IF THE CARRIER PANEL IS NOT TO BE REMOVED attach a chain connected to a suitable lifting device capable of supporting 1600 lbs
131. upport and raise the tailgate with an overhead lift capable of supporting at least 7500 Ibs 3402 kg ENGINE SPEED UP BUTTON 4 Disconnect the telescopic pushout cylinder from 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 re moval 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 lbs 1270 kg and the panel should be secured safely to the re moval device wall 9 32 SECTION 9 SERVICE AND REPAIR INSTALLATION OF PUSHOUT PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install the pushout panel into the body of the unit 2 Slowly extend the telescopic cylinder until the case end is beneath the crossmember of the pushout panel where the lifting eye is welded NOTE Do not allow the cylinder to become stuck or wedged while it is being extended 3 Attach a lifting device capable of supporting 750 Ibs 341 kg to the cylinder and the lifting eye welded to the crossmember 4 Raise the cylinder and slowly extend it until it can be attached to the pushout panel with the bearing clamp halves and capscrews 9 33 SECTION 9 DESCRIPTION OF CARRIER AND PACKER PANELS The carrier and packer panels operate as a single
132. ure solenoid mounting is correct and Repair or replace engine mounts as required 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 Section 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 SECTION 8 TROUBLESHOOTING CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON P
133. urer s rec ommended procedure Always set the parking brake before leaving the cab 16 Turn on appropriate warning lights put on a safety 21 22 23 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 o 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 system 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 veh
134. urface for excessive or uneven wear scoring or other damage Replace a worn bearing assembly Install the bearing housing over the packer panel tube and secure to the carrier panel channel with through bolts shims and nuts Torque to 900 ft Ibs 1221Nm then tack weld the nuts to the bolts 8 Install the grease fitting and lubricate as described in LUBRICATION CHART Sec 6 PRE VENTIVE MAINTENANCE Check that the packer panel torque tube is straight Even a slightly bent torque tube may cause damage to other components Replace the tube if bent or worn ROLLER REPLACEMENT SHIMMING OPERATIONAL STATUS Truck Running PTO Engaged Speed n Up 1 Shift the control levers and cycle the unit several times while observing the rollers and action of the packer and carrier panels Watch for sideways movement or twisting to determine where shim ming and or new rollers may be needed OPERATIONAL STATUS Truck Off PTO Disengaged 2 Remove capscrews 1 lockwashers 2 spacers 3 and cover weldments 4 for both upper and lower track holes on each side of the tailgate 9 13 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed B n Up 3 Shiftthe control levers and cycle the panels as nec essary to align the upper and lower rollers with the track holes NOTE If the top roller is removed first place a wedge b
135. ys ensure that a hook is positioned properly as slack is removed from the chain cable before lifting Slack should be removed from the cable without the use of the engine speed up button by moving the winch con trol lever in the direction shown on the instruction decal to raise the container When the cable is tight the speed up button should be depressed and held to provide suf ficient hydraulic power to lift the container The container should be raised until the contents begin to slide into the hopper of the packer or until it is resting against the container bump bar Do not overfill the hopper After assuring that all per sons are standing clear lower the container to check the load condition of the container and the hopper Lower the container enough to see between the con tainer and the tailgate while standing on the ground without placing yourself between them CONTAINER CONTROL LEVERS ATTACH CONTAINER LOWER TO CHECK CONTENTS CORRECT 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 Repea

New 2RII Service manual - Superior Truck Equipment Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents