Leach Alpha, Beta, Delta refuse body Service Manual

Alpha • Beta • Delta

Service Manual

Over Serial Number

3500

This Book is Printed on Recycled Paper Part No. 105282

TO ORDER PARTS

Contact your local Leach Signature Original Factory parts distributor

Your Authorized Leach Distributor

provide the following information:

A.

Company name

B.

Date

C.

Your order number

D.

Routing instructions

E.

Quantity, part number and description

*F.

Model and serial number of unit

Accept only Leach Signature Original Factory Parts.

Alpha

Beta

Delta

*

*

*SERIAL NUMBER LOCATION

©Copyright Leach Company; 2737 Harrison Street, P.O. Box 2608, Oshkosh, Wisconsin 54903-2608 April 15, 1998

PREFACE

The Alpha, Beta and Delta rear loaders over serial number 3500 share many safety, operational and design similarities. This manual combines the necessary information for these models into one publication.

I

II

FOREWORD

The Leach Company has been a leader in the refuse industry for over 100 years. The Leach

Alpha is the industry standard for both quality and performance. We at the Leach Company are justifiably proud of the quality engineering, material and workmanship that goes into each and every packer we produce. This commitment to quality extends to the best parts, service and distributor organization in the industry.

One area of great importance to us at the Leach Company is your safety. This unit was built in accordance with the American National Standards Institute (ANSI) standard for Mobile Refuse

Collection and Compaction Equipment — Safety Requirements, ANSI Z245.1 - 1992. Before operating this unit please read and understand the safety precautions found in Section 1 of the

Service and Operators manual. They are important and are provided to assist you in the safe operation of the unit.

This manual was produced with the intention of providing clear, concise instructions for the proper operation and servicing of your refuse packer. It was produced with the latest 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. The Leach Company has an aggressive manual and product improvement program. In any conversation or correspondence dealing with information provided in any Leach manual please refer to the part number of that manual located in the lower right hand corner of the front cover.

The manuals provided with the unit are considered a permanent part of the unit and should be included in the event of a resale. Additional manuals are available, free of charge, from your local authorized Leach distributor. These manuals should be kept readily available for easy reference.

We ask that if you have comments or suggestions concerning this manual please contact us at

(920) 231-2770. We are here to be of service to you, our valued customers.

WARRANTY

Refuse bodies manufactured by Leach Company, (“Company”) are supplied and sold under a Limited

Warranty that they are and will remain free of defects in workmanship or material for a period of six

(6) months from date of original sale under reasonable conditions of use and operation, providing required preventive maintenance services are performed. Additional optional warranties are available for purchase. If a failure occurs during said period because of such defect in the opinion of the

Company, the component or part shall be repaired or replaced by an authorized Leach Distributor at no cost to the customer provided the unit is brought to the distributor’s service facility. After three (3) months, performance of adjustments or the replacement of wear/expendable components is not 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, LEGAL-

ITY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF ANY KIND OR

NATURE. THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL

DAMAGES OF ANY KIND OR NATURE, OTHER THAN ITS LIMITED WARRANTY OF REPLACE-

MENT HEREIN. NO OTHER PERSON, FIRM OR CORPORATION CAN BIND THE COMPANY TO

ANY WARRANTY OTHER THAN HEREIN ABOVE STATED.

To validate the new unit warranty, an authorized Leach distributor must have completed a pre-delivery inspection before the unit is placed into service, and the delivery report form signed by both the customer and distributor must be submitted to the Leach Customer Support Service Department.

Because Company products are engineered to work only with genuine Company parts, this limited warranty will be void and no effect if: (a) Company products are modified other than as done at its factory or as authorized to be done by the factory in writing; or (b) Parts or assemblies 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.

III

TABLE OF CONTENTS

ORDERING PARTS

. . . . . . . . . . . . . . . . . . . . IFC

PREFACE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

FOREWORD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . II

WARRANTY

. . . . . . . . . . . . . . . . . . . . . . . . . . . III


. . . . . . . . . . . . . . . . . . IV

SECTION 1 – SAFETY PRECAUTIONS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Danger, Warning and Caution Decals . . . . . . . . . 1-1

Prior To Start Up . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SECTION 3 – OPERATION (continued)

Loading the Hopper . . . . . . . . . . . . . . . . . . . . . 3-13

Attaching a Container to the Packer . . . . . . . . . 3-13

Using a Winch or Container Lift Cylinder. . . . . . 3-14

Using a Container Push Bar (CPB) . . . . . . . . . . 3-15

Packing the Load . . . . . . . . . . . . . . . . . . . . . . . 3-15

Pushout Panel Operation During Packing

Pushout Cylinder . . . . . . . . . . . . . . . . . . . . 3-16

Disconnecting the Container . . . . . . . . . . . . . . . 3-16

Unloading at Dumpsite . . . . . . . . . . . . . . . . . . . 3-17

Lifting the Tailgate . . . . . . . . . . . . . . . . . . . . . . 3-17

Ejecting the Load . . . . . . . . . . . . . . . . . . . . . . . 3-18

Lowering the Tailgate . . . . . . . . . . . . . . . . . . . . 3-18

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

SECTION 2 – INTRODUCTION

Terms You Will Need To Know. . . . . . . . . . . . . . . 2-1

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Compaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Unloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Container Attachment. . . . . . . . . . . . . . . . . . . . . 2-4

Container Handling Systems . . . . . . . . . . . . . . . 2-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Terms You Need to Know . . . . . . . . . . . . . . . . . . 2-5

Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Container . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Container Attachment. . . . . . . . . . . . . . . . . . 2-5

Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Container Lifting Cylinder (CLC) . . . . . . . . . . 2-6

Container Push Bar (CPB) . . . . . . . . . . . . . . 2-6

Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

SECTION 4 – GENERAL REPAIR PRACTICES

Preparation for Service. . . . . . . . . . . . . . . . . . . . 4-1

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 4-2

Prior to Performing Any Service or Repair . . 4-2

Safety During Service and Repair. . . . . . . . . . . . 4-2

Welding Precautions. . . . . . . . . . . . . . . . . . . . . . 4-2

Electric Welders . . . . . . . . . . . . . . . . . . . . . . 4-2

Oxy-Acetylene Torches. . . . . . . . . . . . . . . . . 4-3

Removal, Disassembly and Repair . . . . . . . . . . . 4-3

Reassembly and Installation . . . . . . . . . . . . . . . . 4-4

Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Checking for Voltage . . . . . . . . . . . . . . . . . . 4-4

Checking Continuity . . . . . . . . . . . . . . . . . . . 4-4

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . 4-5

Capacity of Lifting Device Required for Removal . . . . 4-5

Sling Strap Specifications . . . . . . . . . . . . . . . . . . 4-5

Chain and Hardware Specifications . . . . . . . . . . 4-5

Capscrew Marking and Torque Values . . . . . . . . 4-6

SECTION 3 – OPERATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Description of Operating Controls . . . . . . . . . . . . 3-1

Location of Operating Controls . . . . . . . . . . . . . . 3-2

Operating Procedures . . . . . . . . . . . . . . . . . . . . 3-6

Pre-operating Walk-around Inspection . . . . . . . . 3-6

Walk-around Inspection Checklist . . . . . . . . . . . 3-10

Start Up (Operating Instructions) . . . . . . . . . . . 3-11

Positioning Pushout Panel . . . . . . . . . . . . . . . . 3-12

SECTION 5 – SPECIFICATIONS

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Leach Hydraulic Fluid Recommendation . . . . . . . 5-1

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SECTION 6 – PREVENTIVE MAINTENANCE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operating and Maintenance Records . . . . . . . . . 6-1

IV

SECTION 6 – PREVENTIVE MAINTENANCE

(continued)

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Hydraulic System Service. . . . . . . . . . . . . . . . . . 6-4

Checking Fluid Level (Daily) . . . . . . . . . . . . . 6-4

Clean Tank Breather (Weekly) . . . . . . . . . . . 6-4

Check/Replace Return

Line Filter Element . . . . . . . . . . . . . . . . . . 6-4

Replacement of Filter Element . . . . . . . . . . . . . . 6-4

Cleaning Hydraulic Strainer (Monthly). . . . . . 6-4

Flushing Hydraulic System (Yearly) . . . . . . . 6-5

Hydraulic System Service. . . . . . . . . . . . . . . . . . 6-6

Contamination . . . . . . . . . . . . . . . . . . . . . . . 6-6

Commercial Hydraulic Fluid Testing . . . . . . . 6-6

In House Fluid Testing . . . . . . . . . . . . . . . . . 6-6

Preventive Maintenance Requirements . . . . . . . . 6-7

Daily Preventive Maintenance. . . . . . . . . . . . 6-7

Weekly Preventive Maintenance . . . . . . . . . . 6-8

Yearly Preventive Maintenance . . . . . . . . . . . 6-9


SECTION 7 – CHECK-OUT

(DELTA–Pink Pages)

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Check Hydraulic Tank Fluid Level . . . . . . . . . . . 7-17

Check Engine Solenoid Switch . . . . . . . . . . . . . 7-18

Check Engine Speed-Up Switches . . . . . . . . . . 7-18

Check Packing Cycle Time . . . . . . . . . . . . . . . . 7-19

Check Pressures . . . . . . . . . . . . . . . . . . . . . . . 7-19

Check Main Line Pressure . . . . . . . . . . . . . . . . 7-20

Check Pushout Pressure . . . . . . . . . . . . . . . . . 7-21

Check Resistance Pressure . . . . . . . . . . . . . . . 7-22

Check Packer and Carrier Panel Shifting Pressure . . 7-23

Check Wear Blocks . . . . . . . . . . . . . . . . . . . . . 7-24

Power Take Off (PTO). . . . . . . . . . . . . . . . . . . . 7-24


(ALPHA–White Pages)

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Pushout Pressure . . . . . . . . . . . . . . . . . . 7-5

Check Resistance Pressure . . . . . . . . . . . . . . . . 7-6

Check Packer and Carrier Panel Shifting Pressure . . . 7-7

Check Wear Blocks . . . . . . . . . . . . . . . . . . . . . . 7-8

Power Take Off (PTO). . . . . . . . . . . . . . . . . . . . . 7-8


(BETA–Blue Pages)

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Check Hydraulic Tank Fluid Level . . . . . . . . . . . . 7-9

Check Engine Solenoid Switch . . . . . . . . . . . . . 7-10

Check Engine Speed-Up Switches . . . . . . . . . . 7-10

Check Packing Cycle Time . . . . . . . . . . . . . . . . 7-11

Check Pressures . . . . . . . . . . . . . . . . . . . . . . . 7-11

Check Main Line Pressure . . . . . . . . . . . . . . . . 7-12

Check Pushout Pressure . . . . . . . . . . . . . . . . . 7-13

Check Resistance Pressure . . . . . . . . . . . . . . . 7-14

Check Packer and Carrier Panel Shifting Pressure . . 7-15

Check Wear Blocks . . . . . . . . . . . . . . . . . . . . . 7-16

Power Take Off (PTO). . . . . . . . . . . . . . . . . . . . 7-16

SECTION 8 – TROUBLESHOOTING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Compaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Dieseling in Hydraulic Systems. . . . . . . . . . . . . . 8-2

Operation is Erratic. . . . . . . . . . . . . . . . . . . . . . . 8-3

Pump Noise is Excessive . . . . . . . . . . . . . . . . . . 8-3

Engine Will Not Speed-Up When Carrier Panel

Lever or Speed -Up Button is Engaged. . . . . 8-4

Engine Speed Will Not Return to Normal

When Packing Cycle Is Completed or Speed-Up Button Is Released . . . . . . . . . 8-4

Packer Panel Valve Section Shifts Too Soon . . . . 8-4

Carrier Panel Valve Section Shifts to

Neutral Too Soon . . . . . . . . . . . . . . . . . . . . . 8-5

Packer Panel Valve Section Will Not Shift . . . . . . 8-5

Carrier Panel Valve Section Will Not Shift

To Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Packer Panel Does Not Deliver Full Force to Pack Load Into Body . . . . . . . . . . . . . . . . 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

Automatically . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Carrier and Packer Panel Stop Short of Home Position After Each Cycle . . . . . . . . 8-6

Pushout Cylinder Will Not Extend to Push

Out Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Packer Panel Drifts Open While Packing

Load Into Body. . . . . . . . . . . . . . . . . . . . . . . 8-7

Cycle Time is Too Slow. . . . . . . . . . . . . . . . . . . . 8-7

Tailgate Will Not Raise . . . . . . . . . . . . . . . . . . . . 8-8

Container Won’t Lift . . . . . . . . . . . . . . . . . . . . . . 8-8

Winch Motor Leaking . . . . . . . . . . . . . . . . . . . . . 8-8

Container Raises Very Slowly . . . . . . . . . . . . . . . 8-8

V


SECTION 8 – TROUBLESHOOTING

(continued)

Description of Hydraulic System . . . . . . . . . . . . . 8-9

System Component Nomenclature . . . . . . . . . . . 8-9

System Flow Charts . . . . . . . . . . . . . . . . . . . . . 8-10

SECTION 9 – SERVICE AND REPAIR

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Description of Cylinders . . . . . . . . . . . . . . . . . . . 9-1

Test for Leaking Packer Panel Cylinders . . . . . . . 9-2

Test for Leaking Carrier Panel Cylinders . . . . . . . 9-4

Removal of Packer Panel Cylinders . . . . . . . . . . 9-7

Removal of Carrier Panel Cylinders . . . . . . . . . . 9-8

ALPHA–White Pages

Disassembly of Packer Panel Cylinders . . . . . . . 9-9

Inspection and Replacement . . . . . . . . . . . . . . . 9-9

Reassembly and Installation . . . . . . . . . . . . . . . . 9-9

Disassembly of Carrier Panel Cylinders . . . . . . 9-10

Inspection and Replacement . . . . . . . . . . . . . . 9-10

Reassembly and Installation . . . . . . . . . . . . . . . 9-10

BETA–Blue Pages

Disassembly of Packer Panel Cylinders . . . . . . 9-11






DELTA–Pink Pages

Disassembly of Packer Panel Cylinders . . . . . . 9-13






Description of Tailgate Lift Cylinder . . . . . . . . . . 9-15

Removal of Tailgate Lift Cylinder . . . . . . . . . . . . 9-15

Disassembly of Tailgate Lift Cylinder . . . . . . . . . 9-16

Inspection, Reassembly and Installation . . . . . . 9-16

Description of Tailgate Assembly . . . . . . . . . . . 9-17

Removal of Tailgate Assembly . . . . . . . . . . . . . 9-17

Inspection and Replacement of Tailgate . . . . . . 9-18

Description of Carrier and Packer Panels . . . . . 9-18

Removal of Packer Panel . . . . . . . . . . . . . . . . . 9-19

Inspection and Replacement of Packer Panel . . 9-20

Replacement of Packer Panel Edge . . . . . . . . . 9-20

Installation of Packer Panel. . . . . . . . . . . . . . . . 9-20

Roller Replacement/Shimming . . . . . . . . . . . . . 9-21

Removal of Carrier Panel . . . . . . . . . . . . . . . . . 9-23


(continued)

Track Bar Replacement . . . . . . . . . . . . . . . . . . 9-23

Inspection and Replacement of Carrier Panel . . 9-24

Installation of Carrier Panel. . . . . . . . . . . . . . . . 9-24

Description of Pushout Panel . . . . . . . . . . . . . . 9-25

Inspection and Replacement of Wear Blocks . . 9-25

Shimming Wear Blocks With Panel In Place . . . 9-25

Removal of Pushout Panel . . . . . . . . . . . . . . . . 9-25

Installation of Pushout Panel . . . . . . . . . . . . . . 9-26

ALPHA–White Pages

Main Control Valve (MCV) . . . . . . . . . . . . . . . . 9-27

Removal of the Main Control Valve (MCV) . . . . 9-28

Disassembly and Inspection of the

Main Control Valve (MCV) . . . . . . . . . . . . . 9-29

Reassembly of Main Control Valve (MCV). . . . . 9-29


Knockout Positioner . . . . . . . . . . . . . . . . . . 9-30

Reassembly of Knockout Positioner . . . . . . . . . 9-30

BETA–Blue Pages









DELTA–Pink Pages









Front Control Valve (FCV) . . . . . . . . . . . . . . . . . 9-39

Removal of Front Control Valve (FCV) . . . . . . . 9-39

Disassembly and Inspection of

Front Control Valve (FCV). . . . . . . . . . . . . . 9-39

Reassembly of Front Control Valve (FCV) . . . . . 9-40

Reinstallation of Front Control Valve (FCV) . . . . 9-41

Removal of Pushout Cylinder . . . . . . . . . . . . . . 9-42

Single Stage Pushout Cylinder . . . . . . . . . . . . . 9-43

Single Stage Pushout Cylinder

Packing Replacement. . . . . . . . . . . . . . . . . 9-44

Single Stage Pushout Cylinder Disassembly . . . 9-44

Telescopic Cylinder Packing Replacement . . . . 9-45

VI


(continued)

Telescopic Cylinder Disassembly . . . . . . . . . . . 9-46

Leach Hydraulic Pump (203834)

Description of Hydraulic Pump . . . . . . . . . . 9-47

Removal of Hydraulic Pump . . . . . . . . . . . . 9-47

Disassembly of Hydraulic Pump . . . . . . . . . 9-48

Replacing Shaft Seals . . . . . . . . . . . . . . . . 9-48

Reassembly of Hydraulic Pump . . . . . . . . . 9-49

Installation of Hydraulic Pump . . . . . . . . . . 9-50

New Pump Preparation . . . . . . . . . . . . . . . 9-50

Testing a New Pump . . . . . . . . . . . . . . . . . 9-50

Leach Hydraulic Pump (307451-01)

Description of Hydraulic Pump . . . . . . . . . . 9-51

Removal of Hydraulic Pump . . . . . . . . . . . . 9-51

Disassembly of Hydraulic Pump . . . . . . . . . 9-52

Replacing Shaft Seals . . . . . . . . . . . . . . . . 9-52

Reassembly of Hydraulic Pump . . . . . . . . . 9-53

Installation of Hydraulic Pump . . . . . . . . . . 9-54

New Pump Preparation . . . . . . . . . . . . . . . 9-54

Testing a New Pump . . . . . . . . . . . . . . . . . 9-54

Description of Electrical System . . . . . . . . . . . 9-55

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-55

Grounding the Electrical System. . . . . . . . . . . . 9-55

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . 9-57

SECTION 10 – SERVICE TOOLS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Manual Order Form

Reward


VII

SECTION 1

SAFETY PRECAUTIONS

GENERAL

The Alpha, Beta and Delta have been designed with the operator in mind. However, as with any industrial machinery, especially those that are large and apply forces through hydraulic pressures, the ultimate responsibility for safety rests with you — the user. An alert, conscientious attitude and observance of all known safe operating practices are the best ways to prevent accidents.

Before operating the unit it is the operator’s responsibility to be thoroughly familiar with the instructions contained in the Operator’s Manual.

Publication of these precautions does not imply or in any way represent an all inclusive list. It is the operator’s responsibility to be familiar with and ensure that operation is in accordance with safety requirements and codes including all applicable Occupational Safety

& 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 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.

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 could result in minor personal injury or property or product damage.

Strict compliance to these “safety alerts” combined with “common sense” operations are important accident prevention measures.

The word NOTE is also used throughout the manual. It precedes information that provides special emphasis or clarification on a specific operation or procedure.

1-1

SECTION 1


PRIOR TO START UP

1.

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.

5.

Walk completely around the vehicle to make sure all persons and obstructions are clear before starting the unit.

6.

The container handling system is a critical component of the unit, use only the proper replacement parts.

2.

Never operate machinery while under the influence of alcohol, narcotics or other mood altering substances. Workers who operate machinery while under the influence are a hazard to themselves and others.

7. Inspect all hooks, chains and cables daily to ensure serviceable condition. Replace damaged or worn parts.

(See Section 5, Preventive

Maintenance)

3.

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 fastening device, place a sign on the steering wheel indicating the unit is inoperative.

8. Before operating the vehicle the driver must be thoroughly familiar with the employer’s safety program concerning traffic rules, warning devices and hand signals.

9. Be sure to know where to get assistance in the event of an emergency.

10. Know your machine. Know the location and function of all controls, gauges, instruments and protective devices.

4.

Proper servicing requires specialized tools and procedures. Service must be performed by authorized personnel only following procedures in the Service manual.

11. 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.

1-2

SECTION 1


OPERATION

GENERAL

1. It is the operator’s responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operator’s manual and in accordance with all applicable codes including

Occupational Safety and Health Act (OSHA) and

American National Standards Institute (ANSI) regulations.

2. Do not attempt to operate this equipment without proper training.

3. Move the vehicle as slowly as possible without stalling when traveling in reverse.

4. Always make sure the area behind the unit is clear before traveling in reverse.

5. Do not travel in reverse for distances greater than those dictated by local ordinances. If reverse travel exceeds 10 feet, use a “spotter” or move the vehicle in 10 foot increments only, and then check to make sure the area behind the unit is clear between increments.

6. 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.

7. Never use the unit to push or tow another vehicle.

8. Never unload uphill or against a pile of refuse or into the bank of a hill.

9. Never place head, body, fingers or any limbs into a scissors point or pinch point on the equipment.

10. Before operating the vehicle the driver must be thoroughly familiar with the employer’s safety program concerning traffic rules, warning devices and hand signals.

11. Know where to get assistance in the event of an emergency.

12. Know your machine. Know the location and function of all controls, gauges, instruments and protective devices.

13. Wear your seat belt.

14. Start the engine following the manufacturer’s recommended procedure.

15. Always set the parking brake before leaving the cab.

16. Turn on appropriate warning lights, put on a safety vest, protective glasses and protective shoes.

17. All service opening covers and access doors must be maintained and latched in place while operating equipment.

18. Ensure all co-workers are in view before operating or moving any controls or the unit.

19. Ensure that there is sufficient overhead clearance before operating the unit.

20. 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 2 ⁄

10 of one mile. Do not mount or dismount riding step when vehicle is in motion.

21. Never allow anyone to ride on the steps when the vehicle is backing up.

22. Stop the vehicle immediately if warning lights for the TAILGATE AJAR system come on.

23. 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.

24. Make sure the backup alarm is working properly.

25. 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.

26. Do not move the vehicle with the tailgate raised except during unloading and then only as necessary to clear the load before lowering.

27. Stand clear when the tailgate is being raised or lowered and during the unloading cycle. If it is necessary to manually clear debris from the hopper, use a long metal probe and DO NOT stand under the tailgate.

28. Never load the hopper above the loading sill.

29. Never allow material to extend outside of the hopper when packing.

30. Allow the packer panel control lever and carrier panel control lever to shift automatically.

31. To avoid possible bodily injury or equipment damage, lower the tailgate slowly.

32. Never enter the body unless the pressure in the telescopic ejection system cylinder is released,

PTO disengaged and ignition key removed and placed in your pocket.

33. Do not attempt to load refuse into the hopper after

1-3

SECTION 1


the packing cycle has begun. The packer panel must be in the “home” position and stopped before loading the hopper.

34. 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.

35. The tailgate clamps must be tightened securely before starting to load.

36. Do not step on the throttle pedal while the speed up system is engaged.

37. 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.

38. Never use a rear loader to transport a container.

39. Follow all safety directions listed in the refuse body

Operator and Service manual under SAFETY PRE-

CAUTIONS.

.

40. Never use container handling chains or cable for towing or pulling.

41. When not handling containers, keep the container attachment closed and latched.

42. Do not operate the rear loader’s packing mechanism with a container off the ground.

43. If it is necessary to manually free debris from the container, use a long metal probe while the container is on the ground, and DO NOT place yourself between the container and the packer body.

44. Attach hook to the tailgate and take up the excess slack when not in use.

54. Never hold the hook on an attachment point while taking up slack.

46. Take up excess cable slack before moving the vehicle.

47. Check overhead clearance before dumping a container.

48. Do not move the vehicle with a container attached.

49. Always set the vehicle parking brake before attaching or lifting a container.

50. Never lift a container which is non-compatible with the Leach container attachment.

51. Never lift a container without first latching both container latch arms.

52. Raise the container with a smooth even movement.

Do not bounce the container.

53. Do not slam the container against the packer tailgate or bump bar.

54. Do not attach the hook to any lift point which will not be completely encircled by the hook with the safety latch closed. Do not remove the hook safety latch.

55. Read and obey all container decals issued by the container manufacturer.

56. Read and follow container manufacturers information on accepted use practices.

57. Do not attempt to lift overloaded containers.

58. Center the container on the attachment.

59. All containers should be inspected for serviceability and repaired if not in a safe, usable condition.

60. Do not use a non-standard or damaged trunnion bar.

61. Never cross under a raised container.

62. Stand clear when dumping containers.

63. Before attempting to lift a container, below 32°F

(0°C) make sure it is not frozen to the ground.

64. When using an eye type container attachment point, the base of the hook must be positioned to lift on the inside of the eye.

65. Place the container on a flat, level surface.

1-4

SECTION 1


HYDRAULICS

1.

Hydraulic fluid operates under high temperatures.

Avoid contact with piping, hoses or cylinders to prevent burns.

2.

Never use hands to check for leaks. Hydraulic fluid escaping under pressure may cause injury.

3.

In case of injury seek proper medical treatment immediately.

FIRE PROTECTION

1.

Keep a fire extinguisher accessible at all times, as recommended by the Bureau of Motor Carrier

Safety.

2.

Never use lighted smoking materials, open flame or sparks around when working with flammable materials 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 accident prevention.

1.

Keep handrails and steps clean and free of grease or debris.

2.

Do not store brooms or other equipment where they could inadvertently activate the packer controls.

3.

Rubbish, scrap paper and litter are highly combustible. Such material should be stored in metal containers entirely clear of sparks and flames.

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.

1-5

SECTION 1


1

6

1

7 9 8 7 4 2 6 5

2

4

3

7

5

10

8

9

1-6

3

1

10

SECTION 1


3 4

5

6

1

1 2

2

3

4

5

6

1-7

SECTION 1


14 23

11

3 2 1 17 5 12

1

2

3

5

6

6

7

4

9

10

1-8

8

4

7

9

10

13 15 16 18 19

8 20 21 22

11

15

12

16

19

20

21

17

13

SECTION 1


14

18

22

23

1-9

SECTION 1


6 12 44

44

15 5 8 4

4

7

39 16 21 35 40 28

5

6

12

16 8

20

21

35

28

15

43

30

39

44

40

1-10

20 30 43

7

SECTION 1


2

3

6

9

11

12

4

1

7

13

8

5

10

14

17

16

18

15

19

1-11

TERMS YOU WILL NEED TO KNOW

TAILGATE

ASSEMBLY

SECTION 2

INTRODUCTION

BODY

LOADING

EDGE

HOPPER

HYDRAULIC

TANK

2-1

SECTION 2

INTRODUCTION

The main purpose of the packer is to safely and efficiently: load, compact, transport and unload refuse. The following describes how the unit performs those tasks in the most basic terms. For a more detailed description of the unit and its components, read the complete

Alpha, Beta and Delta SERVICE MANUAL. Before going further, look at the accompanying illustrations and become familiar with the terms you will need to know.

LOADING

Refuse is first loaded into the hopper of the tailgate assembly. The carrier and packer panels, which sweep up and pack the refuse from the hopper, will be in the

“home” position.

CARRIER

PANEL

PACKER

PANEL

COMPACTION

When the operator starts the packing cycle the packer panel opens and the carrier and packer panels automatically move rearward, over the load.

PACKER PANEL

MOVES OVER LOAD

Next, the carrier and packer panels automatically stop at the “interrupted cycle” position.

2-2

The operator again activates the packing cycle. The carrier and packer panels move forward and sweep the refuse from the hopper up into the body and pack it against the pushout panel. Having completed a cycle, the carrier and packer panels are back into the “home” position and the hopper is cleared for more refuse.

COMPACTION CYCLE

Also, during the compaction cycle, considerable hydraulic pressure is applied to the cylinders which control movement of the carrier and packer panels. This causes the refuse to be compacted tightly allowing for a large carrying capacity.

As loading and compaction continues, the pushout panel gradually moves forward until the body is full.

Once the body is full the unit can be moved to the dumpsite for unloading.

PUSHOUT PANEL

MOVES FORWARD

SECTION 2

INTRODUCTION

PUSHOUT

PANEL

UNLOADING

At the dumpsite the unit is unloaded in two easy steps:

First, the tailgate is raised by the operator.

Second, the pushout panel is moved to the rear of the body, pushing out the load.

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 PANEL

MOVES REARWARD

EJECTING LOAD

PUSHOUT PANEL

2-3

SECTION 2

INTRODUCTION

CONTAINER ATTACHMENT

The Leach Container Attachment system consists of a loading edge with a latch assembly and a guide ear

(ear) on each side of the packer tailgate. The standard container for use with the Leach rear loader must have an ANSI Standard 1 1 ⁄

4

" – 1 3 ⁄

4

" diameter trunnion bar which is between 77 1 ⁄

2

" and 78" end to end. This trunnion bar length will center the container between the

“ears” and prevent the container from moving sideways. The latch arms must be manually raised and secured by the arm latch. The container arms, when properly latched together with the guide ears, will secure the container to the packer.

Only containers that meet the American

National Standards Institute (ANSI) regulations should be used in conjunction with Leach

Container Handling Systems.

CONTAINER HANDLING SYSTEMS

To lift or dump a container, several systems are available.

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 lb. ratings. The Leach container lift cylinder is rated at 12,000 pounds.

NOTE:

Leach bodies are capable of being equipped with more than one container handling system.

PUSH BAR

DRUM

WINCH

LIFTING

CYLINDER

2-4

SECTION 2

INTRODUCTION

GENERAL

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 systems are available to be mounted on Leach rear loaders.

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 container handling terms you will need to know.

HOOK

1. Throat Opening

2. Back

3. Heel

4. Hook Safety Latch

5. Point

6. Base

2

1

4

5

6

3

3

2

CONTAINER

1. Trunnion bar

2. Hook point

3. Lid

CONTAINER ATTACHMENT

1. Loading sill

2. Arm

3. Latch

4. Guide ear

1

3

2

1

4

2-5

SECTION 2

INTRODUCTION

WINCH

1. Control lever

2. Engine speed up button

3. Hook

4. Hook safety latch

5. Cable

6. Winch assembly

7. Container attachment

8. Bump bar/Lid guard

4

5

3

6

CONTAINER LIFTING

CYLINDER (CLC)

1. Control lever

2. Engine speed-up button

3. Roller guide

4. Hook

5. Hook safety latch

6. Cable

7. Lifting cylinder assembly


9. Bump bar/Lid guard

9

4

5

3 6

7 8 2 1

7

8

CONTAINER PUSH BAR (CPB)

1. Control lever

2. Push bar

3. Lift pad

4. Container dumping cylinder

5. Bump bar


6

5

7

2 3 4

2-6

2 1

1

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 container to the rear loader by securing it with the latch arms of the container attachment.

DUMP

A container handling system is used to raise the container and empty the refuse into the hopper of the rear loader.

ATTACH CONTAINER

DISCONNECT

When the container is empty, it is lowered to the ground, the latch arms released and the truck is moved forward.

DUMP

SECTION 2

INTRODUCTION

DISCONNECT

2-7

SECTION 2

INTRODUCTION

2-8

GENERAL

This section will provide all of the instructions necessary to operate the Alpha, Beta and Delta. However, prior to attempting any operation of the unit, make sure you are familiar with all of the safety information contained in Section 1, SAFETY PRECAUTIONS.

SECTION 3

OPERATION

DESCRIPTION OF OPERATING CONTROLS

The following information is for descriptive purposes only. It is not to be misconstrued as operating instructions. For operating instructions, refer to

OPERATING PROCEDURES later in this section.

There are only a few controls required for the complete and efficient operation of the Alpha, Beta and Delta. It is important that you know the location and function of each control before attempting to operate the unit. Refer to the accompanying illustrations for their locations.

3-1

SECTION 3

OPERATION

LOCATION OF OPERATING CONTROLS

8

8

1 2 3

9 7 10

11 12

3-2

5

4 6

7

8

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 chassis style and control panel location. The

Pump/PTO may be engaged by use of a lever, rocker switch, push-pull cable, toggle lever or positive control button depending on the style. Be sure to read all safety decals associated with the Pump/PTO before attempting operation.

SOLENOID ON-OFF SWITCH (2)

This switch energizes the engine speed-up system. It is located on the cab control panel (exact location dependent on cab make and style).

NOTE:

The engine speed-up system consists of the solenoid ON-OFF switch, a relay and solenoid air cylinder. 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 defective 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 hydraulic 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.

NOTE

Additional speed-up control buttons may be installed with optional winches and container attachments.

FRONT CONTROL VALVE

The front control valve is located behind the access door on the front left hand side of the body. The control levers for this valve extend out through a cutout in the door. This valve controls the ejection (pushout) panel and the lifting of the tailgate.

PUSHOUT SYSTEM (5)

The pushout panel is attached directly to the pushout cylinder. Moving the control lever rearward (toward the tailgate) 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.

Moving the lever forward (toward the cab) will lower the tailgate.

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.

CAUTION

Before attempting to loosen the tailgate clamps, pressure against the tailgate must be relieved by opening the packer panel to the

“interrupted cycle” stop position.

3-4

PUSHOUT

LEVER

TAILGATE

LIFT

LEVER

ENGINE SPEED-UP BUTTON

SECTION 3

OPERATION

DRIVER SIGNAL PUSH BUTTONS (8)

These two push buttons, one located on each side of the tailgate, are connected to a buzzer mounted under the 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.

DRIVER SIGNAL PUSH BUTTON

PACKER AND CARRIER PANEL

OPERATIONAL LEVERS (9)(10)

SIGNAL

PUSH

BUTTON

The packer panel operational control lever is located 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.

CONTAINER HANDLING

CONTROL LEVERS

CARRIER PANEL LEVER

PACKER PANEL LEVER

COMPACTION CYCLE OPERATION

The carrier panel operational control lever is located 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.

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 operating levers to neutral. The packer or carrier panel can be moved independently.

CONTAINER HANDLING CONTROL

LEVERS (11) (12)

These control levers are provided when container handling attachments (drum winch, reeving cylinder or container push bar) are added to the unit. They are used to raise and lower the container causing the refuse to be deposited in the hopper for compaction. The levers are located on the right (curb) side of the tailgate directly above the packer and carrier panel control levers. A refuse vehicle may have none, one or two control levers, depending on the configuration of the unit.


CONTROL LEVERS



SIGNAL

PUSH

BUTTON

3-5

SECTION 3

OPERATION

OPERATING PROCEDURES

This section of the manual provides all the instructions necessary to start and operate the Alpha, Beta and

Delta, including specific instructions for loading, 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 decals are in place and readable. Replace any decals that are not.

NOTE

A decal kit, free of charge, is available from your local authorized Leach distributor.

2.

As you are checking for decals, also look for fluid leaks on and around the unit. Check for fluid leaks at the hydraulic cylinders, valves and fittings.

3.

Inspect the mounting sills and attaching hardware.

Make sure everything is tight and that there are no broken or excessively worn parts. Check capscrews and fasteners for looseness, visible welds for cracks and control levers for each movement.

NOTE

Torque mounting bolt to 700 ft. lbs. and front mounting springs to 3 1 ⁄

2

" plus or minus 1 ⁄

8

".

MOUNTING SILL

SPRING LATERAL RESTRAINT

3-6

SECTION 3

OPERATION

4. Make sure the tailgate clamps are in the closed position and securely tightened.

5. Check the hydraulic tank gauge to make sure the fluid is in the “safe” range. Add fluid, if necessary.

(See Sec. 5, SPECIFICATIONS for the correct type of fluid to use.) The pushout cylinder must be retracted, the tailgate down, the carrier and packer cylinders in the retracted position to check the hydraulic fluid level.

1 1 /

2

"

TAILGATE CLAMPS

6. Make sure all operating levers are in the neutral position.

Check: a. Packer panel lever; b. Carrier panel lever; c. Pushout lever; d. Tailgate lift lever; e. Container handling levers.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

Never operate the unit with any part of the control system or levers removed or serious damage will result.

SPEED-UP

BUTTON

Never under any circumstances enter the body if the truck is running. Open the packer panel and release any pressure in the pushout cylinder before entering the body. Always make sure the truck engine is off and the keys are in your pocket before entering the body.


CONTROL LEVERS



SIGNAL

PUSH

BUTTON

3-7

SECTION 3

OPERATION

7.

Look around the pushout panel area. Clean out any refuse caught in this area that could possibly hamper the pushout panel operation.

Never under any circumstances enter the body if the truck is running. Open the packer panel and release any pressure in the pushout cylinder before entering the body. Always make sure the truck engine is off and the keys are in your pocket before entering the body.

8. Start the truck according to the manufacturers instructions and while it is warming up, continue the walk-around inspection.

9. Check all of the operating and running lights. Make sure none are missing and that there are no burned out bulbs.

The “tailgate open” warning light should be off.

Do not operate the unit if the light is illuminated.

Never place hands in or near the packer panel during operation.

10. With the engine running, the speed-up solenoid switch ON, the PTO engaged and the transmission in neutral and the brakes applied, depress the speedup push-button on the forward left (street) side of the body. You should hear the engine speed-up.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

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.

3-8

11. Move both the packer panel lever and carrier panel lever inward and let go. Check for the following: a.

Engaging the carrier panel lever will activate an engine speed up switch, you should hear the engine speed up.

b.

Observe the carrier and packer panel movement, it should be smooth. The panels should stop automatically at the “interrupted cycle” position.


CONTROL LEVERS



SECTION 3

OPERATION

SIGNAL

PUSH

BUTTON

12. Move both the packer panel lever and carrier panel lever outward and let go. Observe the carrier and packer panel movement, it should be smooth. The panels should stop automatically at the “home” position.

13. Depress the two driver signal push buttons located on both sides of the tailgate to make sure that the audible alarm located in the cab is working.

14. Back the unit up a few feet to ensure that the backup alarm is working properly.

15. Loosen the tailgate clamps and swing out. Raise the tailgate approximately 6" and check to see if the tailgate ajar light on the dash is on and if the backup alarm is audible. (Do not have the unit in reverse).

TAILGATE CLAMPS

3-9

SECTION 3

OPERATION

Do not operate a unit that is in need of service or repair.

16. Report any problems found during the pre-operation walk-around inspection to the maintenance supervisor for service or repair, place a tag on the steering wheel, using a non-reusable fastener, stating the unit is inoperative and remove the keys.

WALK-AROUND INSPECTION

CHECKLIST

1. Decals in place and readable.

2. Look for any fluid leaks.

3. Mounting hardware tight and in place.

4. Tailgate clamps closed and tightened.

5. Hydraulic fluid reservoir at correct level.

6. All operating levers in neutral positions.

7. Pushout panel area clear of debris.

8. Engine warmed up according to manufacturer’s instructions.

9. All operating and running lights functioning.

10. Engine speed-up buttons operational.

11. Packing cycle operates properly.

12. Driver signal alarm can be heard.

13. Back-up alarm and tailgate ajar light are operable.

14. Report any problems to proper personnel.

3-10

START UP

(OPERATING INSTRUCTIONS)

1. Inspect and start the truck as described in pre-operational walk-around inspection.

2. Engage the Pump/PTO control (to start the hydraulic pump).

3. Place the solenoid switch in the ON position.

SECTION 3

OPERATION

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.

2. Depress and hold the speed-up push button.

SPEED-UP

BUTTON

3. Push the pushout lever rearward until the pushout cylinder is fully extended.

4. Release the speed-up button.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

3-12

TAILGATE

CLAMPS

LOADING THE HOPPER

There are only a few but important points to remember during loading of refuse.

1. Load the hopper evenly on both sides.

2. Load heavy objects in the center of the hopper.

3. Do not load refuse higher than the loading edge.

Always follow proper loading procedures.

ATTACHING A CONTAINER TO THE PACKER

Place the container on a flat, level surface. For large non-moveable containers the driver should back the unit toward the container following all vehicle and refuse body safety restrictions.

The vehicle should be backed with latch arms open until the container trunnion bar is between the guide ears and within the latch assembly. Center the container on the attachment.

ATTACHING CONTAINER

After 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 secure them to the packer.

LATCH ARMS

ATTACHED

SECTION 3

OPERATION

3-13

SECTION 3

OPERATION

USING A WINCH OR CONTAINER LIFT CYLINDER

ATTACH CONTAINER

Once the container is secured within the latch assembly, 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 always ensure that a hook is positioned properly as slack is removed from the chain/cable before lifting.

Slack should be removed from the cable, without the use of the engine speed-up button, by moving the winch control lever in the direction shown on the instruction decal to raise the container. When the cable is tight, the speedup button should be depressed and held to provide sufficient 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 persons 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 container and the tailgate while standing on the ground without placing yourself between them.

LOWER TO CHECK CONTENTS

INCORRECT CORRECT

HOOK

ATTACHMENT POINT

CONTAINER

CONTROL LEVERS

NOTE

On units with a roof mounted container lifting cylinder, the speed of the device is limited during both the up and down movement. This speed reduction is for safety considerations.

LOWER TO GROUND

When the hopper is full, lower the container to the ground, assure all persons are standing clear and then engage the packer mechanism. See Sec. 3 Operation -

Packing Load.

After the packer panel has passed the loading sill, the container may be raised to again fill the hopper.

Repeat this process until the container is empty.

3-14

SECTION 3

OPERATION

DUMPING WITH CPB USING A CONTAINER PUSH BAR (CPB)

Once the container is secured within the latch assembly the container is ready to be dumped. After assuring that all persons are standing clear, the operator moves the CPB control lever in the direction shown on the instruction decal to raise the container. When raising a container with the push bar, it is normal for the 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 container enough to see between the container and the tailgate while standing on the ground without placing yourself between them.

CONTAINER

CONTROL

LEVERS

Releasing the CPB control handle when the container begins to tip will allow the container trunnion bar to lower within the latch slots with ease.

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 moving both the packer panel lever and the carrier panel lever inward, toward the tailgate, then let go. The packer panel will open and the packer panel lever will automatically shift to neutral. The carrier panel will then move down to above the loading edge, stop in the “interrupted cycle” position and the carrier panel lever will automatically shift to neutral.


CONTROL LEVERS



SIGNAL

PUSH

BUTTON

2. To finish the cycle, move both the packer panel lever and the carrier panel lever outward, away from the tailgate, then let go. The packer panel will sweep the hopper and the packer panel lever will automatically shift to neutral. The carrier panel will then move up into the body and stop in the home position and the carrier panel lever will automatically shift to neutral.


CONTROL LEVERS



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.

SIGNAL

PUSH

BUTTON

3-15

SECTION 3

OPERATION

PUSHOUT PANEL OPERATION DURING PACKING

PUSHOUT CYLINDER

The pushout panel is normally moved toward the front of the body automatically. When the resistance circuit is adjusted to produce maximum load density, it may become necessary to manually retract the pushout cylinder in order to allow the compacted refuse to move forward in the body. When the pushout panel has reached the front of the body, neither the packer panel operating lever nor the carrier panel lever should be overridden except to clear the final hopper load.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

DISCONNECTING THE CONTAINER

Once the container is empty, it should be lowered to the ground, the latch arms released and the cable disconnected.

DISCONNECTED

3-16

UNLOADING AT DUMPSITE

CAUTION

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.

SECTION 3

OPERATION

LIFTING THE TAILGATE

Stand clear when the tailgate is raised! If you need to clean debris from the edges, use a long pole while standing to the side.

1.

Depress and hold engine speed-up button.

2.

Push the tailgate lift lever rearward and hold until the tailgate is fully raised.

PUSHOUT LEVER

TAILGATE LIFT LEVER

SPEED-UP

BUTTON

TAILGATE RAISED

The “tailgate open” light and backup lights should illuminate. The backup alarm should also sound.

3-17

SECTION 3

OPERATION

EJECTING THE LOAD

1. Depress and hold engine speed-up button, push the pushout lever rearward and hold until the pushout panel stops. This will eject the entire load.

2. Slowly pull the unit ahead to clear the refuse.

3. Clean debris from the edges with a long pole while standing clear off to one side.

SPEED-UP

BUTTON

Never drive the unit more than 10 feet with the tailgate in a raised position.

The pushout cylinder remains fully extended. If the unit is going to travel over one mile empty, 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.

2. Place the tailgate clamps in the closed position and tighten securely.

NOTE:

The “tailgate open” light, backup lights and backup alarm should be off after closing the tailgate.

TAILGATE LIFT LEVER

3-18

SHUTDOWN

1.

Move the packer panel lever and carrier panel lever to place the packer panel in the “home” position.

2.

Put all controls in neutral.

3.

Set parking brake.

4.

Disengage PTO.

5.

Shut off engine.

6.

Shut off solenoid dashboard switch.

7.

Remove key.

8.

Lock truck.

SECTION 3

OPERATION

3-19

SECTION 3

OPERATION

3-20

SECTION 4

GENERAL REPAIR PRACTICES

Proper service and repair is important for the safe, reliable operation of all mechanical products. the service procedures recommended and described in this service manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. Since Leach Company could not possibly know, evaluate and advise the service trade of all possible ways in which service might be done or of the possible hazardous consequences of each way, we have not accordingly , anyone who uses a service procedure or tool which is not recommended by Leach Company must first thoroughly satisfy himself that neither his nor the operator’s safety will be jeopardized by the service methods selected. Any person who modifies their equipment must do so in accordance with American National Standards Institute

Z245.1-1992. It is important to note that deviating from these procedures could cause damage to the unit or render it unsafe. However, please remember that these procedures are not all inclusive.

PREPARATION FOR SERVICE

Proper preparation is very important for efficient safe service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and reduce the incidence of misplaced tools and parts. If the portion of the unit to be repaired is excessively dirty, it should be cleaned before work starts. The cleaning process may include the use of high pressure equipment and strong chemicals. Follow the manufacturer’s instructions and precautions during this process. Cleaning will occasionally uncover trouble sources. tools, instruments and parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a needless delay. Special tools required for a specific job are listed in Section 11.

REPLACEMENT PARTS

Of growing concern to the Leach Company is the use of counterfeit, will-fit or substitute parts. Leach Signature replacement parts are designed and manufactured to exacting standards. The use of counterfeit, will-fit or substitute parts may affect the operation and performance of the unit and will void the warranty. Insure maximum reliability and protect your investment - insist on Leach

Signature original factory replacement parts.

SERVICE BULLETINS

In addition to the information provided in this Service

Manual, Service Bulletins are issued when needed to cover interim changes or to provide supplementary information necessary for maintaining the refuse unit in a proper safe operating condition. (Check with your authorized Leach dealer.)

4-1

SECTION 4



PRIOR TO PERFORMING ANY

SERVICE OR REPAIR

1.

Set the parking brake.

2.

Put the vehicle in park, or if equipped with a manual transmission, put the unit in gear and remove the ignition key.

3.

Place an OSHA approved chock block in front of and behind the front tire.

4.

If steel supports are to be used to support the tailgate, place them as shown in Section 9, SERVICE

AND REPAIR, under TAILGATE REPAIR.

5.

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.

6.

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.

2.

Disengage the PTO, turn off the ignition and remove the keys before: a. Leaving the truck cab.

b. Examination or lubrication of the PTO, pump or drive shafts.

c. Entering the front of the body.

d. Entering the tailgate.

5.

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 lbs.

6.

Never enter the body when the load is under compaction pressure. Bring the packer plate to the

“interrupted cycle” stop position and retract the pushout plate slightly.

3.

Always check to make sure the body access door is locked shut before entering the cab.

4.

Pump removal; due to the weight and location of the pump, it is advisable to place a floor jack beneath the pump and apply a slight pressure, so that when the bolts are removed the pump is supported.

WELDING PRECAUTIONS

ELECTRIC WELDERS

1.

Electric arc welders should have a separate, fused disconnect circuit.

2.

Welders must be used according to the manufacturers specifications.

3.

All electric welding should be done in a well-ventilated area.

4.

The radiation given off by the arc will destroy the retina of the eye. Wear an approved welder’s helmet.

5.

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.

4-2

SECTION 4


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 decomposition without the presence of air. No other industrial gas has such a wide explosive range.

2.

Oxygen will spontaneously ignite in the presence of oil and grease. The hoses, torch handles and regulators must be kept free of petroleum products.

3.

Before using the equipment, inspect it for cleanliness and for leaks.

4.

Hoses cannot be safely repaired; when they show signs of deterioration, they should be replaced.

5.

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.

6.

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.

7.

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.

8.

When opening the tank valves, stand alongside of the regulators, out of the way, in case they blow out.

9.

Backfiring or “machine gunning” at the torch is very dangerous and can lead to a major explosion.

10.

Welding should be done in a location well away from flammable materials.

REMOVAL, DISASSEMBLY AND REPAIR

1.

Cleanliness is very important; dirt is the number one cause of wear in bearings, bushings and especially in hydraulic components.

8.

When disassembling a component, note the position of each part as it is removed to aid in reassembly.

2.

Inspect hydraulic components for leaks before cleaning. The dirt buildup on the component can aid in tracing fluid leaks.

3.

Clean hydraulic connections before removal to prevent dirt from entering the component.

4.

Loosen hydraulic fittings slowly to release pressure.

5.

Cap hydraulic fittings immediately after removal to prevent fluid from leaking.

6.

Clean the component in non-flammable solvent before disassembly.

7.

Inspect the component after cleaning for signs of wear or external damage.

9.

During disassembly note the condition of each part as it is removed to aid in diagnosing problems and to help prevent them in the future.

10.

Clean and inspect disassembled parts for wear, cracks,dirt, etc.

11.

After cleaning and inspection, 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 immediately, they should be wrapped in a clean lint free cloth or paper to prevent nicks or scratches.

12.

When repacking a cylinder, or resealing a valve, replace all seals and o-rings that are disturbed during repair. The price of a few seals is very little compared to a return repair job.

4-3

SECTION 4


REASSEMBLY AND INSTALLATION

1.

Assemble parts in the same position as removed.

2.

Align parts accurately before mating.

3.

Inspect o-ring and seal grooves for sharp edges, nicks or burrs before installing new sealing parts.

4.

Lubricate all new sealing parts with clean, fresh hydraulic fluid before installation.

5.

Use care not to damage new sealing parts on reassembly.

6.

Use correct torque values when reassembling and installing components. See CAPSCREW MARK-

ING AND TORQUE VALUES later in this section.

7.

Always check the hydraulic fluid in the hydraulic tank after performing any service or repair of the hydraulic system.

8.

Always lubricate components with grease fittings after they have been repaired and reinstalled.

9.

Use only Leach Signature replacement parts.

NOTE:

See Section 9, SERVICE AND REPAIR for specific repair instructions.

ELECTRICAL TESTING

The electrical system used on the unit consists of various lights, switches and wiring. Testing the components 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 electricity in a live circuit. Connect the test light clip to a good ground and the probe at the point where the presence of voltage is to be checked. If voltage is present, the light will be on...if no voltage is present, the light will be off.

CHECKING CONTINUITY

A continuity tester is used to check the ability of a conductor 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 component is not able to pass current, there is no continuity 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6010, E6011, E6013

Top hinge area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7018

Tailgate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6010, E6011, E6013

Carrier plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6010, E6011

Packer plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7018

5.

Use ER-70S-6 wire for all locations.

4-4

SECTION 4


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

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 lbs. (227 kg.)

Telescopic Pushout Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (454 kg.)

Carrier Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 lbs. (726 kg.)

Packer Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 lbs. (726 kg.)

Pushout Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 lbs. (1270 kg.)

Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7500 lbs. (3402 kg.)

SLING STRAP SPECIFICATIONS

Nylon sling straps should be used for the removal of cylinders. The following specifications should be used to determine the type of sling straps to use for lifting.

Type USS-26-EN1

Rating

Vertical lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4800 lbs. (2177 kg.)

Choker lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 lbs. (1633 kg.)

Basket lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9600 lbs. (4354 kg.)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 in.

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . depends on type of lifting device used.

CHAIN AND HARDWARE SPECIFICATIONS

Chains should be used to lift and/or support the carrier and packer panel, pushout panel and tailgate. The following specifications should be used to determine the type of chain and hardware to use for lifting.

Chain

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.O.F. (Double Branch, Oblong link, Foundry Hook)

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ⁄

2 in.

Hammer locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ⁄

2 in.

Oblong rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ⁄

2 in.

4-5

SECTION 4


CAPSCREW MARKING AND TORQUE VALUES

Usage Much Used Used at Times Used at Times

Capscrew Diameter

& Minimum Tensile

Strength PSI

To 3 ⁄

4

- 120,000

To 1 - 115,000

To 5 ⁄

8

- 140,000

To 3 ⁄

4

- 133,000

150,000

Quality of Material

SAE Grade Number

CAPSCREW HEAD MARKINGS

Manufacturer’s marks may vary.

These are all SAE Grade 5 (3-line.)

Min. Commercial

5

Med. Commercial

6 or 7

Best Commercial

8

Capscrew Body Size

(Inches) - (Thread)

Torque

Ft-Lb (kg m)

Torque

Ft-Lb (kg m)

Torque

Ft-Lb (kg m)

1 ⁄

4

- 20

- 28

5 ⁄

16

- 18

- 24

3 ⁄

8

- 16

- 24

7 ⁄

16

- 14

- 20

1 ⁄

2

- 13

- 20

9 ⁄

16

- 12

- 18

5 ⁄

8

- 11

- 18

3 ⁄

4

- 10

- 16

7 ⁄

8

- 9

- 14

1 - 8

- 14

8 (1.11)

10 (1.38)

17 (2.35)

19 (2.63)

31 (4.29)

35 (4.84)

49 (6.78)

55 (7.61)

75 (10.37)

85 (11.76)

110 (15.21)

120 (16.60)

150 (20.75)

170 (23.51)

270 (37.34)

295 (40.80)

395 (54.63)

435 (60.16)

590 (81.60)

660 (91.28)

10 (1.38)

19 (2.63)

34 (4.70)

55 (7.61)

85 (11.76)

120 (16.60)

167 (23.10)

280 (38.72)

440 (60.85)

660 (91.28)

12 (1.66)

14 (1.94)

24 (3.32)

27 (3.73)

44 (6.09)

49 (6.78)

70 (9.68)

78 (10.79)

105 (14.52)

120 (16.60)

155 (21.44)

170 (23.51)

210 (29.04)

240 (33.19)

375 (51.86)

420 (58.09)

605 (83.67)

675 (93.35)

910 (125.85)

990 (136.92)

NOTES:

1. Always use the torque values listed above when specific torque values are not available.

2. The above is based on use of clean, dry threads.

3. Reduce torque by 10% when engine oil is used as a lubricant.

4. Reduce torque by 20% if new plated capscrews are used.

5. General Formula for calculating Torques is as follows: Torque in Inch Lbs. = .2 x Nominal Diameter of Screw x

Loads in Lbs., where Load = 80% of Yield Strength, expressed in Lbs., not pounds per square inch.

4-6

SECTION 5

SPECIFICATIONS

HYDRAULIC FLUID

To serve its purpose and give long and satisfactory service, hydraulic fluid must possess desirable physical and chemical characteristics. Stability over a wide range of temperatures and under agitation is very important.

Premium hydraulic fluids should be used in Leach hydraulic systems. In addition to the above characteristics selected 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 products and generally speaking, higher quality is worth the higher initial cost.

LEACH HYDRAULIC FLUID RECOMMENDATION

All Leach hydraulic systems are factory filled with a high quality anti-wear hydraulic fluid meeting an ISO 32 specification. On units put into service where there are high ambient temperatures or sustained high duty cycles, it may be desirable to change the fluid to an ISO 46 specification (higher viscosity). In colder climates or light duty, an ISO

22 might be more appropriate. The International Standards Organization assigns specification numbers so that a consumer receives the same product from various suppliers.

GRADE ISO/VISCOSITY . . . . . . . . . . . . . . . . . . . . . . . .

AGMA NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gravity API. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flash,° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pour Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SSU @100° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SSU @ 210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . cSt @ 40° C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cSt @ 100° C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASTM Oxidation Test (Hours to 2.0 Neut. No.) . . . . . . . .

ASTM Rust Test, A & B . . . . . . . . . . . . . . . . . . . . . . . . .

Foam Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vickers Vane Pump Test . . . . . . . . . . . . . . . . . . . . . . . . .

Dielectric Strength (ASTM 877) EC # @ 180° F . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

—

33

375

-20

112

40

21

4.1

98

2500

Pass

Pass

Pass

25Kv

40-37-3(10)

32

—

31

380

-20

158

44

30.5

5.2

99

2500

Pass

Pass

Pass

25Kv

40-37-3(15)

46

1

31

390

-20

228

48

44

6.5

99

2500

Pass

Pass

Pass

25Kv

40-37-3(15)

HYDRAULIC SYSTEM

Approximate Capacity

Filtration, Suction Line

Filtration, Return Line

Pump

Pump Capacity

System Pressure

Do not use engine oil, automatic transmission fluid (ATF) or add diesel fuel or kerosene to the hydraulic fluid. Service life of all hydraulic system components may be adversely affected.

ALPHA

45 Gallons

Reusable wire, mesh type

Disposable filter element

Positive displacement gear type

42 GPM @ 1200 RPM

2150 PSI (148 BAR)

BETA

45 Gallons




42 GPM @ 1200 RPM

2300 PSI (157 BAR)

DELTA

45 Gallons




35 GPM @ 1200 RPM

2300 PSI (157 BAR)

LUBRICANTS

Oil . . . . . . . . . . . . . .SAE #10 or equivalent Grease . . . . . . . . . . . Multiservice (quality grade)

5-1

SECTION 5

SPECIFICATIONS

5-2

GENERAL

The Alpha, Beta and Delta have been designed for long periods of efficient uninterrupted operation. Careful attention to proper preventive maintenance, as described in this section, will ensure and extend trouble-free operation of the unit. Particular attention to correct lubrication of the unit 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.

SECTION 6

PREVENTIVE MAINTENANCE

OPERATING AND MAINTENANCE RECORDS

Prepare and adhere to a maintenance schedule. Keep detailed records of all maintenance performed.

Regularly inspect operating and maintenance records for deviations from normal operating conditions.

Analyze the records for indications of potential trouble.

NOTE

Occasionally distributors will receive service bulletins from Leach Company concerning updated maintenance information. Keep those bulletins with this manual and make notes at the appropriate places in the manual referencing the updated information.

6-1

SECTION 6


LUBRICATION CHART

6 5

10

3

2

1 4

In below freezing climates all grease and fluids should have a cold test rating of at least -20° F.

INSTRUCTIONS

●

Grease weekly (every 40 hrs. of operation) with

MOBILUX EPI-SERVICE grease or equivalent.

■

Oil weekly (every 40 hrs. of operation) with SAE #10 or equivalent.

LUBE POINT QTY NOTE ILLUS.#

■

1

●

2

●

3

●

●

4

5

Control levers

PTO shaft

Rollers

2

2

Tailgate lift cylinders 4

(top and bottom)

Tailgate clamps 2

4 1 & 2

NOTES:

1. Move roller track access covers to grease roller.

2. Rollers need lubrication — roller tracks do not!

Grease on tracks will only cause rollers to slide.

Keep tracks clean and dry.

3. Remove top covers for access to lube points.

ILLUS.# LUBE POINT QTY NOTE

NOTE

The packer panel must be in the home position to lubricate the following lube points.

●

6 Packing lever control 10 3

●

7

●

8 linkage

Packer panel pivot

Operating cylinder

●

9 rod ends

Operating cylinder

●

10 case ends

Optional control levers

●

Not shown Pushout cylinder pivot pins

2

4

4

2

4

3

6-2

1

2

SECTION 6


4

5

6

3

7

8

9

10

11

6-3

SECTION 6


HYDRAULIC SYSTEM SERVICE

(See accompanying Hydraulic System illustration)

Proper maintenance of the hydraulic components is of vital importance to the service life of the system and the operation of the unit as a whole.

CHECKING FLUID LEVEL (DAILY)

Position and fully retract the pushout, carrier, and packer cylinders to check the fluid level. (1) When checking the fluid level in the hydraulic tank, also note any frequent or sudden loss of fluid. This may indicate leakage, which must be traced and corrected to avert equipment failure and possible damage to other components.

If low, fill the hydraulic tank to the “NORMAL FILL LEVEL” with hydraulic fluid as specified in Sec. 4 SPECIFICA-

TIONS according to operating and weather conditions.

REPLACEMENT OF FILTER ELEMENT

(See Hydraulic System Illustration)

1. Remove filter cover (4).

2. Remove o-ring (5).

3. Remove element (6) and discard.

4. Install a new element (6).

5. Coat a new o-ring (5) with fresh hydraulic fluid and install in filter cover (4).

6. Install the cover and secure to the bowl with the attaching hardware.

7. Check the fluid level and replenish with fresh fluid as described earlier in this section under CHECK-

ING FLUID LEVEL.

CLEAN TANK BREATHER (WEEKLY)

Clean the air breather (2) every week. Replace a breather that cannot be cleaned adequately.

Extended operation of the unit without proper filtration will result in reduced service life of hydraulic system components.

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 components. 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 operation or sooner, if so indicated by the filter replacement 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.

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 solvent.

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.

6-4

FLUSHING HYDRAULIC SYSTEM

(YEARLY)

1.

Drain all fluid from the hydraulic tank into a suitable container. Dispose of it properly.

2.

Wipe off the magnetic ring and wipe out the bottom of the tank.

3.

Clean strainer as described previously.

4.

Fill the hydraulic tank with fresh fluid as specified in

Sec. 5, SPECIFICATIONS, according to operating and weather conditions.

5.

Start the unit and operate all hydraulic levers as described in Sec. 3, OPERATION. Leave all hydraulic cylinders in the retracted position and shut down unit.

6.

Recheck the fluid level and add fluid as necessary to bring level to the “NORMAL FILL LEVEL” on the sight gauge.

NOTE

Refer to Sec. 9, SERVICE & REPAIR for detailed instructions pertaining to those items requiring repair or replacement.

SECTION 6


6-5

SECTION 6


HYDRAULIC SYSTEM SERVICE

CONTAMINATION

It is estimated that as much as 90% of all hydraulic problems may be traced directly to the fluid. It is of utmost importance that all foreign matter be kept from the hydraulic fluid. Invisible quantities of abrasive type contamination may cause serious pump wear, malfunctioning 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 critical. It should be done according to ANSI Standard

B93.19M(R1980). This standard is available from the

National Fluid Power Association, 3333 N. Mayfair Rd.,

Milwaukee, WI 53222.

Samples should be taken from the center of the reservoir when the fluid is at operating temperature and placed in a clean, dry glass bottle with a nonshedding screw-on cap. The bottle should be labeled with the date, type of fluid, model and serial number of the machine.

Two identical samples should be taken. One for laboratory analysis and one for your own preliminary analysis while you are waiting for the lab report.

We recommend the use of commercial laboratory services 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.

of water contamination, the source of which must be found and eliminated immediately. Common sources are inadequate outdoor storage, unsealed reservoir covers or condensation.

A “BLOTTER SPOT TEST” may also be performed to test for OXIDATION. Place a DROP of fluid on a piece of white blotter paper. Order Leach part number 102480 for 20 sheets.

NOTE:

The Blotter Test will provide an indication that a more complete test may be necessary.

A.

If the blotter remains colorless or develops only a light yellow ring, oxidation is under control.

B.

If color develops but is uniform throughout, the fluid is still serviceable but should be checked for correct additive content.

C.

If the sample shows distinct rings the fluid should be changed.

D.

If a distinct dark spot remains in the middle, but a lighter colored fluid migrates outward in the blotter paper the fluid is about to dump (or already has) sludge or other by-products into the system. The time for replacement of this fluid has already passed.

Kits are available from your fluid supplier to test for acid

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 contamination problem, the source of which must be located and corrected immediately. Common sources of this kind of contamination may be component wear, undersealed reservoir covers or dirty air breather filters.

If the sample is the least bit “cloudy” it is an indication

6-6

content in much the same way you would test the condition 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.

SECTION 6


PREVENTIVE MAINTENANCE REQUIREMENTS

DAILY PREVENTIVE MAINTENANCE

Each day perform the following maintenance:

1. INSPECTION

Perform the PRE-OPERATIONAL INSPECTION described in Sec. 3, OPERATION.

4. CONTAINER HANDLING

EQUIPMENT

In addition to performing the daily vehicle and packer body pre-operating inspection, also check the container handling system. Each day perform the following inspection.

Never go under the vehicle with the engine running. Death or serious injury could result.

a. When checking for hydraulic leaks pay particular attention to hose fittings and connections at the cylinders and valves. A build up of hydraulic fluid and dirt indicates a small leak that can probably be corrected by tightening the fitting or connection.

b. Check the visual indicator to determine the 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 be torqued to 700 ft. lbs. and inspected daily.

2. CLEANING

Hose the entire unit inside and out with clean water. Make sure no refuse is lodged in the body through or behind the pushout plate especially near the clamp area or rear of the tank. Make sure there is no grease on the pushout bar.

3. LUBRICATION

Frequent inspection of grease points will indicate when lubrication is needed.

a.

Check the condition and operation of the container latch assemblies. If the latch arms will not latch securely in the assembly do not use the unit.

b.

A visual inspection of the wire rope (cable) should identify any broken wires or obvious damage. A visual inspection of the chains should identify any damaged or elongated links.

c.

Make a visual inspection of the hook for obvious damage. Make sure that the hook latch is working properly.

d.

Check the operation of the container handling system. The lifting mechanism should move smoothly with no jerkiness or binding.

LATCHES

6-7

SECTION 6


WEEKLY PREVENTIVE MAINTENANCE

1. CLEANING

Clean and paint exposed metal surfaces to remove and prevent the formation of rust.

5. CHECK-OUT PROCEDURES

Each week perform the CHECK-OUT PROCE-

DURES listed in Sec. 7 of this manual.

2. INSPECTION

a.

In addition to the body mounting hardware which is checked daily, inspect all other accessible mounting hardware and fittings for tightness. Refer to the CAPSCREW MARKING

AND TORQUE VALUE CHART provided in

Sec. 4, GENERAL REPAIR PRACTICES.

6. CONTAINER HANDLING

SYSTEM HARDWARE

Check all container handling system hardware to make sure that no damage exists and that all fasteners are secure.

b.

Check electrical wiring and insulation for frays, breaks and loose connections.

7. PIVOT POINTS

Check all pivot points for wear and smooth operation.

3. LUBRICATION

Refer to the LUBRICATION CHART in this section and service those items which require weekly lubrication.

8. WIRE ROPE (CABLE)

A detailed inspection of all wire rope (cable) should be made weekly or every 40 hours of use — which includes checking the wire rope for damage, deterioration 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.

4. HYDRAULIC SYSTEM

a.

The return line filter element is vital to the service life of the hydraulic system. Check the replacement indicator on the filter assembly weekly. Refer to HYDRAULIC SYSTEM SER-

VICE for more detailed information about this important item.

NOTE

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 NORMAL

1 ⁄

2

" DIAMETER

OF MORE

THAN 3 ⁄

64

"

WIRE ROPE CHART

MORE THAN 1

BROKEN WIRE AT

A DEAD-END

CONNECTION

EVIDENCE OF HEAT DAMAGE

FROM ANY CAUSE

WEAR GREATER THAN

1 ⁄

3

DIAMETER OF OUT-

SIDE INDIVIDUAL WIRES

KINKING,

CRUSHING OR

DISTORTION

OF ROPE

STRUCTURE

6 BROKEN

WIRES IN ANY

ONE LAY OR

3 BROKEN

WIRES IN ONE

STRAND IN

ANY LAY

6-8

MAINTENANCE RECOMMENDATIONS

The packer/carrier assembly should be visually inspected every forty (40) hours of operation for cracked or fatigued welds, loose or broken fasteners, worn bearings, pin hubs or pins.

SECTION 6



a.

Once a month, remove and clean the hydraulic tank fluid strainer as described in HYDRAULIC SYS-

TEM SERVICE in this section.

b.

Each month check the tailgate lift cylinder air breather. If plugged, replace it with a new breather.

YEARLY PREVENTIVE MAINTENANCE


a.

Once a year drain, flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SER-

VICE in this section.

b.

Once a year replace the hydraulic tank air breather.

c.

Once a year replace the fibrous tailgate lift cylinders’ air breathers.

LIFTING HOOK

A thorough inspection of any container lifting hook should be completed once a month consisting of checking for distortion, cracks, nicks, wear, latch engagement and secure end connections. Maximum distortion allowable is an 8 percent increase in the throat dimension or a 10 degree twist in the hook. Cracks, nicks and wear must not exceed 10 percent of any dimension.

Visually inspect before each use for obvious damage.

THROAT OPENING

BACK

HEEL

LATCH

POINT

BASE

6-9

SECTION 6


6-10

ALPHA

GENERAL

The Alpha 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 precautions listed in Sec. 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 operational mode as indicated by the

OPERATIONAL STATUS block presented at the beginning of each check.

NOTE

Because of the location of various controls, some checks will require two people.

OPERATIONAL STATUS

Truck Running PTO Engaged Sol.

Sw.

On

CHECK HYDRAULIC TANK

FLUID LEVEL

1.

Make sure the tailgate is down and clamped securely.

2.

Move the carrier and packer panel levers to position the carrier and packer cylinders in the retract position.

3.

Pull the pushout lever to position the pushout cylinder in the retract position.

4.

The fluid level should be between the safe range marks on the sight gauge.

IF NOT:


Truck Off PTO Disengaged

5.

Add hydraulic fluid for normal operating and weather conditions. See Sec. 6, PREVENTIVE MAINTE-

NANCE for additional information about servicing the hydraulic tank.

SECTION 7

CHECK-OUT

1 1 /

2

"

7-1

7-2

SECTION 7

CHECK-OUT

ALPHA

CHECK ENGINE SOLENOID SWITCH



Sw.

On

IF ENGINE SPEEDS UP:



The system is grounded. Locate the short and repair as described under ELECTRICAL SYSTEM in Sec. 9,

SERVICE AND REPAIR.

CHECK ENGINE SPEED-UP SWITCHES



Sw.

On

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

1.

Depress the engine speed-up pushbutton. The engine should speed up.

IF NOT:


SPEED-UP

BUTTON


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:






CONTROL LEVERS



SIGNAL

PUSH

BUTTON

ALPHA

CHECK PACKING CYCLE TIME



Sw.

On

0

26 SECONDS

1.

Activate both the packer panel lever and carrier panel lever. Using a stopwatch, time a complete cycle. A complete cycle should take 26 to 28 seconds.

IF NOT:




CONTROL LEVERS



LENGTHEN FOR

LONGER CYCLE

SECTION 7

CHECK-OUT

SIGNAL

PUSH

BUTTON

2.

Adjust the cable length between the solenoid or air cylinder and throttle linkage as needed to obtain the correct cycle time.

SOLENOID

NOTE

It is important the the cycle time is correct before performing the following pressure checks.

AIR

CYLINDER

SHORTEN FOR

SHORTER CYCLE

CHECK PRESSURES

The pressure checks provided below will indicate the operating condition of the hydraulic system. Detailed adjustment procedures are provided later in this section and are referenced at the appropriate check-out procedure. Prior to performing pressure checks:



1. Install a gauge capable of reading at least 3000 PSI

(207 BAR) on the main relief test coupling.

2. Start the unit, engage the PTO and turn solenoid switch ON.

MAIN RELIEF

TEST COUPLER

7-3

7-4

SECTION 7

CHECK-OUT

CHECK MAIN LINE PRESSURE



Sw.

On

1.

Depress speed-up button.

2.

Move pushout control lever to fully retract pushout cylinder.

3.

Hold lever and read gauge. Pressure should be at least 2150 PSI (148 BAR) but no more than 2200

PSI (152 BAR).

IF NOT:

4.

Perform TEST FOR LEAKING Pushout CYLIN-

DER SEAL as described in Section 9, SERVICE

AND REPAIR. Start truck, repeat steps 2 and 3 and again check gauge for correct pressure.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

ALPHA

2000

1000 3000

0 4000

2150 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN RELIEF

ALPHA

CHECK PUSHOUT PRESSURE



1.

Connect a gauge to the workport relief test coupler.

2.

Start the unit, engage the PTO and turn the solenoid switch on.

3.

Unlatch both tailgate clamps.

4.


5.

Move the tailgate control lever to the rear to fully raise the tailgate.

NOTE

The tailgate lift time is 24 to 28 seconds.

6.

Move the pushout control lever to the rear to fully extend the pushout cylinder.

7.

While continuing to hold the pushout control lever, observe the reading on the gauge.

8.

The pressure should be at 1950 PSI (135 BAR) plus or minus 100 PSI (7 BAR).

IF NOT:

9.




IF NOT:

10. Replace the two stage workport relief.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

SECTION 7

CHECK-OUT

2000

1000 3000

0 4000

1950 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

7-5

7-6

SECTION 7

CHECK-OUT

CHECK RESISTANCE PRESSURE



Sw.

On

1.

Move pushout control lever to fully extend the pushout cylinder.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

ALPHA



2.

Connect a porta-power with a gauge to the workport relief test coupler.

3.

Slowly pump the porta-power and read the gauge to see what pressure the two stage workport relief

“cracks” open at. The pressure should be 600 PSI

(42 BAR).

IF NOT:

4.

Verify all pressure in the signal line is relieved by moving the tailgate control lever forward to relieve any pressure in the circuit. Repeat step 3.

IF NOT:

5.

Disconnect signal line at the two stage workport relief.

6.

Loosen locknut and adjust the relief. If reading was below 600 PSI (42 BAR), turn adjustment clockwise. If reading was over 600 PSI (42 BAR), turn adjustment counter-clockwise.

7.

Secure locknut, connect signal line and confirm resistance pressure reading.

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

2000

1000 3000

0 4000

600 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

ALPHA

CHECK PACKER AND CARRIER

PANEL SHIFTING PRESSURES

There are two methods to determine accurate pressure settings.

2000

1000 3000

0 4000

SECTION 7

CHECK-OUT



0-3000 PSI

GAUGE

PACKER

LEVER

1.

Use an electronic pressure gauge that maintains and records maximum system pressures.

2.

If an electronic gauge is unavailable and a mechanical gauge must be used, the following procedure is recommended: a.

Install a 0-3000 PSI (0-207 BAR) pressure gauge at the quick disconnect coupler on the two spool directional valve at front of the unit.

Check the main relief pressure as described in

Section 7, “Check-Out”, of the Service Manual.

b.

Reduce the main relief setting to below the lowest knockout pressure.

PACKER PANEL SECTION

CARRIER PANEL

SECTION

ADJUSTING

SCREW

INLET COVER

ACCESSORY

SECTION

OUTLET COVER


Truck Off PTO Disengaged c.

Remove the button plug from the end of the

Main Control Valve bonnet using a screwdriver, then shift the Main Control Valve linkage to the detented power position and release, leaving the valve spool in the detented position.



Sw.

On 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.

CARRIER

LEVER

e.

The knockout pressures should be set at 1800

PSI (124 BAR) for the packer panel section and

2000 PSI (138 BAR) for the carrier panel section. If the knockout pressure setting requires adjustment, it may be changed by turning the knockout pressure adjustment screw, located inside the bonnet, clockwise to increase the knockout pressure setting or counter-clockwise to decrease the setting. Once the proper knockout setting has been attained, reinstall the button plug to seal the Main Control Valve.

f.

Return the main relief valve pressure setting to its specified value as described previously.

7-7

7-8

SECTION 7

CHECK-OUT

CHECK WEAR BLOCKS



1.

Visually inspect all wear blocks for excessive wear.

These items must be replaced before there is metal to metal contact.

2.

Shim or replace worn parts as described in Sec. 9,

SERVICE AND REPAIR under PUSHOUT PANEL.

Wear Block

ALPHA

POWER TAKE OFF (P.T.O.)



1.

Periodically re-torque the mounting bolts or studs as outlined in the P.T.O. manufacturers service manual.

Wear Block

BETA

GENERAL

The Beta 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.



NOTE




Sw.

On


FLUID LEVEL

1.


2.


3.


4.


IF NOT:



5.



SECTION 7

CHECK-OUT

1 1 /

2

"

7-9

SECTION 7

CHECK-OUT




Sw.

On





SERVICE AND REPAIR.




Sw.

On

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

1.


IF NOT:


SPEED-UP

BUTTON




2.


IF NOT:






CONTROL LEVERS



BETA

SIGNAL

PUSH

BUTTON

7-10

BETA




Sw.

On

0

29 SECONDS

1.


IF NOT:




CONTROL LEVERS



LENGTHEN FOR

LONGER CYCLE

SECTION 7

CHECK-OUT

SIGNAL

PUSH

BUTTON

2.


SOLENOID

NOTE


AIR

CYLINDER

SHORTEN FOR

SHORTER CYCLE

CHECK PRESSURES







MAIN RELIEF

TEST COUPLER

7-11

SECTION 7

CHECK-OUT




Sw.

On

1.


2.


3.


PSI (165 BAR).

IF NOT:

4.

Perform TEST FOR LEAKING Pushout CYLINDER

SEAL as described in Section 9, SERVICE AND

REPAIR. Start truck, repeat steps 2 and 3 and again check gauge for correct pressure.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

BETA

2000

1000 3000

0 4000

2300 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN RELIEF

7-12

BETA




1.


2.


3.


4.


5.


NOTE

The tailgate lift time is 24 to 28 seconds.

6.


7.


8.


IF NOT:

9.




IF NOT:


PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

SECTION 7

CHECK-OUT

2000

1000 3000

0 4000

1950 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

7-13

SECTION 7

CHECK-OUT




Sw.

On

1.


PUSHOUT

LEVER

TAILGATE

LIFT LEVER



2.


3.



(76 BAR).

IF NOT:

4.


IF NOT:

5.


6.


7.


SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

BETA

2000

1000 3000

0 4000

1100 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

7-14

BETA




2000

1000 3000

0 4000

SECTION 7

CHECK-OUT



0-3000 PSI

GAUGE

PACKER

LEVER

1.


2.





b.



CARRIER PANEL

SECTION

ADJUSTING

SCREW

INLET COVER

ACCESSORY

SECTION

OUTLET COVER







Sw.

On d.



CARRIER

LEVER

e.




f.


7-15

SECTION 7

CHECK-OUT




1.



2.



Wear Block

BETA




1.


Wear Block

7-16

DELTA

GENERAL

The Alpha, Beta and Delta have 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.



NOTE




Sw.

On


FLUID LEVEL

1.


2.


3.


4.


IF NOT:



5.



SECTION 7

CHECK-OUT

1 1 /

2

"

7-17

SECTION 7

CHECK-OUT

DELTA




Sw.

On





SERVICE AND REPAIR.




Sw.

On

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

1.


IF NOT:


SPEED-UP

BUTTON




2.


IF NOT:






CONTROL LEVERS



SIGNAL

PUSH

BUTTON

7-18

DELTA




Sw.

On

0

23 SECONDS

1.


IF NOT:




CONTROL LEVERS



LENGTHEN FOR

LONGER CYCLE

SECTION 7

CHECK-OUT

SIGNAL

PUSH

BUTTON

2.


SOLENOID

NOTE


AIR

CYLINDER

SHORTEN FOR

SHORTER CYCLE

CHECK PRESSURES







MAIN RELIEF

TEST COUPLER

7-19

SECTION 7

CHECK-OUT




Sw.

On

1.


2.


3.


PSI (162 BAR).

IF NOT:

4.




PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

DELTA

2000

1000 3000

0 4000

2300 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN RELIEF

7-20

DELTA




1.


2.


3.


4.


5.


NOTE

The tailgate lowering time is 24 to 28 seconds.

6.


7.


8.


IF NOT:

9.




IF NOT:


PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

SECTION 7

CHECK-OUT

2000

1000 3000

0 4000

1950 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

7-21

SECTION 7

CHECK-OUT




Sw.

On

1.


PUSHOUT

LEVER

TAILGATE

LIFT LEVER



2.


3.



(21 BAR).

IF NOT:

4.


IF NOT:

5.


6.


7.


SPEED-UP

BUTTON

WORKPORT

RELIEF TEST

COUPLER

DELTA

2000

1000 3000

0 4000

300 PSI

TWO STAGE

WORKPORT

RELIEF

MAIN RELIEF

TEST COUPLER

MAIN

RELIEF

7-22

DELTA




2000

1000 3000

0 4000

SECTION 7

CHECK-OUT



0-3000 PSI

GAUGE

PACKER

LEVER

1.


2.





b.



CARRIER PANEL

SECTION

ADJUSTING

SCREW

INLET COVER

ACCESSORY

SECTION

OUTLET COVER







Sw.

On d.



CARRIER

LEVER

e.




f.


7-23

SECTION 7

CHECK-OUT




1.



2.



Wear Block

DELTA




1.


Wear Block

7-24

SECTION 8

TROUBLESHOOTING

GENERAL

Troubleshooting is a matter of quickly and logically isolating the cause of a problem and taking corrective action. Factory trained mechanics, experienced operators, 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 working conditions.

For the most part, problems with the unit will be limited to hydraulic and electrical system component malfunction or control linkage adjustment.

Hydraulic flow diagrams are provided in this section.

These diagrams can be helpful in determining which parts are associated with a particular function. For example, the clamp cylinder is part of the load pushout function.

An electrical wiring diagram is included in Sec. 9, SER-

VICE AND REPAIR under ELECTRICAL SYSTEM.

Problems in the hydraulic system may be found by performing 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 remember 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 compaction rate of a unit.

4.

Preventive maintenance. A properly maintained unit will achieve higher compaction rates than one that is poorly maintained. The condition of the hydraulic system, pump, main relief setting and the condition of the operating cylinder seals will all have an effect on unit performance and compaction. Some chassis components will also affect compaction. The engine speed during packing, fluid level in an 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 consistent loads and has been properly maintained according the the Service manual, then it is safe to assume that it is getting maximum compaction for your particular 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 contamination, air is compressible and contains oxygen. It is these two (2) properties of air contamination that provide 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 oxygen to support combustion, but also the means for generating 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 ignitions that result from dieseling in the hydraulic system are small in size and many may be needed to eventually 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 contain 10% air by volume. As the pressure on the fluid increases, the amount of air that can be absorbed also increases.

A good example may be a front mounted pump dry valve system. In the dry mode of operation, system hydraulic fluid is drawn through a small orifice. This provides lubrication and cooling for the pump, but also provides 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 2RII 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.

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 negative 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.

After making any repairs on the hydraulic system, bleed the system at reduced engine speed and pressure to remove any trapped air. Depending on the size of the component, e.g. cylinder, hose, it may be necessary to cycle the unit several times. Of course the larger the air pocket, the more cycles are needed. To avoid potential problems, thoroughly bleed all hydraulic systems and ensure that all inlet connections are tight and not ingesting air.

8-2

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.

SECTION 8

TROUBLESHOOTING

REMEDY

1. Check electrical system. See Sec. 9, Service and Repair.

2. Make sure solenoid is mounted firmly and mounting does not flex.

3. Repair or replace as required.

4. Check for proper grade of fluid. See Sec. 6,

Preventive Maintenance.

5. Check fluid level. Add fluid if necessary.

6. Test for leaking cylinders. See Sec. 9, Service and Repair.

7a. Bring fluid to operating temperature.

7b. Check for proper grade of hydraulic fluid. See

Sec. 5, Specifications.

8. Repair, replace or realign damaged linkage.

PUMP NOISE IS EXCESSIVE

NOTE: ALL PUMPS MAKE A CERTAIN AMOUNT OF NOISE.

POSSIBLE CAUSE

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.

REMEDY

1a. Open gate valve.

1b. Check fluid level.

1c. Check hydraulic fluid filter and tank.

1d. Check for obstruction in suction lines, hoses kinked or collapsed.

2a. Bring fluid to normal operating temperature.

2b. Change hydraulic fluid to proper grade for operating conditions. See Sec. 5, Specifications.

3. Repair, replace and/or balance all parts.

4. Replace pump.

5. Replace with proper grade of hydraulic fluid.

See Section 5, Specifications.

6a. Tighten the suction hose.

6b. Tighten packing on the gate valve stem.

6c. Replace the pump shaft seal.

6d. Replace the suction hose.

6e. Replace the o-rings on the pump.

6f. Tighten or repair any leaks in the hydraulic system.

8-3

SECTION 8

TROUBLESHOOTING

ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR

SPEED-UP BUTTON IS ENGAGED

POSSIBLE CAUSE

1. Short in electrical wiring.

2. Blown fuse on speed-up relay.

3. Relay, solenoid or switch is defective.

4. Solenoid-to-carburetor or governor cable is broken.

5. Electrical system not grounded properly.

6. Carrier panel lever speed-up switch or linkage defective.

7. Solenoid mounting loose, broken or incorrect.

8. Truck engine mounts loose, worn, broken or missing.

REMEDY

1. Repair broken wire. See Electrical System,

Sec. 9, Service and Repair.

2. Replace fuse and check electrical system for shorts. See Electrical System, Sec. 9, Service and Repair.

3. Check for and replace defective parts as described in the Electrical System Section.

See Sec. 9, Service and Repair.

4. Replace cable.

5. Check all ground connections for corrosion or breaks. Clean or repair as described in the

Electrical System Section. See Sec. 9,

Service and Repair.

6. Repair, replace or adjust as required.

7. Be sure solenoid mounting is correct and secure.

8. Repair or replace engine mounts as required.

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.

REMEDY

1. Check for and repair short in system as described in Electrical Section. See Sec. 9,

Service and Repair.

2. Repair, replace or adjust as required.

3. Be sure solenoid mounting is correct and secure.

4. Repair or replace engine mounts as required.

PACKER PANEL VALVE SECTION SHIFTS TOO SOON

POSSIBLE CAUSE

1. Object in hopper that the packer panel cannot move.

2. Cycle time too fast.

3. Packer panel valve section pressure too low.

REMEDY

1. Recycle unit. Rearrange or remove refuse if necessary.

2. Adjust speed-up cable length.

3. Perform pressure checks as described in Sec.

7, Check-out.

8-4

SECTION 8

TROUBLESHOOTING

CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON

POSSIBLE 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

1. Packer panel cylinder seal leaking.

2. Packer panel valve section pressure too high.

3. Linkage binding or restrictive.

REMEDY

1. Perform test for leaking cylinder. See Sec. 9,

Service and Repair.


7, Check-out.

3. Inspect and free linkage as necessary.

CARRIER PANEL VALVE SECTION WILL NOT SHIFT TO NEUTRAL

POSSIBLE CAUSE

1. Carrier cylinder seal leaking.

2. Pressure too high.

3. Linkage binding or restrictive.

REMEDY


Service and Repair.


7, Check-out.

3. Inspect and free linkage as necessary.

PACKER PANEL DOES NOT DELIVER FULL FORCE

TO PACK LOAD INTO BODY

POSSIBLE CAUSE

1. Hydraulic pressure incorrect.

2. Hydraulic fluid in tank is low.

3. Tank strainer screen is dirty (this condition will starve pump and cause noise in the system).

4. Wrong type of hydraulic fluid in system.

5. Main relief section of 2-spool directional valve opens too soon.

6. Hydraulic pump is defective and will not deliver full pressure.

7. Operating cylinder piston seal is leaking.

8. Operating valve pressures are too low.

9. Air in hydraulic lines.

REMEDY

1. Perform checkout procedures through pressure checks. See Sec. 7, Check-out.

2. Add fluid to correct level. See Sec. 6,


3. Service system as described in Sec. 6,


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.


Service and Repair.

8. Perform pressure checks. See Sec. 7, Checkout.

9. Cycle packer 6 or 7 times to bleed air out of system.

8-5

SECTION 8

TROUBLESHOOTING

LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING

PUSHOUT CYLINDER

POSSIBLE CAUSE

1. Excessive fluid flow being forced through the main relief in the 2-spool valve.

REMEDY

1a. Release speed-up button.

1b. Only partially pull (feather) the 2-spool valve control handle.

LOAD WILL NOT PUSH OUT

POSSIBLE CAUSE

1. Less than full pressure in pushout cylinder.

2. The operator is trying to push the load out against a pile of refuse, dirt or bank of a hill.

REMEDY

1a. Perform test for leaking cylinder and repair.

1b. Adjust main relief pressure. See Sec. 9,

Service and Repair.

2. Move the unit forward to finish unloading.

PUSHOUT PANEL SLIDES FORWARD TOO FAST

WHILE PACKING REFUSE

POSSIBLE CAUSE

1. Cylinder bypassing.

2. Resistance setting too low.

REMEDY

1. Perform test for leaking cylinder.

2. Adjust resistance setting.

PUSHOUT PANEL WILL NOT SLIDE FORWARD AUTOMATICALLY

POSSIBLE CAUSE

1. Resistance setting too high.

2. Packer panel not applying full force to move pushout panel forward.

REMEDY

1. Reduce resistance setting.

2a. Check pressures.

2b. Check pump.

CARRIER AND PACKER PANEL STOP SHORT OF HOME POSITION

AFTER EACH CYCLE

POSSIBLE CAUSE

1. Unit full

2. Resistance too high.

3. Packer panel does not deliver full force.

REMEDY

1. Empty unit.

2. Reduce resistance setting.

3. See Section 8, Troubleshooting.

8-6

SECTION 8

TROUBLESHOOTING

PUSHOUT CYLINDER WILL NOT EXTEND TO PUSH OUT LOAD

POSSIBLE CAUSE

1. Operator trying to push load out against pile of refuse, dirt or bank of hill.

2. Leaking piston seal in pushout cylinder.

3. Hydraulic tubing is damaged (pinched shut).

4. Main relief pressure too low.

REMEDY

1. Unload unit as described in Sec. 3, Operation.

2. Perform test for leaking cylinder and repair as required. See Sec. 9, Service and Repair.

3. Replace tubing.

4. Check pressure. See Sec. 7, Check-out.

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.

REMEDY


Service and Repair.

2. Perform pressure test as described in Sec. 7,

Check-out.

CYCLE TIME TOO SLOW

POSSIBLE CAUSE

1. Solenoid to carburetor or governor linkage cable out of adjustment.

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.

9. Solenoid or wiring defective.

10. Defective governor (diesel engine).

REMEDY

1. Adjust cable to achieve 32 seconds cycle time.

2. Fill to proper level. See Sec. 6, Preventive

Maintenance.

3. Service filter. See Sec. 6, Preventive

Maintenance.

4. Service breather. See Sec. 6, Preventive

Maintenance.


Repair.

6. Perform test for leaking operating cylinder seals and repair as required.

7. Refill with proper grade of hydraulic fluid.

See Sec. 5, Specifications.

8. Remount solenoid securely (on engine, if possible).

9. Repair or replace as required. See Electrical

System, Sec. 9, Service and Repair.

10. Diesel engine must have a full variable speed governor to properly operate packer.

8-7

SECTION 8

TROUBLESHOOTING

TAILGATE WILL NOT RAISE

POSSIBLE CAUSE

1. Tailgate clamps still engaged.

2. Insufficient hydraulic pressure.

3. Hydraulic pump is defective.

4. Relief section of 2-spool directional valve out of adjustment or broken.

5. Tailgate lift cylinders leaking or defective.

6. Restriction in tailgate cylinder hose.

REMEDY

1. Disconnect clamps and swing free of tailgate.

2. Check main pressure. See Sec. 7, Check-out.


Repair.

4. Adjust or replace relief as necessary. See

Sec. 9, Service and Repair.

5. Repair or replace as required.

6. Remove and clean hose.

CONTAINER WON’T LIFT

POSSIBLE CAUSE

1. Insufficient hydraulic pressure.

2. Cable broken.

3. Cable loose from the lifting device (drum/cylinder).

4. Container overload.

5. Container frozen to the ground.

6. Control linkage is not moving the directional valve.

7. Lifting motor or cylinder(s) by-passing hydraulic fluid.

8. Shear pin or key broken between winch shaft and drum.

REMEDY

1. Check hydraulic pressure following procedures in service manual.

2. Replace cable.

3. Secure cable to lifting device.

4. Reduce weight of material in container.

5. Do not use lifting device to break container loose from the ground.

6. Repair the linkage.

7. Repair or replace the defective component.

8. Replace the key or pin.

WINCH MOTOR LEAKING

POSSIBLE CAUSE

1. Shaft seal damaged.

2. Motor worn internally.

REMEDY

1. Replace shaft seal.

2. Replace motor.

CONTAINER RAISES VERY SLOWLY

POSSIBLE CAUSE

1. Winch motor by-passing.

2. Rear loader hydraulic system not providing sufficient flow rate or pressure for container handling systems.

REMEDY

1. Repair or replace motor.

2. Check and repair rear loader hydraulic system following procedures in service manual.

8-8

SECTION 8

TROUBLESHOOTING

DESCRIPTION OF HYDRAULIC SYS-

TEM

The following is a description with flow diagrams of what happens in the hydraulic system during the loading, packing and unloading operations of the unit.

Operator action is presented and then a description of the hydraulic flow and the interaction of system components (i.e., valves and cylinders) follows. Before proceeding to the flow diagram, refer to the illustration and become familiar with the system component nomenclature.

SYSTEM COMPONENT NOMENCLATURE

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

MAIN CONTROL

VALVE

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

CARRIER

CYLINDER

TAILGATE

LIFT CYLINDER

HYDRAULIC

FLUID TANK

PUMP

PACKER

CYLINDER

8-9

SECTION 8

TROUBLESHOOTING

NEUTRAL (with the packer panel in “home” position.)

OPERATOR ACTION

Operator starts the truck and engages the PTO and speed up system.

HYDRAULIC SEQUENCE

Hydraulic fluid flows from the tank, by gravity, to the pump; from there, it is pumped to the front control valve. Flow continues through the valve to and through the operating valve and then back to the tank. During packer operation, if pressure increases to the main relief setting, excess flow will be diverted from the front control valve back to tank.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-10

PACKER PANEL SWEEPS BACK

OVER LOAD OPERATOR ACTION

The operator moves the control levers inward to start the compaction cycle.

SECTION 8

TROUBLESHOOTING


Operator action causes the operating valve to shift, diverting flow to the rod end of the packer panel cylinders. The packer panel cylinders retract causing the packer panel to sweep rearward over the load. Return fluid flow from the cylinder is back to the tank.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-11

SECTION 8

TROUBLESHOOTING

CARRIER & PACKER PANELS MOVE DOWN

TO “INTERRUPTED CYCLE” POSITION

OPERATOR ACTION

None-Operating valve shifts automatically.


At the end of the packer panel cylinder stroke pressure builds to knockout setting causing the operating valve to shift, diverting flow to the case end of the carrier cylinders. The cylinders extend, moving the carrier and packer panels down to the “interrupted cycle” position (trapped fluid keeps the packer panel cylinders retracted). At the end of the carrier cylinder extension stroke, pressure builds to knockout setting causing the operating valve to shift to neutral.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

TRAPPED

8-12

SECTION 8

TROUBLESHOOTING

PACKER PLATE SWEEPS HOPPER

OPERATOR ACTION

Operator shifts the control levers outward to start compaction.


Fluid flow is through the operating valve packer section to the case end of the packer panel cylinders. As the cylinders extend, the packer panel sweeps the hopper. With the packer cylinder extension stroke completed, pressure builds to knockout setting causing the operating valve to shift.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-13

SECTION 8

TROUBLESHOOTING

PACKING REFUSE

OPERATOR ACTION

None-Operating Valve shifts automatically.


Fluid flows from the operating valve to the rod end of the carrier panel cylinders. The cylinders retract, moving the carrier and packer panels up, packing refuse against the pushout panel. When the pressure reaches the knockout setting, the operating valve shifts into neutral and the packing cycle is completed. As the carrier cylinders apply force to compact refuse, the pressure of the trapped fluid in the packer cylinders will increase. Should this pressure reach 3500

PSI (242 BAR), a relief valve will open reducing the pressure by allowing some trapped fluid to escape and return to the hydraulic tank.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

TRAPPED

8-14

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 button. Operator moves the tailgate lift lever rearward.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON

SECTION 8

TROUBLESHOOTING


Moving the tailgate lift lever rearward shifts a spool in the front control valve causing flow to the tailgate lift cylinders. The cylinders extend, causing the tailgate to raise. Excess fluid flow from the front control valve returns back to the tank.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-15

SECTION 8

TROUBLESHOOTING

EJECTING LOAD

OPERATOR ACTION

Operator depresses speed-up button and moves pushout lever rearward.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON


Moving the pushout lever rearward shifts a spool in the front control valve causing flow to the pushout cylinder. As the cylinder extends, the load is ejected from the body.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-16

RETRACTING PUSHOUT PANEL

OPERATOR ACTION

Operator releases speed-up button.

Operator moves the pushout lever forward.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SECTION 8

TROUBLESHOOTING

SPEED-UP

BUTTON


Moving the pushout lever forward shifts a spool in the front control valve causing flow to the pushout cylinder. As the cylinder retracts, the pushout panel is positioned near the front of the body.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-17

SECTION 8

TROUBLESHOOTING

LOWERING TAILGATE

OPERATOR ACTION

Operator moves the tailgate lift lever forward.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON


Moving the tailgate lift lever forward shifts a spool in the front control valve allowing fluid in the tailgate lift cylinders to drain back to the tank.

The weight of the tailgate forces fluid out of the cylinders; the cylinders retract and the tailgate lowers.

TAILGATE LIFT

CYLINDER

CARRIER

CYLINDER

PACKER

CYLINDER

MAIN CONTROL

VALVE

CARRIER

CYLINDER

HYDRAULIC

FLUID TANK

PUSHOUT

CYLINDER

FRONT CONTROL

VALVE

PUMP

TAILGATE

LIFT CYLINDER

PRESSURE

RETURN

8-18

GENERAL

This section contains the instructions necessary for the repair and replacement of the main components of the unit.

Before attempting any repair of the unit, become thoroughly 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 CYLINDERS

(CARRIER AND PACKER PANEL)

The two (2) double-acting hydraulic cylinders that control the movement of the carrier panel are called the

“carrier” cylinders.

The two (2) double-acting hydraulic cylinders that control the movement of the packer panel are called the

“packer” cylinders.

SECTION 9

SERVICE AND REPAIR

9-1

SECTION 9


TEST FOR LEAKING PACKER

PANEL CYLINDERS

NOTE

Before testing any cylinder, make sure the main system pressure is correct as described under

MAIN LINE PRESSURE CHECK, Sec. 7, CHECK-

OUT PROCEDURES.



1.

Remove the top sheet over the operating cylinders for better accessibility during testing.



Sw.

On

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.

CAUTION

Loosen the hydraulic fittings slowly to release any trapped pressure. Watch for inadvertent movement of components.



PACKER PANEL

LEVER

3.

Disconnect and cap the lines to the rod end of one cylinder at a time.

CARRIER PANEL

LEVER

9-2

SECTION 9




Sw.

On

4.

Shift the packer panel lever outward to apply hydraulic pressure to the case end of the packer panel cylinders. Hold the lever and observe the fluid flow from the open port on the rod end. The flow of hydraulic fluid should be no more than 2 fluid ounces per minute. A flow greater than 2 ounces indicates an excessive piston seal leak. If the cylinder does not leak excessively, continue test.



5.

Reconnect the hydraulic lines to the end of cylinders. Repeat steps 3-5 for the other cylinder.



Sw.

On

PACKER PANEL

LEVER

6.

Shift the packer panel lever inward to retract the packer panel cylinder (to the “interrupted-cycle” position).



CARRIER PANEL

LEVER

CAUTION


7.

Disconnect and cap the hydraulic lines which connect to the case end of a packer panel cylinder.

9-3

SECTION 9




Sw.

On

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.

Truck Off


PTO Disengaged Keys Removed

PACKER PANEL

LEVER

9.

If the cylinder does not leak, reconnect the hydraulic lines to the cylinder. Repeat steps 7-9 for the other cylinder.

CARRIER PANEL

LEVER

CAUTION


TEST FOR LEAKING CARRIER

PANEL CYLINDERS

NOTE

Before testing any cylinder, make sure the main line pressure is correct as described under MAIN

LINE PRESSURE CHECK, Sec. 7, CHECK-OUT

PROCEDURES.



1.

Remove the top sheet over the operating cylinders for better accessibility during testing.

9-4



Sw.

On

2.

Shift the carrier panel lever outward to fully extend the carrier panel cylinders (“home” position).

PACKER

PANEL

LEVER



3.

Disconnect and cap the lines that connect to the rod end of one cylinder.

SECTION 9


CARRIER

PANEL

LEVER



Sw.

On

CAUTION


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.

PACKER

PANEL

LEVER



CARRIER

PANEL

LEVER

5.

If the cylinder does not leak, reconnect hydraulic lines to the rod end of cylinder

Repeat steps 3-5 for other cylinder.

9-5

SECTION 9




Sw.

On

6.

Shift the carrier panel lever inward to retract the carrier panel cylinder.

PACKER

PANEL

LEVER

CARRIER

PANEL

LEVER

CAUTION




7.

Disconnect and cap the hydraulic lines which connect to the case end of the carrier panel cylinder.



Sw.

On

8. Shift the carrier panel lever inward to apply hydraulic pressure to the rod end of the carrier cylinder. Hold the lever and observe the fluid flow from the port on the cylinder case end. The flow of hydraulic fluid should be no more than 2 fluid ounces per minute. A flow greater than 2 ounces indicates an excessive piston seal leak.

Disassemble the cylinder and replace the piston seal.

PACKER

PANEL

LEVER



9.

If the cylinder does not leak, reconnect the hydraulic lines to the case end of the carrier panel cylinder.

9-6

CARRIER

PANEL

LEVER

REMOVAL OF PACKER

PANEL CYLINDERS


Truck Off Keys Removed

1.

Position the packer panel to the “interrupted cycle” position and then sweep the packer plate to the vertical position.



Sw.

On

2.

Remove the topsheets to provide better accessibility to the packer panel.

NOTE

See Sec. 4, GENERAL REPAIR PRACTICES, for more detailed information about the correct use of slings and lifting chains.

3.

Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device with a minimum lifting capacity of 500 lbs. (227 kg.). Operate the hoist to make the lifting cable snug without applying strain on the cylinder.



PACKER

PANEL

LEVER

4.

Remove the capscrew from the rod end pin retainer.

5.

Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin.

Check for pivot pin or pin hub wear.



Sw.

Off

6.

Slowly operate the packer panel lever inward to completely retract the cylinder.

SECTION 9


CARRIER

PANEL

LEVER

9-7

SECTION 9




7. Disconnect both the case end and rod end hoses.

Immediately cap or plug the hoses and cylinder ports to keep fluid in and dirt out.

8. Remove capscrew from the case end.

9. Remove the pivot pin by using pin puller (See Sec.

10, SERVICE TOOLS).

10. Check for pivot pin or pin hub wear.

REMOVAL OF CARRIER

PANEL CYLINDERS



1.

Remove the topsheets to provide better accessibility.

NOTE


2.

Secure a chain to the lower end of the carrier panel. Attach the other end to a suitable lifting device with a minimum lifting capacity of 1,600 lbs.

Adjust the hoist so that it will support the panel once the carrier cylinders are removed.

3.

Once the carrier panel has been securely supported, secure a nylon sling around the carrier cylinder and attach to a lifting device with a minimum lifting capacity of 500 lbs. Operate the hoist to snug the lifting sling without applying strain to the cylinder.

4.

Remove the capscrew from the rod end. Carefully remove the pivot pin. Use special pin puller (See

Section 10, SERVICE TOOLS).

9-8

ALPHA

SECTION 9


DISASSEMBLY OF

PACKER PANEL CYLINDERS

1. Remove grease fitting, clean parts, drain fluid and follow all other applicable guidelines for disassembly provided in Section 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 device with a minimum lifting capacity of 500 lbs.

4. Remove the setscrew from the gland retainer.

5. Remove the gland retainer.

6. Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder.

NOTE

Use an electric drill with an internal grinding wheel to remove any burrs from the internal groove on the cylinder case. Otherwise the cylinder may be difficult to take apart.

INSPECTION AND REPLACEMENT

1. Carefully and thoroughly inspect the bore of the cylinder case for cracks, rust, scoring, or excessive wear. Replace if found not to be serviceable. Check all other parts for damage.

2. A new rod wiper, rod seal, O-rings, and piston seals must be installed anytime the cylinder is disassembled. Pay particular attention to me way the parts are positioned before disassembly.


Reassemble and install the cylinder in the approximate reverse order of assembly.

NOTE

If the cylinder is not to be installed immediately, keep the ports sealed to prevent contamination from entering the cylinder.

NOTE

Special tools, listed in Section 10, SERVICE

TOOLS, may be necessary to properly reassemble the cylinder.

ZERK

PISTON SEALS

ROD WIPERS,

SEALS, O-RINGS

ZERK

CASE BUSHING

PISTON

NUT

ROD

GLAND

BUSHING

9-9

SECTION 9


ALPHA

DISASSEMBLY OF

CARRIER PANEL CYLINDERS




4. Remove the setscrew that retains the gland.

5. Remove the gland.


NOTE







NOTE


NOTE



ZERK

PISTON SEALS

ROD WIPERS,

SEALS, O-RINGS

ZERK

CASE BUSHING

PISTON

NUT

ROD

GLAND

BUSHING

9-10

BETA

SECTION 9


DISASSEMBLY OF








NOTE







NOTE


NOTE



ZERK

PISTON SEALS

ROD WIPERS,

SEALS, O-RINGS

ZERK

CASE BUSHING

PISTON

NUT

ROD

GLAND

BUSHING

9-11

SECTION 9


BETA

DISASSEMBLY OF





4. Remove the setscrew that retains the gland.

5. Remove the gland.


NOTE







NOTE


NOTE



ZERK

PISTON SEALS

ROD WIPERS,

SEALS, O-RINGS

ZERK

CASE BUSHING

PISTON

NUT

ROD

GLAND

BUSHING

9-12

DELTA

SECTION 9


DISASSEMBLY OF


1. Remove grease fittings, clean parts, drain fluid and follow all other applicable guidelines for disassembly provided in Section 4, General Repair Practices, before proceeding to disassemble the cylinder.


3. Secure the rod end of the cylinder to an overhead hoist or other suitable lifting mechanism with a minimum lifting capacity of 500 lbs.

4. Remove the six nylock screws and three lock segments securing the head gland to the cylinder.


NOTE







NOTE


NOTE



LOCK

SEGMENTS

SCREW GLAND ROD PISTON

CASE

9-13

SECTION 9


DELTA

DISASSEMBLY OF








NOTE







NOTE


NOTE



ZERK

PISTON SEALS

ROD WIPERS,

SEALS, O-RINGS

ZERK

CASE BUSHING

PISTON

NUT

ROD

GLAND RETAINER

GLAND

BUSHING

9-14

SECTION 9


DESCRIPTION OF THE TAILGATE LIFT CYLINDERS

These two (2) 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 cylinder weldment pivot ear is attached to a mounting hub on the tailgate.

The cylinders raise the tailgate by means of hydraulic fluid flowing through a port on the case end of the cylinder, extending the cylinder. The tailgate is lowered by the weight of the tailgate forcing oil from the cylinder.

CHECK FOR LEAKING TAILGATE LIFT CYLINDER

The tailgate lift cylinder utilizes a design that does not incorporate a cylinder piston, such as a typical cylinder would. This cylinder incorporates a hollow piston rod, to allow the hydraulic fluid to extend the rod by applying pressure to the inside of the rod. The rod is ported to allow hydraulic fluid to pass from the area between the rod and the case to inside the case. When the cylinder is being retracted, fluid is then allowed to pass through this porting from the inside of the rod to the area between the rod and the case. Therefore, the cylinder rod is protected in hydraulic fluid when retracted, greatly reducing the chances of damage by means of rust, corrosion, etc.

Visual inspection of the tailgate cylinders is the only leakage test necessary for this design cylinder. Check the cylinder rods for damage such as scratches, nicks, etc. If any external leakage is present, repair the cylinder as described under the removal and disassembly guidelines.

REMOVAL OF TAILGATE LIFT CYLINDER



1. With the tailgate closed, attach a sling connected to a suitable lifting device with a minimum lifting capacity of 500 lbs., to the tailgate lift cylinder.

NOTE

See Section 4, GENERAL REPAIR PRACTICES, for more detailed information about the correct use of slings and lifting chains.

2. Disconnect the hydraulic line (1) at the cylinder base and cap the line.

3. Remove the adapter (2), restriction pin (3) and plug the cylinder port.

4. Remove the capscrew (4), washer (5) and retainer

(6) from the cylinder end.

5. Remove the capscrew (7), lockwashers (8), retainer (9) and pin (10).

9-15

SECTION 9


DISASSEMBLY OF TAILGATE LIFT CYLINDER

1.

Wash the outside of the cylinder assembly completely to prevent contamination and/or damage to the cylinder components.

2.

Secure the case end of the cylinder to a workbench or floor mount and the rod end to an overhead lifting device with a minimum lifting capacity of 500 lbs.

3.

Remove the plug from the port and drain all fluid.

4.

Remove the 1/4" socket head setscrew from side of the cylinder case, and discard.

5.

Remove the bleeder screw and gasket from the end of the cylinder rod. Save these for reassembly.

6.

Unscrew the head gland from the cylinder case completely. Slide the head gland off of the the rod.

7.

Using the overhead lifting device, carefully extend the cylinder rod approximately 1/2 way out of the case.

8.

Apply a 6" piece of 1" masking tape to the chrome 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.

9.

Push the rod back into the case, then again using the overhead lifting device, extend the rod 1/2 way out. The cylinder packing should 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.

10. Using a long screwdriver or pick, remove the retaining 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.

11. Slide the rod assembly out of the case.

12. Remove the wear ring from the bottom of the cylinder rod and discard.

13. Remove the wiper from the head gland.

INSPECTION, REASSEMBLY AND INSTALLATION

1.

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.

2.

Liberally coat all seals and wear rings with clean, fresh hydraulic fluid before installation.

3.

Assembly of the tailgate lift cylinder is in approximate reverse order of disassembly.

4.

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.

5.

Check all cylinder mounting components for cracks or excessive wear before installation. If the cylinder is not to be installed immediately, keep the port sealed to prevent contamination.

6.

After installation of the cylinder is complete, clamp the tailgate 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.

7.

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.

8.

Check for any external leaks on the cylinder and connecting fittings.

PORT

PACKING

PISTON WEAR RINGS, SEALS

RETAINING RING

BLEEDER

CASE

FITTING

GLAND

SET SCREW

ROD

9-16

DESCRIPTION OF THE TAILGATE ASSEMBLY

The tailgate assembly houses the carrier and packer panel cylinders, carrier and packer panels and the

“hopper” where refuse is first loaded into the Delta. The tailgate is raised (for unloading) and lowered by the tailgate lift cylinders which are actuated by the tailgate lift lever.

The need to remove the tailgate is rare and limited to repair of the hopper area and removal of the carrier panel. Procedures for carrier panel removal are different and are covered under REMOVAL OF CARRIER

PANEL.

SECTION 9


REMOVAL OF THE TAILGATE ASSEMBLY



1.

Release the tailgate clamps.

2.

Disconnect and remove the tailgate lift cylinders as described earlier in this section.

3.

Disconnect and cap the hydraulic lines.

4.

Disconnect the electrical conduit and wires from the junction box on the tailgate.

NOTE


5.

Attach chains, connected to a suitable lifting device with a minimum lifting capacity of 7,500 lbs. to the tailgate as shown. Operate the lifting device no more than necessary to support the weight of the tailgate.

6.

Remove the capscrew (1), lockwasher (2), retainer

(3) and hinge pin (4).

7.

Operate the lifting device and/or move the truck to free the tailgate from the body.

8.

Position the tailgate on supports if needed to facilitate repairs. Supports must be capable of supporting a minimum of 7,500 lbs.

9-17

SECTION 9



OF TAILGATE



1.

Inspect all sheet metal for badly bent or dented conditions. Check the hardware holes for enlargement or breaks in the metal. Check threaded holes for stripped or otherwise damaged threads. Check the rubber seal for any sign of deterioration. Check handles for looseness.

2.

Replace any defective part. Follow all safety precautions pertaining to welding described in Sec. 4,

GENERAL REPAIR SAFETY PRECAUTIONS.

3.

See Sec. 4, GENERAL REPAIR INSTRUCTIONS for information pertaining to welding repairs.


OF TAILGATE

Reassemble and install the tailgate in the approximate reverse order of disassembly and removal.

DESCRIPTION OF CARRIER AND

PACKER PANELS

The carrier and packer panels operate as a single unit to sweep refuse from the hopper and pack it against the pushout plate. Their movement through the different cycles is controlled by the operating cylinders.

Movement of the panels within the body is kept in alignment by the roller assemblies, located at each corner of the carrier panel. The rollers ride inside a track channel on each side of the tailgate.

9-18

REMOVAL OF PACKER PANEL



Sw.

On

1.

Position the packer panel at the interrupted cycle position.

2.

Move the packer panel lever upward until the packer plate reaches a vertical position. This will take the pressure off the rod eye when the pin is removed.

PACKER

PANEL

LEVER

SECTION 9


CARRIER

PANEL

LEVER



3.

Remove the locknut and capscrew from the rod end of both packer cylinders.

4.

Secure a nylon sling around the cylinder and attach to a suitable lifting device with a minimum 500 lb.

lifting capacity. Make sure the cylinder weight is securely supported and carefully remove the cylinder rod pin.

5.

After both cylinders have been disconnected, attach a chain connected to a suitable lifting device, with a minimum lifting capacity of 1600 lbs., to the packer panel as shown. Operate the lifting device to support the weight of the packer panel without causing strain on the bearing or roller assemblies.

6.

Remove the roll pins and washers from the packer panel pivot pins.

NYLON SLING

Remain clear of packer panel when removing pivot pins.

7.

Remove the pivot pins.

8.

With the pivot pins removed, carefully operate the hoist and lift the packer panel out of the hopper.

Use care to avoid damaging the hopper.

NOTE


9-19

SECTION 9


INSPECTION AND REPLACEMENT OF PACKER PANEL



1.

Carefully inspect all pivot areas for excessive or uneven wear, scoring or other damage.

2.

Check the plate for broken welds, bent edges or warpage.

3.

Inspect the edge for damage. Replace a badly worn edge as described below.

4.

Replace parts as necessary. (See Sec. 4, GENER-

AL REPAIR INSTRUCTIONS).

REPLACEMENT OF PACKER PANEL EDGE



1.

Remove the old edge with an Air Arc to obtain a clean cut.

2.

Smooth the edge of the packer panel where the new edge will be attached.

3.

Weld a new edge in place.

NOTE


INSTALLATION OF PACKER PANEL

Install the packer panel in the approximate reverse order of disassembly. Prior to installation, inspect the pivot bushings in the carrier panel and replace if worn.

9-20

ROLLER REPLACEMENT/SHIMMING

1.

Shift the operating control levers and cycle the unit several times while observing the rollers and action of the packer and carrier panels. Watch for sideways movement or twisting to determine where shimming and/or new rollers may be needed.



2.

Remove the capscrews (1), lockwashers (2), cover

(3) and cover weldment (4) for the track hole of the roller or rollers to be removed.



Sw.

Off

3.

Shift the operating control levers and cycle the panels as necessary to align the upper and lower roller assemblies with the track holes.

NOTES

If the top roller is removed, first place a wedge between the carrier panel and the partition sheet to take the weight off of the roller assemblies.

If the bottom roller is removed, support the carrier and packer panel assembly before removing the roller.

PACKER

PANEL

LEVER

SECTION 9


CARRIER

PANEL

LEVER

9-21

SECTION 9




4.

Remove one roller and shaft assembly at a time.

5.

Replace any roller that is excessively worn, cracked or out of round. Inspect the condition of the track bar. Replace if necessary.

6.

Install a grease fitting in roller and the original shims or the same amount of new shims as removed.



Sw.

Off

7.

Repeat step 1 to determine if additional shims are required.

CAUTION

Do not over shim rollers. Excessive shimming may damage tailgate walls or wear the track channels.



8.

Remove the appropriate rollers and adjust the shims as required to obtain a smooth operating carrier panel. (This may require adding or removing shims and operating the packing lever several times until the correct alignment is achieved.)

9.

Reinstall the track hole covers in the reverse order of removal.

10. Once the alignment is correct, lubricate each roller as described in the LUBRICATION CHART, Sec. 6,

PREVENTIVE MAINTENANCE.

9-22

SECTION 9


REMOVAL OF CARRIER PANEL

NOTE

Remove the packer panel and four operating cylinders as described earlier in this section.



1.

Attach a chain, connected to a suitable lifting device with a minimum lifting capacity of 1600 lbs.

to the upper and lower end of the carrier plate, as shown.

2.

Remove the rollers as described later in this section.

3.

Lower the carrier panel into the tailgate hopper and disconnect the chains.

NOTE


4.

Remove the tailgate as described earlier in this section. Once the tailgate is removed, the carrier panel can be supported ore removed as necessary for repair.

TRACK BAR REPLACEMENT

Refer to Sec. 4, GENERAL REPAIR INSTRUCTIONS for welding instructions.

1.

Remove the old track bar and make sure the track channel is smooth and clean.

WRONG RIGHT

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.

2.

Weld the new track bar into place. The surface of the track bar must be 90° from the side of the tailgate so the roller will run true.

THIS ANGLE MUST BE 90°

GAP

FLAT - NO GAP

9-23

SECTION 9



OF CARRIER PANEL



1.

Carefully inspect all pivot, bearing and roller surfaces for excessive or uneven wear, scoring or damage.

2.

Check the panel for broken welds, bent edges or warpage.

3.

Inspect the tailgate channel track bars for excessive wear or damage.

4.

Replace parts as necessary.

5.

The roller shaft bushings may be removed using a pin puller (See Sec. 10, SERVICE TOOLS) which screws in the bushing plug.

INSTALLATION OF CARRIER PANEL

Install the carrier panel in the approximate reverse order of disassembly. Pay particular attention to the installation of the roller and bearing assemblies as described earlier in this section.

9-24

SECTION 9


DESCRIPTION OF PUSHOUT PANEL

The pushout panel is connected to, and controlled by, the pushout cylinder. Refuse is packed against the pushout panel during loading. During unloading the pushout panel ejects the load as the pushout cylinder is extended.

The pushout panel will travel the entire length of the body. At the end of the extension stroke the load is completely ejected.

During its movement through the body the pushout panel rides in a trough. Its sideways movement is minimized by replaceable wear blocks.

INSPECTION AND REPLACEMENT OF WEAR BLOCKS



PUSHOUT PANEL

1.

Inspect the wear blocks for wear. Replace worn parts.

SHIMMING WEAR BLOCKS WITH

PANEL IN PLACE

Shims can be added to the wear blocks without removing the pushout panel as follows:



Pushout Cylinder

Mounting

Wear Blocks,

Shims

Wear Blocks,

Shims

1.

Remove attachment bolts and pins for wear blocks.

2.

Pry pushout panel to one side.

3.

Add shims behind the wear block.

4.

Repeat procedure for other side.

5.

Install attachment bolts and pins. Tighten securely.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER

REMOVAL OF PUSHOUT PANEL



Sw.

On

1.

Remove the pushout lever and position the pushout panel at the extreme rear of the body.

2.

Pull the tailgate lift lever to raise the tailgate.

SPEED-UP

BUTTON

9-25

SECTION 9




3.

Support the tailgate from an overhead hoist or crane with a minimum lifting capacity of 7500 lbs.

CAUTION

Loosen the hydraulic fittings slowly to release the pressure.

4.

Disconnect the pushout cylinder from the pushout panel by removing the four (2) bolts in each of the saddle bearings.

NOTE

Be careful not to damage the pushout cylinder during removal of the pushout panel.

5.

Weld an eye to the center of the panel and attach a chain to prevent the panel from tipping over upon removal.

6.

The pushout panel can now be removed from the body. The method of removal will depend on the equipment available. Whatever method is used, the equipment must be capable of lifting a minimum of

2800 lbs. and the panel should be secured safely to the removal device.

INSTALLATION OF PUSHOUT

PANEL

Install the pushout panel in the reverse order of removal.

WELD EYE

Pushout

Cylinder

Saddle Bearing

9-26

ALPHA

MAIN CONTROL VALVE

The main control valve is located on the tailgate above the packer and carrier panels. The valve controls the operation of the packer and carrier panels through the entire packing cycle. It may have additional valve sections, depending on the installation of options.

SECTION 9



MAIN

CONTROL

VALVE

9-27

SECTION 9


REMOVAL OF THE


1.

Place the packer and carrier panels in the “interrupted cycle” position.

CARRIER PANEL

ALPHA

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

CARRIER

PANEL

LEVER

4.

Disconnect the shift linkage.

5.

Disconnect and cap all hydraulic lines and hoses.

6.

Plug all open ports on the valve to prevent contamination.

NOTE:

The valve assembly and bracket weigh approximately 100 lbs. Use appropriate lifting procedures and techniques when handling this assembly.

7.

Remove the capscrews, washers and nuts holding the valve bracket to the tailgate.

PACKER

PANEL

9-28

MAIN

CONTROL

VALVE

ALPHA

SECTION 9


DISASSEMBLY AND INSPECTION

OF MAIN CONTROL VALVE

1.

Wash the valve body with solvent to prevent contamination.

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 covers, remove the four (4) tie bolts which secure the valve sections and overs. Separate carefully, noting the location of o-ring seals.

3.

Thoroughly clean the o-ring counter bores and ground surfaces of each 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 dislodging o-rings from the counterbores.

2.

Secure tie bolts and tighten evenly to 25 ft. lbs.

(33.8Nm).

3.

Torque the 3500 lb relief cartridge, load check and blanking plugs to 20 ft. lbs. (27 Nm).

TIE ROD

BONNET

INLET

COVER

KNOCKOUT

POSITIONER

OUTLET

COVER

CONTAINER

HANDLING

SECTIONS

PACKER

SECTION O-RINGS

CARRIER

SECTION

9-29

SECTION 9


ALPHA

DISASSEMBLY AND INSPECTION OF THE KNOCKOUT POSITIONER

1.

To remove the knockout positioner, remove the four bonnet capscrews (2) and bonnet (3).

2.

Using a

5

⁄

16

" allen wrench remove the spool collar

(6). If the control rod assembly is not installed on the spool end it may be necessary to insert a rod through the spool clevis to keep the spool from rotating when removing the spool collar.

CAUTION

the spool. The detent balls (9) will be free to fall out when the sleeve is slid off.

5.

Remove spring (17), KO ramp (15), dowel pin (8), piston (14), spring pad (13), inner spring (10) and

KO poppet (12).

6.

Remove o-ring from counter bore of valve body.

7.

Remove the four (4) capscrews which secure the linkage side cover bracket to the valve body work section.

8.

Remove retainer plate, retainer plate washer and oring seal.

The spool collar is under spring tension and caution should be used when removing.

CAUTION

NOTE:

It may be necessary to turn the pressure adjustment screw (1) clockwise until it is recessed far enough to allow removal of the spool collar.

Do not remove the valve spool as the seals can be replaced externally.

3.

Remove outer spool collar (4), spool centering spring (5) and inner spool collar (7).

4.

Carefully slide the detent sleeve assembly (16) off

9.

The removal of the 3500 lb. relief valve, load check and blanking plug are taken off as assemblies and repairs are limited to o-ring replacement or complete cartridge assembly.

3 6 1 7 17 8 13

Backup

Washer

O-Ring

9

2 4 5 15 14 10 12 16 9

Spool

REASSEMBLY OF KNOCKOUT POSITIONER

1.

With all o-ring seals removed and counterbores thoroughly clean, lightly oil the new seals. Slide over the valve spools and insert in the seal counterbores.

2.

Replace all seals in the knockout position prior to reassembly.

3.

Apply a liberal amount of general purpose grease to the spring pad (13), inner spring (10) and the KO poppet (12) and insert these parts into the piston

(14). Slide this assembly into the end of the valve spool and push into place.

4.

Insert the dowel pin (8) and slide (17) over end of the KO ramp (15). Insert this assembly into the end of the valve spool and push into place.

5.

Apply a liberal amount of general purpose grease into the detent ball holes (9) in the valve spool and push into place.

6.

Insert one detent ball (9) into each hole and carefully slide the detent sleeve assembly (16), including the seals and retainers, over the valve spool into place next to the valve housing.

7.

Insert the adjustment screw (1) into the spool collar

(6) from the inside and turn a few revolutions. Do not turn the adjustment screws in too far or it will interfere with installation of the spool collar.

8.

Slide inner spring collar (7), centering spring (5), and outer spring collar (4) onto end of valve spool.

While holding in place, screw the spool collar (6) into the spool end.

9.

Torque the spool collar (6) to 10 - 12 ft. lbs. [13,6 -

16,3 Nm]

10. Reassemble parts in reverse order of disassembly.

11. Torque the bonnet screws and linkage end bracket to 60 in. lbs. (6.75 Nm).

9-30

BETA



SECTION 9



MAIN

CONTROL

VALVE

9-31

SECTION 9


REMOVAL OF THE


1.


CARRIER PANEL

BETA

PACKER

PANEL

2.



PACKER

PANEL

LEVER

3.



CARRIER PANEL

CARRIER

PANEL

LEVER

4.


5.


6.


NOTE:


7.


PACKER

PANEL

9-32

MAIN

CONTROL

VALVE

BETA

SECTION 9




1.


NOTE:


2.

To separate valve sections from inlet or outlet covers, remove the four (4) tie bolts which secure the valve sections and overs. Separate carefully, noting the location of o-ring seals.

3.



VALVE

1.


NOTE:


2.


(33.8Nm).

3.


TIE ROD

BONNET

INLET

COVER

KNOCKOUT

POSITIONER

OUTLET

COVER

CONTAINER

HANDLING

SECTIONS

PACKER

SECTION O-RINGS

CARRIER

SECTION

9-33

SECTION 9


BETA

DISASSEMBLY AND INSPECTION OF THE KNOCKOUT POSITIONER

1.

To remove the knockout positioner, remove the four bonnet capscrews (2) and bonnet (3).

2.

Using a

5

⁄

16

" allen wrench remove the spool collar

(6). If the control rod assembly is not installed on the spool end it may be necessary to insert a rod through the spool clevis to keep the spool from rotating when removing the spool collar.

CAUTION

the spool. The detent balls (9) will be free to fall out when the sleeve is slid off.

5.

Remove spring (17), KO ramp (15), dowel pin (8), piston (14), spring pad (13), inner spring (10) and

KO poppet (12).

6.

Remove o-ring from counter bore of valve body.

7.

Remove the four (4) capscrews which secure the linkage side cover bracket to the valve body work section.

8.



CAUTION

NOTE:

It may be necessary to turn the pressure adjustment screw (1) clockwise until it is recessed far enough to allow removal of the spool collar.

Do not remove the valve spool as the seals can be replaced externally.

3.

Remove outer spool collar (4), spool centering spring (5) and inner spool collar (7).

4.

Carefully slide the detent sleeve assembly (16) off

9.

The removal of the 3500 lb. relief valve, load check and blanking plug are taken off as assemblies and repairs are limited to o-ring replacement or complete cartridge assembly.

3 6 1 7 17 8 13

Backup

Washer

O-Ring

9

2 4 5 15 14 10 12 16 9

Spool


1.

With all o-ring seals removed and counterbores thoroughly clean, lightly oil the new seals. Slide over the valve spools and insert in the seal counterbores.

2.

Replace all seals in the knockout position prior to reassembly.

3.

Apply a liberal amount of general purpose grease to the spring pad (13), inner spring (10) and the KO poppet (12) and insert these parts into the piston

(14). Slide this assembly into the end of the valve spool and push into place.

4.

Insert the dowel pin (8) and slide (17) over end of the KO ramp (15). Insert this assembly into the end of the valve spool and push into place.

5.

Apply a liberal amount of general purpose grease into the detent ball holes (9) in the valve spool and push into place.

6.

Insert one detent ball (9) into each hole and carefully slide the detent sleeve assembly (16), including the seals and retainers, over the valve spool into place next to the valve housing.

7.

Insert the adjustment screw (1) into the spool collar

(6) from the inside and turn a few revolutions. Do not turn the adjustment screws in too far or it will interfere with installation of the spool collar.

8.

Slide inner spring collar (7), centering spring (5), and outer spring collar (4) onto end of valve spool.

While holding in place, screw the spool collar (6) into the spool end.

9.

Torque the spool collar (6) to 10 - 12 ft. lbs. [13,6 -

16,3 Nm]

10. Reassemble parts in reverse order of disassembly.

11. Torque the bonnet screws and linkage end bracket to 60 in. lbs. (6.75 Nm).

9-34

DELTA



SECTION 9




9-35

SECTION 9


REMOVAL OF THE


1.


CARRIER PANEL

DELTA

PACKER

PANEL

2.



PACKER

PANEL

LEVER

3.



CARRIER PANEL

CARRIER

PANEL

LEVER

PUSHOUT

PANEL

4.


5.


6.


NOTE:


7.


PACKER

PANEL

9-36

MAIN

CONTROL

VALVE

DELTA

SECTION 9




1.


NOTE:


2.

To separate valve sections from inlet or outlet covers, remove the three (3) bolts which secure the valve sections and covers. Separate carefully, noting the location of o-ring seals.

3.



VALVE

1.


NOTE:


2.


(33.8Nm).

3.


BONNET

BONNET 3500 LB.

RELIEF

KNOCKOUT

POSITIONER

O-RINGS

INLET

COVER

TIE BOLT

OUTLET

COVER

O-RING

CARRIER

SECTION

PACKER

SECTION

ACCESSORY

SECTIONS

9-37

SECTION 9


DELTA

DISASSEMBLY AND INSPECTION OF KNOCKOUT POSITIONER

1.

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.

3.

Remove spool collar (5). If the control rod is not installed on the opposite spool end, it may be necessary to insert a rod through the spool clevis to keep the spool from rotating.

CAUTION


4.

Remove spring collars (7) and centering spring (6).

5.

Carefully slide detent sleeve (8) off the spool. The four detent balls (9) will be free to fall out when the sleeve is removed.

6.

Remove spring guide (10), outer spring (11), and follower (12).

7.

Remove inner spring (13) (if used) and the knockout plunger (14).

8.

Remove spring guide (15) and needle roller (16).

9.

Remove back-up ring and o-ring (17). Remove back-up rings and o-ring (18).

10. Clean and inspect parts for excessive wear or scoring. Clean the o-ring counter bores. Servicing of the detent assembly is limited to o-ring and back-up washer replacement.

(4)

ADJUSTMENT

SCREW

(7)

SPRING

COLLARS

(10)

SPRING

GUIDE

(12)

FOLLOWER

BACK-UP

RING

(17) & (18)

O-RING

(9)

DETENT

BALLS

(14)

KNOCKOUT

PLUNGER

(2)

BONNET

(3)

LOCK

NUT

SPOOL

BACK-UP

RING

(18)

DETENT

BALLS

(9)

INNER

SPRING

(13)

DETENT

SLEEVE

(8)

SPRING

GUIDE

(15)

NEEDLE

ROLLER

(16)

SCREW

(1)

SPOOL

COLLAR

(5)

CENTERING

SPRING

(6)

OUTER

SPRING

(11)


1.

Lightly oil and install backup rings and o-rings (18).

Install needle roller (16).

2.

Apply thread locking compound to threads on spring guide (15). Install spring guide (15) and torque to 5 ft. lbs. (7 Nm).

3.

Install knockout plunger (14), inner spring (13) (if used), follower (12), outer spring (11), and spring guide (10).

CAUTION

The centering spring will have to be compressed during assembly by applying pressure to the spool collar. Caution should be used.

4.

Lightly oil and install the o-ring & backup ring (17).

5.

Apply a liberal amount of general purpose grease into the detent ball holes on the spool. Insert one detent ball (9) into each hole. Carefully slide detent sleeve (8) over the spool and into place.

6.

Install spring collars (7) and centering spring (6).

Install spool collar (5) and torque to 32 in. lbs. (3.6

Nm).

7.

Install adjustment screw (4) and turn the number of turns recorded during disassembly. Install and tighten lock nut (3).

8.

Install bonnet (2) and screws (1). Torque screws to

10 ft. lbs. (13.6 Nm).

9-38

SECTION 9



The front control valve is located behind the access door in the front left hand side of the body. It is manually 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.

Workport Relief

Test Coupler

REMOVAL OF FRONT CONTROL VALVE



Main Relief

Test Coupler

1.

Disconnect the hydraulic lines to the valve. Cap the lines and plug the valve ports to prevent dirt from entering the valve and the hydraulic system.

2.

Remove the capscrews, lockwashers, nuts and remove the valve.

Main

Relief

Signal Line

Two-Stage

Workport

Relief


OF FRONT CONTROL VALVE

1.


NOTE:

Service should be limited to seal replacement, cartridges and individual valve sections. Field repairs of the spool assemblies are not recommended.

2.

To separate valve sections from the inlet or outlet covers, remove the three (3) tie bolts which secure the valve sections and covers. Separate carefully, noting the location of o-ring seals.

NOTE:


3.


4.

To remove handle bracket remove the two capscrews securing the bracket to the work section.

HANDLE

TAILGATE

INLET

TIE BOLT

OUTLET

PUSHOUT

NOTE:

Do not remove the spool from the valve body as the seals can be replaced externally.

9-39

SECTION 9


5.


6.

Thoroughly clean center bore.

7.

To remove the bonnet, remove two (2) capscrews securing the bonnet to the work section.

8.

The spool positions is now exposed for inspection and repair. Remove the capscrew securing the spring collar to the valve spool.

9.

Remove the spring collar and spring to expose the retainer plate, retainer plate washer and o-ring seal.

10. Thoroughly clean counterbore.

11. The removal of the two stage workport relief is accomplished in two (2) steps. First remove the signal line. Then remove the relief.

RETAINER

PLATE

PLUG

TWO STAGE

WORKPORT

MAIN RELIEF BONNET

RELIEF

SPOOL

REASSEMBLY OF FRONT

CONTROL VALVE

1.

With all o-ring seals removed and counterbores thoroughly clean, lightly oil the new seals. Slide over spools and cartridges and insert the seals in the counterbores.

2.

Reassemble parts in reverse order of disassembly.

3.

Torque the spool collar to 10 ft. lbs. (13.6 Nm).

4.

Torque the bonnet and handle bracket capscrews to 10 ft. lbs. (13.6 Nm).

5.


NOTE


9-40

TIE BOLT

SPOOL

COLLAR

BONNET

CAPSCREW

SECTION 9


6.

Torque tie bolts evenly to 32 ft. lbs. (43 Nm).

CAUTION

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 workport relief, main relief cartridge and load check plugs will be 20 ft. lbs. (27.2

Nm)

LOAD

CHECK

MAIN RELIEF

TWO STAGE

WORKPORT

RELIEF

REINSTALLATION OF


1.

Secure the valve to the mounting bracket with the appropriate hardware.

2.

Remove plugs and caps, then attach hydraulic lines.

9-41

SECTION 9


REMOVAL OF PUSHOUT

CYLINDER



Sw.

On

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

TAILGATE

LIFT LEVER

SPEED-UP

BUTTON



3.

Attach a sling connected to a lifting device capable of lifting 750 lbs. to the pushout cylinder.

4.

Remove the capscrews and bearing block halves connecting the pushout panel to the cylinder.

PUSHOUT

LEVER

TAILGATE

LIFT LEVER



Sw.

On

SPEED-UP

BUTTON

5.

Move the pushout lever to slowly retract the pushout cylinder until it is completely retracted.



6.

Disconnect the hydraulic line to the cylinder port.

Cap the hydraulic lines and the cylinder to prevent contamination of the hydraulic system.

7.

Remove the cylinder end case pin.

8.

Using the lifting device, lower the pushout cylinder until it is resting on the floor of the body.

NOTE:

For more information about lifting devices and slings, refer to Sec. 4, General Repair.

9.

Attach a sling connected to a suitable lifting device with a minimum lifting capacity of 750 lbs. (341 kg).

10. Operate the lifting device slowly and guide the cylinder out of the body through the side access door. Take care during removal to avoid damaging the surrounding components or hydraulic lines.

9-42

SINGLE STAGE PUSHOUT CYLINDER

CASE

SECTION 9


PLUNGER

GLAND RETAINER

PIN

ROD EYE

BUSHING

PIN

SINGLE STAGE PUSHOUT CYLINDER

1

2

4

6

3

3

9-43

SECTION 9


SINGLE STAGE PUSHOUT CYLINDER PACKING REPLACEMENT

1.

Drain the hydraulic fluid from the cylinder. Clean the outside of the cylinder prior to working on it to 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 head nut (3) using a strap or chain wrench. If the tube turns with the head nut, tighten the next head nut slightly.

4.

Using a suitable lifting device attached to the rod eye (5), pull up on the tube. The packing (4) should come out as the tube is raised. If it does not, clean off a section of the tube and wrap masking tape around it. Lower the wrapped section of tube down into the packing and then lift the tube once again.

5.

Prior to installing new packing (4), clean the area thoroughly and lubricate the new packing set inside and out with an all-purpose grease.

6.

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.

7.

Replace the head nut (3) being careful not to overtighten.

8.

Replace the plastic plug (1) and setscrew (2).

SINGLE STAGE PUSHOUT CYLINDER DISASSEMBLY

1.

Prior to disassembling the cylinder, first make four clips from thin steel. These clips should be approximately .020" thick, 1 ⁄

2

" wide and 4" long. Bend each clip, at a right angle, about 1" from the end so it can hang over the edge of the tube.

2.



3.

Remove the setscrew (1), plastic plug (2) and head nut (3). Insert a long thin screwdriver under the end of the retaining ring (6), prying it out of the groove.

Using another screwdriver – place it behind the retaining ring and work your way around the cylinder – prying the ring out of the groove as you go.

When you are opposite the starting point, hang one of the clips on the edge of the tube so that the long end of the clip is between the ring and the groove in the cylinder. Continue to use the screwdrivers as

“pry bars” and hang the remaining clips. The clips should be equally spaced around the retaining ring.

4.

Using an appropriate lifting device, raise the tube completely out of the cylinder. The retaining ring (6) will come out with the tube.

5.

Clean, inspect and replace the guide and piston rings (7) as necessary. When installing new rings, the ends should be positioned on opposite sides of the tube to prevent leakage.

6.

After the tube has been installed back into the case, the retaining ring (6) should be installed, packings (4) replaced and the head nut (3) reinstalled.

9-44

TELESCOPIC CYLINDER PACKING

REPLACEMENT

1.



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.\

5.

Using a suitable lifting device attached to the rod eye (5), pull up on the tube. The packing (4) should come out as the tube is raised. If it does not, clean off a section of the tube and wrap masking tape around it. Lower the wrapped section of tube down into the packing and then lift the tube once again.

6.

When removing the packing from succeeding larger 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.

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).

CASE

END

SECTION 9


ROD END

5

3

1 2

4

4

3

3

1 2

9-45

SECTION 9


TELESCOPIC CYLINDER

DISASSEMBLY

1.

Prior to disassembling the cylinder, first make four clips from thin steel. These clips should be approximately .020" thick, 1 ⁄

2

" wide and 4" long. Bend each clip, at a right angle, about 1" from the end so it can hang over the edge of the tube.

2.



3.

Remove the setscrew (1), plastic plug (2) and head nut (3). Insert a long thin screwdriver under the end of the retaining ring (6), prying it out of the groove.

Using another screwdriver – place it behind the retaining ring and work your way around the cylinder – prying the ring out of the groove as you go.

When you are opposite the starting point, hang one of the clips on the edge of the tube so that the long end of the clip is between the ring and the groove in the cylinder. Continue to use the screwdrivers as

“pry bars” and hang the remaining clips. The clips should be equally spaced around the retaining ring.

4.

Using an appropriate lifting device, raise the tube completely out of the cylinder. The retaining ring (6) will come out with the tube.

5.

Clean, inspect and replace the guide and piston rings (7) as necessary. When installing new rings, the ends should be positioned on opposite sides of the tube to prevent leakage.

6.

After the tubes have been installed back into the case, the retaining rings (6) should be installed, packings (4) replaced and the head nuts (3) reinstalled.

CASE

END

ROD END

5

3

1 2

6

4

1 2

4

6

3

7

3

7

9-46

SECTION 9


DESCRIPTION OF LEACH HYDRAULIC PUMP (203834)

The pump which serves the complete hydraulic system is a gear type, coupled to the PTO shaft through a yoke arrangement. It is usually mounted under the body near the front end, curb side. The Leach pump can run in either direction - clockwise or counterclockwise rotation. The locations of the suction and pressure hoses are determined by the direction of rotation; it is therefore imperative to install hoses correctly.

PUMP

REMOVAL OF HYDRAULIC PUMP

P.T.O.

SHAFT

GATE VALVE



1.

Shut the gate valve at the underside of the hydraulic fluid tank.

2.

Remove the hose clamp.

3.

Remove the pump suction line and allow the fluid to drain.

NOTE

The pump suction line (tube and hose) will also be filled with hydraulic fluid. The pump and line may be drained into an absolutely clean container and the fluid poured back into the tank.

4. Disconnect the pressure hose at the pump and cap the end.

5.

Loosen the setscrew (1) and free the yoke (2) from the pump shaft by telescoping the PTO drive shaft toward the PTO.

6. Remove the key (3) from the pump shaft keyway.

7. Remove the attaching hardware (4). The pump assembly may now be removed from the mounting bracket.

CAP

4

3

1

2

9-47

SECTION 9


DISASSEMBLY OF THE HYDRAULIC

PUMP (203834)

1. After removal, thoroughly clean the outside with solvent and a brush. Then blow dry the pump with compressed air. Scribe flange cover (15) and body

(1) so they can be matched for reassembly.

2. Carefully place the pump body in a vise and remove capscrews (17) and washers (16).

3. Lift flange cover (15) off pump body and remove the o-ring (4) from the flange.

4. Remove o-ring (6) and back-up ring (5) from each gear shaft.

5. Remove top isolation plates (10), sealing strips

(11), end separators (7) and center separator.

6. Remove top pressure plates (14), drive gear (12) and idler gear (13).

7. Remove the bottom pressure plate (14) by using an expandable bearing puller and lifting straight up out of the body.

NOTE:

It may be necessary to use a sharp knife to remove the rolled up lapped edge that adjoins the pressure plate. Do not force or bend the pressure plate.

8. Remove the bottom isolation plates (9), sealing strips (11), end separators (7), center separator

(8), back-up rings (5) and o-rings (6).

9. Clean all the internal parts with solvent and blow dry.

10. Inspect all parts carefully.

REPLACING SHAFT SEALS ON THE

HYDRAULIC PUMP

1.

Remove the flange cover (15) from pump as described in steps 1-4 of the Disassembly

Instructions.

2.

First drive out the old wiper (20).

3.

Remove snap ring (19) and then the seal (18).

4.

Clean the flange cover (15) in solvent and blow dry.

5.

Press in a new seal (18).

6.

Install snap ring (19) and a new wiper (20).

7.

Install the flange cover (15) as described in steps

12-16 of the Reassembly Instructions.

9-48

10

1

11

7

8

6

5

15

16

17

4

Be sure to wear eye protection.

5

6

7

14

13

8

9

11

12

15

18

19

20

SECTION 9


REASSEMBLY OF HYDRAULIC PUMP (203834)

1. Place the body (1) so the scribe mark faces you.

2. For easier assembly, use clean hydraulic fluid as a lubricant.

3. Install o-rings (6) and back-up rings (5) on the protruding ends of the bearings at the bottom of the body.

4. Examine the four isolation plates. Note that one pair is slightly different from the other pair. Choose the two that have the rounded outer edges (9) and install them in their proper location at the bottom of the body bore with the rounded edges facing down.

5. Install end separators (7), center separator (8) and sealing strips (11).

6. With the bronze side facing up, lower the bottom pressure plate (14) into place in the bottom pressure plate

(14) into place in the bottom of the body bore. Do not force.

7. Install driver gear (12) by lowering carefully.

8. Install idler gear (13)

9. Install the top pressure place (14) with the bronze side facing down.

10. Install end separators (7), center separator (8), sealing strips (11) and isolation plates (10).

11. Examine the flange cover shaft seal (18) and wiper (2).

If replacement is necessary, see “Seal Replacement

Instructions”.

12. Install o-rings (6) and back-up rings (5) on the extended portion of the bearings inside the flange (15) plate.

13. Install o-ring (4) into the groove in the flange cover (15).

Use heavy grease to hold the o-ring in place.

NOTE:

Coat the drive gear shaft extension with clean, heavy grease to protect the seal lip as the seal slides over the shaft.

15

3

8

9

11

1

5

12

NOTE:

The check valves (3) located in the flange cover (15) are not replaceable. They are only available as part of the flange cover.

4

6

5

7

14

13

6

14. Slide the flange cover (15) down on the drive gear (12) until it touches the dowels (2) in the body.

NOTE:

Use extreme care when seating the flange cover against the body. If not pressed down carefully, the extended portion of the flange cover bearings can pinch the sealing strips.

15. Insert washer (16) and capscrews (17) into the holes in the flange cover (15). Tighten opposite and even to 80 foot pounds of torque.

16. Test the pump by using an adjustable wrench with a key installed in the drive gear. When attempting to turn the shaft, it should feel tight with a maximum of 5 to 10 foot pounds of torque. If the shaft does not turn properly disassemble, find the problem, and carefully reassemble.

2

15

16

17

9-49

SECTION 9


INSTALLATION OF HYDRAULIC PUMP (203834)



1.

Install the pump in the reverse order of removal.

MAKE SURE suction and pressure lines are installed correctly for pump rotation. Tighten all mounting hardware and hose clamps.

2.

Be sure to re-install any shaft guards that may have been removed.

PRESSURE

NEW PUMP PREPARATION

Before installing a new pump, refer to Sec. 6, PRE-

VENTIVE MAINTENANCE and the following. This will prevent contamination of the new pump.

1.

Remove and clean the hydraulic tank strainer (1).

2.

Change the filter element (2).

3.

Drain and flush the hydraulic tank as described in

Sec. 6, PREVENTIVE MAINTENANCE (3).

4.

Clean the magnetic plug (4).

CLOCKWISE

SUCTION

2

4

3

1

TESTING A NEW PUMP



Sw.

On

After installing a new pump, check for correct cycle time and main line pressure as described in Sec. 7, CHECK-

OUT.

SUCTION

9-50

PRESSURE

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 accommodate PTO shafts that turn either clockwise or counterclockwise rotation. The locations for the suction and pressure hoses are clearly indicated by markings in the housing.

PUMP

REMOVAL OF HYDRAULIC PUMP



1. Shut the gate valve at the underside of the hydraulic fluid tank.

SECTION 9


P.T.O.

SHAFT

GATE VALVE

CAP

2. Remove the hose clamp.

3. Remove the pump suction line and allow the fluid to drain.

NOTE

The pump suction line (tube and hose) will also be filled with hydraulic fluid. The pump and line may be drained into an absolutely clean container and the fluid poured back into the tank.

4. Disconnect the pressure hose at the pump and cap the end.

5. Loosen the setscrew (1) and free the yoke (2) from the pump shaft by telescoping the PTO drive shaft toward the PTO.

6. Remove the key (3) from the pump shaft keyway.

7. Remove the attaching hardware (4). The pump assembly may now be removed from the mounting bracket.

4

1 2

9-51

SECTION 9


DISASSEMBLY OF HYDRAULIC PUMP (307451-01)

1. After removal, thoroughly clean and dry the pump.

Scribe the rear housing (1) and the front housing

(9) so they are marked for reassembly.

2. Carefully place the pump body in a vise and remove capscrews (10) and washers (11).

3. Lift the front housing (9) from the rear housing (1) and remove o-ring (8). Be sure dowels (7) do not fall out.

4. Remove pressure balance (2) and pressure plate

(6).

5. Remove keys (5) from the gears (4). Remove gears

(4), pressure plate (3) and pressure balance (2).

NOTE:

Care should be taken not to bend or damage the pressure plates.

1

6. Clean and dry all parts. Inspect parts carefully for wear.

3

4


5

6 2 7 14

8 2

4

11

10

13

12

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.

9-52

7

9

12 13

SECTION 9


REASSEMBLY OF HYDRAULIC PUMP (307451-01)

1. Place the rear housing (1) with the opening up and the scribe mark visible.

6. Install o-ring (8) into groove in rear housing (1).

2. For easier assembly, use clean hydraulic fluid as a lubricant.

7. Lubricate the gear shaft extensions with grease to protect lip seals.

3. Install pressure balance (2) and pressure plate (3) into rear housing (1).

8. Install seals (12) and snap rings (13) into front housing (9) as described in steps 1-6 of the replacing seals instructions.

NOTE:

Pressure plates must be assembled with the traps

(opening) to the outlet side of the pump.

4. Carefully lower gears (4) into the rear housing (1).

Install the gears one at a time.

5. Install pressure plate (6) and pressure balance (2).

1

9. Install dowels (7) into holes in rear housing (1).

10. Carefully lower front housing (9) (with seals installed) onto rear housing (1). Insert washers (11) and capscrews (10). Tighten opposite and even to

80 ft. lbs.

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 disassemble, find the problem, and carefully reassemble the pump.

3

4


5

6 2 7 14

8 2

4

11

10

13

12

7

9

12 13

9-53

SECTION 9


INSTALLATION OF HYDRAULIC PUMP (307451-01)



FRONT VIEW

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.

PRESSURE

REAR VIEW

NEW PUMP PREPARATION

Before installing a new pump, refer to Sec. 6, PRE-

VENTIVE MAINTENANCE and the following. This will prevent contamination of the new pump.

1. Remove and clean the hydraulic tank strainer (1).

2. Change the filter element (2).

3. Drain and flush the hydraulic tank as described in

Sec. 6, PREVENTIVE MAINTENANCE (3).

4. Clean the magnetic plug (4).

SUCTION

2

TESTING A NEW PUMP



Sw.

On

4

After installing a new pump, check for correct cycle time and main line pressure as described in Section 7,

CHECK-OUT.

1

SUCTION

PRESSURE

3

9-54

SECTION 9


DESCRIPTION OF

ELECTRICAL SYSTEM

The packer electrical system includes all of the body running and marker lights, operational speed up switches, the operator ready and back-up warning buzzers, and all interconnected wiring, as shown on the accompanying wiring diagram.

REPAIR

Repair of the electrical system is limited to the replacement of burned out light bulbs and other defective parts or wiring.

TESTING

To locate a defective component or break in the wiring, perform a continuity check across the between suspected components as described in Sec. 4, GENERAL

REPAIR.

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 insulation 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 following areas:

1.

Buzzer System - between the pushbutton and bracket.

2.

Speed Up System - between the pushbutton and bracket.

3.

Back Up Alarm - between the backup alarm and bracket.

4.

Taillight - between the light and bracket.

The internal lockwasher will bite into the metal and ensure a positive ground.

TYPICAL EXAMPLE

TOOTHED

WASHER

9-55

SECTION 10

SERVICE TOOLS

GENERAL

The service tools shown will be required for some service and repair procedures. These tools are available from your local authorized Leach distributor.

The actual use of each tool is described in Section 9, Service and Repair.

6

1

2

7

8

3 4

5 9

10-1

SECTION 10

SERVICE TOOLS

NO.

PART NO.

1 30522

6

7

8

4

5

2

3

T-SK-793-100

T-2R-1006-2

T-2R-1313-2

T-SR-9541-20

100368

402325

103081

9 405-638

DESCRIPTION

Pressure Gauge

EXPLANATION

To measure system pressure

Pin Puller Remove pivot pins

Tube Nut Wrench 1 1 ⁄

2

" Remove/Install tube nut

Tube Nut Wrench 2"

Pump Shaft Seal Tool

Snap Connector

Pivot Puller

O-Ring Kit

Remove/Install tube nut

Install seal

Quick coupling for pressure gauges

Remove upper carrier pivots

Various size o-rings

Carrier Cylinder

Fitting Wrench

Remove/install fittings

UNIT

All except

FL104/Beta

All

2R/2RII

2R/2RII

All

All

2RII

All except

FL104

2RII

10-2

Leach Alpha, Beta, Delta refuse body Service Manual

Assistant Bot

Alpha • Beta • Delta

Service Manual

Over Serial Number

3500

Contact your local Leach Signature Original Factory parts distributor

provide the following information:

A.

Company name

B.

Date

C.

Your order number

D.

Routing instructions

E.

Quantity, part number and description

*F.

Model and serial number of unit

Accept only Leach Signature Original Factory Parts.

Alpha

Beta

Delta

*

*

*SERIAL NUMBER LOCATION

I

II

III

ORDERING PARTS

PREFACE

FOREWORD

WARRANTY

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS

SECTION 3 – OPERATION (continued)

SECTION 2 – INTRODUCTION

SECTION 4 – GENERAL REPAIR PRACTICES

SECTION 3 – OPERATION

SECTION 5 – SPECIFICATIONS

SECTION 6 – PREVENTIVE MAINTENANCE

IV

SECTION 6 – PREVENTIVE MAINTENANCE

(continued)

SECTION 7 – CHECK-OUT

SECTION 7 – CHECK-OUT

SECTION 7 – CHECK-OUT

SECTION 8 – TROUBLESHOOTING

V

SECTION 8 – TROUBLESHOOTING

(continued)

SECTION 9 – SERVICE AND REPAIR

SECTION 9 – SERVICE AND REPAIR

(continued)

VI

SECTION 9 – SERVICE AND REPAIR

(continued)

SECTION 10 – SERVICE TOOLS

Manual Order Form

Reward

VII

GENERAL

DANGER, WARNING AND CAUTION

DECALS

DANGER WARNING AND 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 could result in minor personal injury or property or product damage.

1-1

PRIOR TO START UP

1-2

OPERATION

GENERAL

1-3

1-4

HYDRAULICS

FIRE PROTECTION

HOUSEKEEPING