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2RIII Maintenance Manual - Superior Truck Equipment Inc.

1. 57 Check Replace Return Line Filter 57 Flushing Hydraulic System 57 59 Commercial Hydraulic Fluid Testing 59 In House Hydraulic Fluid Testing 59 Preventive Maintenance Requirements 60 Daily Preventive 60 Weekly Preventive 61 Monthly Preventive 62 Yearly Preventive 62 TABLE OF CONTENTS SECTION 7 CHECK OUT A 63 Check Hydraulic Tank Fluid Level 63 Check Engine Speed Up Switch Cab 64 Check Engine Speed Up Switches Body 64 Check Pack Cycle lime ize 65 Check 00 65 Check Main Line 66 Check Packer And Carrier Panel Shift Pressures 67 Check Resistance Cartridge Pressure 68 Check Packer Panel High Pressure Circuit Relief 69 Check Accessory Circuit Relief Pressure 70 Check Pushout Panel 71 Check
2. See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains PACKER PANEL LEVER N SLING CYLINDER OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 6 OPERATIONAL STATUS Truck Off PTO Disengaged 7 Check for bent pivot pins and inspect pin hubs for SECTION 9 SERVICE AND REPAIR Shift the packer panel lever inward to completely retract the cylinder Disconnect both the case end 1 and rod end 2 pressure tubes Immediately cap or plug the pres Loosen the hydraulic fittings slowly to release any sure tubes and cylinder ports to keep fluid in and trapped pressure Watch for inadvertent movement dirt out of components Remove capscrew 1 securing the pivot pin 2 Remove the pivot pin by using special packer pin puller See Sec 10 SERVICE TOOLS broken welds and elongated holes 99 9 8 SECTION 9 SERVICE AND REPAIR REMOVAL OF CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheets to provide better accessibil ity NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Secure a chain to the lower end of the carrier panel Attach the other end to suitable lifting device with a minimum lifting capacity of 1 600 Ibs 726 kg Adjust the hoist
3. 119 Removal 120 Installation Of Pushout 121 Description Of Carrier And Packer Panels 122 Removal Of Packer 123 Inspection And Replacement Of Packer Panel 124 Replacement Of Packer Edge 125 Installation Of Packer 125 Carrier Panel citaciones 126 Removal 126 Inspection And Replacement Of Carrier Panel 128 Installation Of 128 Track Bar 128 Roller Replacement Shimming 129 Description Of Hydraulic 132 TABLE OF CONTENTS SECTION 9 Continued Removal Of Hydraulic Installation Of Hydraulic Pump New Pump SECTION 10 SERVICE TOOLS Service lIools inen nter cre cer NOTES PAGE oei acii GENERAL The Alpha lll has been designed with the operator in mind However as with any industrial machinery especial
4. gt mol ANI la DOWN er M t ry NOTE Both container latch arms must be in place and latched before raising container LINE PULL SECTION 1 SAFETY PRECAUTIONS DECAL PLACEMENT PACKER PACKER CARRIER CARRIER CARRIER WARNIN YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS raining and experience in the sale operatio Training includes complete knowledge of your employer s work rules all governmental regulations and manufacturer s operator and safety manuals relative to this machines safe AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY Rotating power take off shaft hazard Do not enter under chassis unless engine is stopped and key removed A CAUTION Serious pump damage will result if vehicle is operated at highway speed with pump engaged Move unit with pump engaged only as required to perform its function as a refuse collection compaction vehicle at speeds less than 10 mph ENGINE BEACON LIGHT E DRIVER SIGNAL 4 A CAUTION Serious pump damage will result if pump is run dry Disconnect pump drive to run engine if tank valve is required to be closed or if oil tank is not at proper fill level SECTION 1 SAFETY PRECAUTIONS DECAL PLACEMENT Falling hazard Do not operate vehicle at speeds in excess of 10 mph for distances over 2 tenths mile or in reverse gear when ri
5. 15 Container Attachment Latch and Ears 16 Container Handling 16 17 Terms You Will Need To 17 HOOK idees 17 iii 17 17 WIM m 18 Container Lifting Cylinder CLC 18 Container Push Bar CPB 18 Basic 222 0000 19 Attach 19 DIM Pratdip riada lei 19 DISCONN 19 SECTION 3 OPERATION General 21 Description of Operating Controls 21 Location of Operating Controls 22 Pump PTO 23 Speed Up Toggle Switch 23 Tailgate Open 2 1 23 Engine Speed Up Push Button 24 Front Control 24 Push 24 Tailgate Lift 24 Tailgate 24 Driver Signal Buttons sss 25 Packer and Carrier Pane
6. gt 505056 6 sas ess OXO MAIN CONTROL VALVE SSS 9 22 113 SECTION 9 SERVICE AND REPAIR REMOVAL OF THE MAIN CONTROL VALVE 1 Place the packer and carrier panels in the inter rupted cycle position 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 Turn off the engine remove the keys Disconnect the shift linkage Disconnect and cap all hydraulic lines and hoses Plug all open ports on the valve to prevent con tamination NOTE The Main Control Valve MCV assembly weighs ap proximately 100 Ibs 45 3 Kg Use appropriate lifting procedures and techniques when handling this assem bly 7 Remove the capscrews washers and nuts secur ing the valve to the mounting plate 9 23 114 INTERRUPTED CYCLE POSITION CARRIER PANEL OO PACKER PANEL LEVER PACKER PANEL CARRIER PANEL PACKER PANEL MAIN CONTROL VALVE MCV DISASSEMBLY AND INSPECTION OF MAIN CONTROL VALVE 1 Wash the valve body with solvent to prevent con tamination NOTE Before disassembly it is suggested that each work sec tion be marked numerically to avoid incorrect assem bly 2 To separate valve sections from the inlet or outlet covers remove the four 4 tie bolts whi
7. SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE See accompanying Hydraulic System Illustration Proper maintenance of the hydraulic components is of vital importance to the service life of the system and the operation of the unit as a whole CHECKING FLUID LEVEL DAILY Position and fully retract the pushout packer and car rier cylinders to check the fluid level 1 When check ing the fluid level in the hydraulic tank also note any frequent or sudden loss of fluid This may indicate leak age which must be traced and corrected to avert equip ment 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 SPECI FICATIONS according to operating and weather condi tions CLEAN TANK BREATHER WEEKLY Clean the air breather 2 every week Replace a breather that cannot be cleaned adequately CHECK REPLACE RETURN LINE FILTER ELEMENT The return line filter is a vital component of the hydrau lic 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 Replace ment 1 After the first five days of unit operation 2 After the first calender month of unit operation 3 Thereafter every twelve calender months orsooner if so indicated by the filter replacement indicato
8. 105 Test For Leaking Tailgate Lift Cylinders 105 Removal Of Tailgate Lift Cylinders 106 Disassembly Of Tailgate Lift Cylinder 107 Inspection Reassembly And Installation Of Tailgate Lift inpol asec A 107 Description Of Tailgate Assembly 108 Removal Of Tailgate Assembly 108 Inspection 109 Reassembly And Installation Of Tailgate 109 Front 110 Removal Of Front Control Valve 110 Disassembly And Inspection Of Front Control ELT M N 110 Reassembly Of Front Control Valve 111 Reinstallation Of Front Control Valve 112 Main 113 Removal Of Main Control Valve 114 Disassembly And Inspection Of Main Control Valve 115 Reassembly Of Main Control Valve 115 Removal Of Telescopic Cylinder 116 Telescopic Cylinder Packing Replacement 117 Telescopic Cylinder Disassembly 118 Description Of Pushout 119 Wear Block
9. Above Serial Number 071065 labrie environmental group equipment for the solid waste industry LEACH WITTKE 111 Juggler INDUSTRIALE FOREWARD Leach rear load refuse bodies are the industry standard for both quality and performance Labrie Environmental Group is 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 Labrie Environmental Group 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 1999 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 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 Labrie Environmental Group has an aggressive manual and product improvement program In any conversation or correspon d
10. LEVER HYDRAULIC SEQUENCE Moving the tailgate lift lever forward shifts a spool in the FCV Front Control Valve allowing fluid in the tailgate lift cylinders to drain back to tank The weight of the tailgate forces fluid out of the cylinders the cylinders PRESSURE retract and the tailgate lowers e eee RETURN as al TAILGATE LIFT CYLINDER EQ Q M 4 ER S HYDRAULIC FLUID TANK FRONT CONTRO VALVE PUSHOUT A CYLINDER Q Q VA Q j N N PUMP ES CARRIER A y S CYLINDER i N TAILGATE LIFT CYLINDER PACKER CYLINDE 2 8 19 SECTION 9 SERVICE AND REPAIR GENERAL This section contains the instructions necessary for the repair and replacement of the main components of the unit Before attempting any repair of the unit become thor oughly familiar with the OPERATION instructions Sec 3 and GENERAL REPAIR PRACTICES Sec 4 Also before performing any work on the unit know and OB SERVE 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 j gt gt DEl ALS DESCRIPTION OF OPERATING CYLINDERS CARRIER AND PACK
11. OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On While observing the pressure gauge slowly in crease 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 5 The knockout pressures should be set at Alpha 1800 PSI 124 BAR Packer 2000 PSI 138 BAR Carrier Beta 2000 PSI 138 BAR Packer 2100 PSI 145 BAR Carrier Delta 1800 PSI 124 BAR Packer 2100 PSI 145 BAR Carrier If the knockout pressure setting requires adjust ment it may be changed by turning the knockout pressure adjusting screw located inside the bon net clockwise to increase the knockout pressure setting or counter clockwise to decrease the pres sure setting Once the proper knockout setting has been attained reinstall the button plug to seal the Main Control Valve bonnets 67 SECTION 7 CHECK OUT Return the main relief valve pressure setting to its specified value as described previously PACKER LEVER CARRIER LEVER ao REDUCE MAIN RELIEF 12 PRESSURE TO BELOW 1000 PSI 69 BAR CARRIER PACKER VALVE VALVE SECTION SECTION ADJUSTING SCREWS 7 5 SECTION 7 CHECK OUT CHECK RESISTANCE CARTRIDGE PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Use the test fixture part number 605018 and test as shown on illustration
12. SECTION 3 PERATION 4 Make sure the tailgate clamps are in the closed posi tion and securely tightened 5 Check the hydraulic tank gauge to make sure the fluid is in the safe range Add fluid if necessary See SECTION 5 SPECIFICATIONS of the Service Manual for the correct type of fluid to use The pushout cylinder must be retracted the tailgate down the carrier and packer panels in the interrupted cycle position to check the hydraulic fluid level Y 11 2 TAILGATE CLAMPS 6 Make sure all operating levers are in the neutral posi tion Check a packer panel lever b Carrier panel lever c Pushout lever d Tailgate lift lever FRONT CONTROL ACAUTION VANE y LEVER Never operate the Alpha Series with any part of the control system or levers removed or serious dam age will result Never under any circumstances enter the body if ENGINE SPEED UP ae the truck is running Open the packer panel and BUTTON release the pushout panel cylinder pressure before entering the body Always make sure the truck en gine is off and the keys are in your pocket before entering the body CARRIER PANEL PACKER PANEL 7 LEVER 29 SECTION 3 OPERATION 7 Start the truck according to the manufacturers instruc tions and while it is warming up continue the walk around inspection 8 Check all of the operating and running lights Mak
13. Using the overhead lifting device carefully extend the cylinder rod approximately 1 2 way out of the case Apply a 6 piece of 1 masking tape to the chrome INSPECTION REASSEMBLY AND INSTALLATION dle Thoroughly check all components of the cylinder for cracks scoring or uneven wear Parts that must be replaced together such as seals and wear rings are available as a repair kit from your authorized Leach dealer Liberally coat all seals and wear rings with clean fresh hydraulic fluid before installation Assembly of the tailgate lift cylinder is in approxi mate reverse order of disassembly Install the packing into the cylinder using a flat punch to push it in place Tighten the head gland only enough to prevent leakage from the cylinder Check all cylinder mounting components for cracks or excessive wear before installation If the PACKING PISTON WEAR RINGS SEALS RETAINING RING SET SCREW 107 10 11 Remove the wear ring from the bottom of the cylin 13 SECTION 9 SERVICE AND REPAIR surface of the exposed section of the cylinder rod about 1 2 way up the cylinder rod The tape should be applied in a diagonal fashion on the rod Push the rod back into the case then again using the overhead lifting device extend the rod 1 2 way out The cylinder packing should slide out with the taped section of the rod If not repeat until the pack ing slides out Slide the packing off of the rod and d
14. be sure the overall height is rechecked and overall height plus 3 inches is noted on the decals GENERAL OPERATION 1 It is the operator s responsibility to ensure that op eration of the unit is in accordance with the guide lines contained in the Operator s manual and in ac cordance with all applicable codes including Occu pational Safety and Health Act OSHA and Ameri can National Standards Institute ANSI regulations Do not attempt to operate this equipment without proper training Move the vehicle as slowly as possible without stall ing when traveling in reverse Always make sure the area behind the unit is clear before traveling in reverse Do not travel in reverse for distances greater than those dictated by local ordinances If reverse travel exceeds 10 feet use a spotter or move the ve hicle in 10 foot increments only and then check to make sure the area behind the unit is clear between increments Do not attempt to dislodge any material above waist level unless wearing eye protection such as ap proved side shielded safety glasses or a full face shield Never use the unit to push or tow another vehicle Never unload uphill or against a pile of refuse or into the bank of a hill Never place head body fingers or any limbs into a scissors point or pinch point on the equipment Before operating the vehicle the driver must be throughly familiar with the employer s safety program
15. tainer latch arms Raise the container with a smooth even movement Do not bounce the container Do not slam the container against the packer tail gate or bump bar Do not attach the hook to any lift point which will not be completely encircled by the hook with the safety latch closed Do not remove the hook safety latch Read and obey all container decals issued by the container manufacturer Read and follow container manufacturers informa tion on accepted use practices Do not attempt to lift overloaded containers Center the container on the attachment All containers should be inspected for serviceabil ity and repaired if not in safe usable condition Do not use non standard or damaged trunnion bar Never cross under a raised container Stand clear when dumping containers Before attempting to lift a container below 32 de grees F 0 degrees C make sure it is not frozen to the ground When using an eye type container attachment point the base of the hook must be positioned to lift on the inside of the eye Place the container on a flat level surface HYDRAULICS 1 Hydraulic fluid operates under high temeratures Avoid contact with piping hoses or cylinders to pre vent burns Never use hands to check for leaks Hydraulic fluid escaping under pressure may cause injury FIRE PROTECTION 1 Keep a fire extinguisher accessible at all times as recommended by the Burea
16. 1 Control lever 2 Engine speed up button 3 Cable 4 Winch assembly 5 Container attachment 6 Stop bar Lid guard CONTAINER LIFTING CYLINDER CLC 1 Control lever 2 Engine speed up button 3 Roller guide 4 Cable 5 Lifting cylinder assembly CONTAINER PUSH BAR CPB 1 Control lever 2 Push bar 3 Lift roller 4 Container dumping cylinder 5 Stop bar Lid guard 6 Container attachment 20 SECTION 2 INTRODUCTION BASIC OPERATION All Leach container handling systems have three 3 basic steps for operation ATTACH The first step in container handling is to attach the con tainer to the rear loader by securing it with the latch arms of the container attachment ATTACH CONTAINER DUMP A container handling system is used to raise the con DUMP tainer and empty the refuse into the hopper of the rear loader DISCONNECT When the container is empty it is lowered to the ground the latch arms released and the truck is moved forward DISCONNECT 21 22 GENERAL This section will provide all of the instructions neces sary to operate the Alpha Series 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 pur poses only It is n
17. 9 Service and Repair Hydraulic fluid too hot Check for proper grade of fluid See Sec 5 Speci fications Hydraulic fluid level too low Check fluid level Add fluid if necessary Bypass in cylinders Test for leaking cylinders See Sec 9 Service and Repair Hydraulic fluid too cold Bring fluid to operating temperature Check for proper grade of hydraulic fluid See Sec 5 Specifications Operating linkage bent or binding Repair replace or realign damaged linkage PUMP NOISE IS EXCESSIVE NOTE ALL PUMPS MAKE A CERTAIN AMOUNT OF NOISE POSSIBLE CAUSE REMEDY Pump starving for fluid Hydraulic fluid too cold PTO driveshaft and or u joints badly worn or out of balance Pump gears end plates bearings etc badly worn Improper grade of hydraulic fluid fluid foaming Air entering the system 15 Open ball valve Check fluid level Check hydraulic fluid filter and tank Check for obstruction in suction lines hoses kinked or collapsed Bring fluid to normal operating temperature Change hydraulic fluid to proper grade for operat ing conditions See Sec 5 Specifications Repair replace and or balance all parts Replace pump Replace with proper grade of hydraulic fluid See Sec 5 Specifications Tighten the suction hose Replace the pump shaft seal Replace the suction hose Replace the o rings on the pump Tighten or repair any leaks in t
18. Connect the clip to one side of the com ponent to be tested and touch the probe to the other side If the component has the potential to pass cur rent has continuity the light will be on if the compo nent is not able to pass current there is no continuity and the light will be off 2 When repairing a cracked weld the old weld should be completely removed before rewelding 3 When adding a part or attachment be sure the metal is clean before welding the part is properly located and the weld will not cause damage to adjacent parts 4 Use E7018 rod for all locations 5 Use ER 70S 6 wire for all locations 46 SECTION 4 GENERAL REPAIR PRACTICES LIFTING INSTRUCTIONS Because of the size and weight of the major components found on the unit it is necessary to use suitable lifting devices for removal The following components require lifting devices for removal cylinders carrier panel packer panel pushout panel and tailgate CAPACITY OF LIFTING DEVICE REQUIRED FOR REMOVAL enr p E E E 500 Ibs 227 kg Telescopic Pushout Cylinders 2c ea 1000 Ibs 454 kg Carrier Panel scort Ioa Unda biie 1600 Ibs 726 kg 224 1600 Ibs 726 kg Pushout 511151 2800 lbs 1270 kg A ate aac 8000
19. L L L L L L L L L HYDRAULIC PUMP SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PANEL SWEEPS HOPPER OPERATOR ACTION Operator shifts the control levers outward to start com paction HYDRAULIC SEQUENCE Fluid flow is through the MCV Main Control Valve packer section to the case end of the packer panel inders As the cylinders extend the packer panel sweeps the load forward in the hopper As the packer cylinders extension stroke continues pressure builds to Alpha 1800 PSI 124 BAR Beta 2000 PSI 138 BAR Delta 1800 PSI 124 BAR PRESSURE causing the MCV Main Control Valve to shift e eee RETURN TAILGATE LIFT CYLINDER d FRONT CONTRO s CARRIER VALVE 7 y O 5 Pa PUSHOUT 6 CYLINDER PUMP 2 CARRIER CYLINDER lt gt wh 4 S TAILGATE LIFT CYLINDER packer Sx ES ge 8 13 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKING REFUSE OPERATOR ACTION None MCV Main Control Valve shifts automatically HYDRAULIC SEQUENCE Fluid flows from the MCV Main Control Valve to the rod end of the carrier panel cylinders The cylinders re tract moving the carrier and packer panels up packing refuse against the pushout panel When the pressure reaches Alpha 2000 PSI 138 BAR Beta 2100 PSI 145 BAR Delta 2100 PSI 145 BAR the MCV Main Control Valve shifts into neutral and the p
20. LIFT LEVER The tailgate open light and backup lights should illuminate The backup alarm should also sound ENGINE SPEED UP BUTTON 39 SECTION 3 OPERATION EJECTING THE LOAD 1 Depress and hold the engine speed up button push the pushout lever rearward and hold until the pushout panel stops Slowly pull the unit ahead to clear the refuse pile when the tailgate is lowered Clear debris from the edges with a pole while standing clear off to one side SPEED UP BUTTON With the telescopic circuit the pushout cylinder remains fully extended If the unit is going to travel over one mile empty completely retract the cylin der When packing is about to resume extend the cylinder and start packing LOWERING THE TAILGATE 1 Pull forward on the tailgate lift lever slowly and in small increments to lower the tailgate a little at a time AVOID SLAMMING SHUT the tailgate 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 40 Never drive the unit more than 10 feet with the tail gate in the raised position PUSHOUT LEVER RAR O A SU M AR ay M TAILGATE LIFT LEVER SECTION 3 OPERATION SHUT DOWN 1 Move th
21. approximately half way up the pushout panel During its movement through the body the pushout panel rides in a trough The panel rides on replaceable plastic wear blocks that control its movement in the trough and reduce friction WEAR BLOCK REPLACEMENT The wear blocks should be replaced before there is metal to metal contact between the pushout panel and trough floor OPERATIONAL STATUS Truck Off PTO Disengaged 1 Raise the side of the pushout panel one side at a time enough to take the weight off the wear blocks Use a hydraulic jack or pry bar Support the pushout panel and remove the capscrews nuts and lockwashers securing the wear block retainers 2 Slide the upper and lower wear blocks out and re place Reinstall the wear block retainers and tighten the capscrews 4 Lower the pushout panel 5 Repeat this procedure for the other side 119 SECTION 9 SERVICE AND REPAIR PUSHOUT PANEL WEAR BLOCKS WEAR BLOCKS 9 28 SECTION 9 SERVICE AND REPAIR REMOVAL OF PUSHOUT PANEL OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Move the pushout lever rearward and position the pushout panel at the extreme rear of the body 2 Remove the tailgate lift cylinders as described ear lier in this section OPERATIONAL STATUS PUSHOUT LEVER 3 Remove the tailgate as described earlier in t
22. nels 9 39 130 TRACK HOLES SHIMS Co d 0 GREASE FITTING SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged 8 Remove the appropriate rollers and add shims as required to obtain smooth operation of the packer and carrier panel This may require adding or re moving shims and operating the packing lever sev eral times until the correct alignment is achieved 9 Once alignment is correct lubricate each roller as described in the LUBRICATION CHART Sec 6 PREVENTIVE MAINTENANCE 10 Using the capscrews lockwashers and spacers 1 secure the cover weldment 2 amp 3 over the four track holes 131 9 40 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF HYDRAULIC PUMP The pump which serves the complete hydraulic system is a gear type coupled either to the PTO or chassis engine through a yoke arrangement PTO driven hy draulic pumps will be mounted near the chassis trans mission Front mount pumps will be mounted forward of the chassis cab behind the bumper REMOVAL OF HYDRAULIC PUMP OPERATIONAL STATUS Truck Off PTO Disengaged 1 Shut the ball 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 th
23. the load is ejected from the body PRESSURE e eee RETURN TAILGATE LIFT CYLINDER RSS ie AN lt q E LBS a CARRIER MAIN CONTRO CYLINDER VALVE O X 2 5 9 PUSHOUT LP CYLINDER CARRIER CYLINDER 6 TAILGATE LIFT CYLINDER KE PACKER CYLINDER 89 HYDRAULIC FLUID TANK SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RETRACTING PUSHOUT PANEL OPERATOR ACTION Operator releases speed up button NOTE Speed up may have to be used to retract pushout panel if engine RPM drops too far Operator moves the pushout lever forward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever forward shifts a spool in the FCV Front Control Valve causing flow to the telescopic cylinder As the cylinder retracts the pushout panel is positioned near the front of the body TAILGATE LIFT CYLINDER NA woe BY 5 Mi L FRONT CONTROL CARRIER MAIN CONTRO VALVE VALVE 4 gt PUSHOUT CYLINDER CARRIER CYLINDER TAILGATE LIFT CYLINDER PACKER CYLINDE 8 18 84 PUSHOUT LEVER mu PRESSURE e eee RETURN HYDRAULIC FLUID TANK PUMP SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM LOWERING TAILGATE OPERATOR ACTION Operator moves the tailgate lift lever forward SPEED UP BUTTON TAILGATE LIFT
24. tie bolts which secure the valve sections and covers Separate carefully noting the location of o ring seals NOTE Before disassembly it is suggested that each work sec tion be marked numerically to avoid incorrect assem bly 3 Thoroughly clean the o ring counter bores and ground surfaces of each section 9 19 110 FRONT CONTROL VALVE h SAS a 7 TIE BOLT OUTLET PUSHOUT sh A TAILGATE 8E s dl O a E A a 2 FR AT NOTE Do not remove the spool from the valve body as the seals can be replaced externally SECTION 9 SERVICE AND REPAIR o Remove boot retainer plate retainer plate washer o ring seal and back up washer Thoroughly clean counterbore To remove the bonnet remove two 2 capscrews securing the bonnet to the work section The spool positioner is now exposed for inspection and repair Remove the capscrew securing the spring collar to the valve spool Remove the spring collar and spring to expose the retainer plate retainer plate washer o ring seal and back up washer Thoroughly clean counterbore 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 Reassemble parts in reverse order of disassembly Torque the s
25. 2 Pressure should be Alpha 1100 PSI Beta 1800 PSI Delta 600 PSI ATTACH PORT A POWER WITH 0 3000 PSI GAUGE TO PORT MARKED P SOME DRAINAGE DURING TESTING MAY OCCUR AT THIS POINT WHEN THE ADJUSTED PRESSURE IS REACHED FLUID WILL DRAIN FROM PORT INSTALL RESISTANCE CARTRIDGE TIGHTEN TO 20 FT LBS ADJUSTING SCREW RESISTANCE CARTRIDGE dii 5 7 6 68 a V 9 RR ec 4 LU N SECTION 7 CHECK OUT CHECK PACKER HIGH PRESSURE CIRCUIT RELIEF CARTRIDGE OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture part number 710475 and test as shown on illustration x WHEN THE ADJUSTED PRESSURE IS REACHED 3700 PSI FLUID WILL DRAIN FROM PORT MARKED 1 INSTALL RELIEF CARTRIDGE IN 0 PORT MARKED WPRV 7 a TIGHTEN TO 20 FT LBS ADJUSTING SCREW N T 7 3000 Me 74500 1 450 9 4 a Y NUT 2 3700 PSI 69 7 7 SECTION 7 CHECK OUT CHECK ACCESSORY CIRCUIT RE LIEF CARTRIDGE OPERATIONAL STATUS Truck Off 7 8 PTO Disengaged Use the test fixture part number 710475 and test as shown on illustration ATTACH PORT A POWER WITH 0 3000 PSI GAUGE TO PORT MARKED P1 17
26. 499 mm 57 1 448 mm 155 3 937 mm 5 127 mm 3 0 cu yd 2 3 m Notes 1 Truck selected must be capable of carrying net weight of body plus weight of refuse to be collected 2 CA must be usable with no obstructions protruding above frame 3 32 yd body requires additional 6 AF 51 5 1 SECTION 5 SPECIFICATIONS LUBRICANTS eae ens SAE 10 or equivalent Grease Multiservice quality grade HYDRAULIC SYSTEM CAPACITY approximately FIUIG hr tp qc 50 gallons Total system System pressure Set llgs 2 via rr E ER RU Ec E 2350 PSI 162 BAR fittlnigs u AT Steel tubing with brazed ORFS fittings reinforced rubber hose with crimped full flow ORFS fittings o ring fittings ligo Suction Reusable wire mesh type Return line Disposable filter element located on return line to the tank PUMP Qu ca HM que o dl Positive displacement gear type driven by the PTO from the truck transmission or by the engine eri M 42 GPM 1200 RPM LEACH HYDRAULIC FLUID RECOMMENDATION All Leach hydraulic systems are factory filled with a high quality anti wear hydraulic fluid meeting an ISO 32 specification On units put into service where there are high ambient temperatures or sustained high duty cycles it may be desirable to change
27. LOAD SECTION 2 INTRODUCTION PACKER CARRIER PANEL COMPACTION POSITION PUSHOUT PANEL lt CARRIER PANEL PACKER PANEL PUSHOUT PANEL MOVES FORWARD TAILGATE 4 OO TAILGATE RAISED TAILGATE ha PUSHOUT cL lt PANEL OO SECTION 2 INTRODUCTION CONTAINER ATTACHMENT The AL III Container Attachment system consists of a loading edge with a latch assembly and a guide ear on each side of the packer tailgate The latches and ears are installed to accomodate containers from one 1 to ten 10 cubic yard capacity The standard container for use with the Leach rear loader must have an ANSI Stan dard 1 1 4 1 3 4 diameter trunnion bar which is be tween 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 avail able A hydraulically operated container push bar is available to handle containers of a one 1 to three 3 cubic yard capacity The handling of
28. WIPERS SEALS O RINGS LOCK ROD SEGMENTS HEAD GLAND BUSHING 9 11 102 INSPECTION AND REPLACEMENT 1 Carefully and thoroughly inspect the bore of the cyl inder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 2 Anewwiper rod seal o rings and piston seals must be installed anytime the cylinder is disassembled Pay particular attention to the way the parts are po sitioned before disassembly REASSEMBLY AND INSTALLATION Reassemble and install the cylinder in the approximate reverse order of disassembly NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from enter ing the cylinder PISTON SEALS PISTON DISASSEMBLY OF CARRIER PANEL CYLINDERS ALPHA AND BETA 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Sec 4 GENERAL REPAIR PRAC TICES before proceeding to disassemble the SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT Carefully and thoroughly inspect the bore of the inder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage cylinder 2 Anewwiper rod seal o rings and piston seals must be installed anytime the cylinder is disassembled Pay particular attention to the way the parts are po sitio
29. action of the packer and carrier panels Watch for sideways movement or twisting to determine where shimming and or new rollers may be needed OPERATIONAL STATUS 2 Remove capscrews lockwashers spacers 1 and cover weldments 2 amp 3 for both upper and lower track holes on each side of the tailgate EN 70 7 NN i S T D Q Vt 129 9 38 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 3 Shift the control levers and cycle the panels as nec essary to align the upper and lower rollers with the track holes NOTE If the top roller is removed first place a wedge between the carrier panel and the partition sheet to take the weight off the roller assemblies If the bottom roller is removed support the carrier and packer panel assem bly before removing the roller OPERATIONAL STATUS Truck Off PTO Disengaged 4 Remove one roller at a time 5 Replace any roller that is excessively worn cracked or out of round Inspect the condition of the track bar 6 Replacement rollers should be installed with the original shims or the same amount of new shims grease fitting should be installed in the replacement roller OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 7 Repeat step 1 to determine if additional shims are required Do not over shim rollers Excessive shimming may damage the tailgate walls or wear the track chan
30. check for correct cycle time and main line pressure as described in Sec 7 CHECK OUT 133 PRESSURE SECTION 9 SERVICE AND REPAIR LS SUCTION 9 42 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF ELECTRICAL SYSTEM The packer electrical system includes all of the body running and marker lights operational speed up switches the operator ready and back up warning alarms and all interconnected wiring TESTING To locate a defective component or break in the wiring perform a continuity check across the between sus pected components as described in Sec 4 GENERAL REPAIR PRACTICES SCHEMATICS Electrical and hydraulic schematics may be viewed or downloaded from FS Depot 9 43 134 REPAIR Repair of the electrical system is limited to the replace ment of burned out bulbs and other defective parts or wiring INSPECTION 1 Operate all light switches and push button controls to insure that they are operating normally 2 Check all wiring for breaks frayed or worn insula tion and loose terminal connections SERVICE TOOLS GENERAL The Service Tools shown in this section 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 of the appropriate service manual 10 1 135 SECTIO
31. concerning traffic rules warning devices and hand signals Know where to get assistance in the event of an emergency Know your machine Know the location and func tion of all controls gauges instruments and protec tive devices Wear your seat belt Start the engine following the manufacturer s rec ommended procedure Always set the park brake before leaving the cab 16 17 18 19 21 23 24 25 27 28 SECTION 1 SAFETY PRECAUTIONS Turn on appropriate warning lights put on a safety vest protective glasses and protective shoes All service opening covers and access doors must be maintained and latched in place while operating equipment Ensure all co workers are in view before operating or moving any controls or the unit Ensure that there is sufficient overhead clearance before operating the unit 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 Never allow anyone to ride on the steps when the vehicle is backing up Stop the vehicle immediately if warning lights for the TAILGATE AJAR system come on Never use controls or hoses for hand holds when mounting or dismounting Controls and hoses are movable They do not provid
32. 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 a winch with 12 000 rating The Leach container lift cylinder is rated at 12 000 Ibs NOTE Leach bodies are capable of being equipped with more than one container handling system 2 4 ARM LATCH 00 00 5 PUSH BAR DRUM WINCH LIFTING CYLINDER SECTION 2 INTRODUCTION GENERAL TERMS YOU NEED TO KNOW The main purpose of a refuse body is to load compact Before going further become familiar with the container transport and unload refuse To assist in loading of refuse handling terms you will need to know 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 ac cording to the container s type and size HOOK 1 Throat Opening 2 Back 3 Heel 4 Hook Safety Latch 5 Point 6 Base CONTAINER 1 Trunnion bar 2 Hook point 3 Lid CONTAINER ATTACHMENT 1 Loading sill 2 Arm 3 Latch 4 Guide ear 2 INTRODUCTION WINCH
33. pushout lever to position the pushout cylin der in the retract position 4 The fluid level should be between the safe range marks on the sight gauge IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged 5 Add hydraulic fluid for normal operating and weather conditions See Sec 6 PREVENTIVE MAINTE NANCE for additional information about servicing the hydraulic tank 63 SECTION 7 CHECK OUT 1 1 2 D 7 1 SECTION 7 CHECK OUT CHECK ENGINE SPEED UP SWITCH ENGINE OPERATIONAL STATUS SPEED UP SYSTEM OFF ON Truck Running PTO Engaged Speed Up On IF ENGINE SPEEDS UP OPERATIONAL STATUS 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 BODY OPERATIONAL STATUS Depress the engine speed up pushbutton The en gine should speed up IF NOT OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or switch and repair See 9 SERVICE AND REPAIR ELECTRICAL SYS SPEED UP BUTTON 2 Activate carrier panel lever Engine should speed up IF NOT OPERATIONAL STATUS CARRIER Locate the fault in the wiring or switch and repair See Sec 9 SERVICE AND REPAIR ELECTRICAL SYS TEM 7 2 64 SECTION 7 CHECK OUT CHECK PACK CYCLE TIME Q Q OPERATIONAL STATUS DELTA 1 Activate both the pac
34. ring oxidation is under control B If color develops but is uniform throughout the fluid is still serviceable but should be checked for cor rect additive content C If the sample shows distinct rings the fluid should be changed D Ifa distinct dark spot remains in the middle but a lighter colored fluid migrates outward in the blotter paper the fluid is about to dump or already has sludge or other by products into the system The time for replacement of this fluid has already passed Kits are available from your fluid supplier to test for acid content in much the same way you would test the con dition of swimming pool water A shift in acid content may indicate a breakdown in the fluid KEEP ACCURATE DATED RECORDS OF ALL PER TINENT INFORMATION GAINED FROM THESE TESTS SECTION 6 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE Each day perform the following maintenance 1 INSPECTION Perform the PRE OPERATIONAL INSPECTION de scribed in Sec 3 OPERATION Never go under the vehicle with the engine running Death or serious injury could result a When checking for hydraulic leaks pay particular attention to hose fittings and connections at the cylinders and valves A build up of hydraulic fluid and dirt indicates a small leak that can probably be corrected by tightening the fitting or connection b Check the visual indicator to determine the condi tion of the return
35. 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 ca pacity of 500 Ibs 227 kg Operate the hoist to snug the lifting sling without applying strain to the cylinder 4 Remove the capscrew from the rod and case ends Carefully remove the pivot pins Use special pin puller See Section 10 SERVICE TOOLS 9 9 100 SLING CAPSCREW DISASSEMBLY OF PACKER PANEL CYLINDERS ALPHA AND DELTA 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Sec 4 GENERAL REPAIR PRAC TICES before proceeding to disassemble the SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT Carefully and thoroughly inspect the bore of the inder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage cylinder 2 Anewwiper rod seal o rings and piston seals must be installed anytime the cylinder is disassembled Pay particular attention to the way the parts are po sitioned before disassembly 2 Secure the case end of the cylinder to the floor or workbench 3 Secure the rod end of the cylinder to an overhead hoist device with a minimum lifting capacity of 500 lbs 227 kg REASSEMBLY AND INSTALL
36. to the rod CYLINDER eye 5 pull up on the tube The packing 4 should come out as the tube is raised If it does not clean off a section of the tube and wrap masking tape around it Lower the wrapped section of tube down into the packing and then lift the tube once again 6 When removing the packing from succeeding larg er stages replace the head nut 3 on the stage directly above the section you need access to Wrap a strap under the head nut and use it to lift the tube 7 Prior to installing new packing 4 clean the area thoroughly and lubricate the new packing set inside and out with an all purpose grease CASE END 8 Ifthe proper size packing driver is not available the packing may be installed by turning the head nut over placing it on the packing and using a rubber or plastic mallet tap the packing into place 9 Replace all of the head nuts 3 being careful not to overtighten 10 Replace the plastic plug 2 and setscrew 3 JL 117 9 26 SERVICE AND REPAIR TELESCOPIC CYLINDER DISASSEMBLY ROD END 5 1 Prior to disassembling the cylinder first make four clips from thin steel These clips should be approx imately 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 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to prevent contamination from enterin
37. 00 PSI WHEN THE ADJUSTED PRESSURE IS REACHED 1700 PSI FLUID WILL DRAIN FROM PORT MARKED T1 INSTALL RELIEF CARTRIDGE IN 0 PORT MARKED WPRV a TIGHTEN TO 20 FT LBS ADJUSTING NUT 70 SECTION 7 CHECK OUT CHECK PUSH OUT PANEL SHOES OPERATIONAL STATUS 1 Visually inspect all pushout shoes for excessive wear These items must be replaced before there is metal to metal contact Shim or replace worn parts as described in Sec 9 SERVICE AND REPAIR under PUSHOUT PANEL POWER TAKE OFF OPERATIONAL STATUS 1 Periodically re torque the mounting bolts or studs as outlined in the P T O manufacturers service manual SECTION 7 7 10 72 GENERAL Troubleshooting is a matter of quickly and logically iso lating the cause of a problem and taking corrective ac tion 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 prob lem 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 malfunc tion or control linkage adju
38. 17 5 512 mm 20 Cu yd B Overall Length 230 5 842 mm CA Note 2 93 2 362 mm 106 2 692 mm 118 2 997 mm 131 3 327 mm Min Truck GVWR 28 000 Ibs 30 000 Ibs 31 500 Ibs 33 000 Ibs Requirement Note 1 12 701 kg 13 608 kg 14 288 kg 14 969 kg TANDEM AXLE 25 Cu yd 29 Cu yd 32 Cu yd Overall Length 268 6 807 mm 301 7 645 mm 324 8 230 mm CA Note 2 156 3 962 mm 189 4 801 mm 206 5 232 mm Min Truck GVWR 50 000 Ibs 56 000 Ibs 58 500 Ibs Requirement Note 1 22 680 kg 25 401 kg 26 535 kg BODY DIMENSIONS Continued SINGLE AXLE ALL SIZES TANDEM AXLE ALL SIZES AF After Frame Note 3 Hopper Opening Width Hopper Opening Height Load Sill Below Chassis Frame Hopper Capacity CNDOVZACS Rear of Body to Rear of Tailgate Closed Height Above Chassis Frame Tailgate Raised 38 965 mm 84 2 134 mm 59 1 499 mm 57 1 448 mm 155 3 937 mm 5 127 mm 3 0 cu yd 2 3 m 51 1 295 mm Height Above Chassis Frame 93 2 362 mm 93 2 362 mm Body Outside Width 96 2 438 mm 96 2 438 mm Body Inside Width Max 90 2 286 mm 90 2 286 mm Hopper Depth 16 406 mm 16 406 mm Start of Clear CA to Body Front 2 51 mm 2 51 mm Top of Step Below Chassis Frame 23 584 mm 23 584 mm Hopper Bottom Below Chassis Frame 25 635 mm 25 635 mm 84 2 134 mm 59 1
39. ATION Reassemble and install the cylinder in the approximate 4 Remove the setscrew from the gland retainer reverse order of disassembly 5 Remove the gland retainer NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from enter ing the cylinder 6 Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder ZERK PISTON SEALS ROD WIPERS sa Nes ZERK SEALS O RINGS BUSHING GLAND RETAINER GLAND PISTON 101 9 10 SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF PACKER PANEL CYLINDERS BETA 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Sec 4 GENERAL REPAIR PRAC TICES 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 Ibs 227 kg 4 Remove the six nylock screws and three lock seg ments securing the head gland to the cylinder 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 cylin der case Otherwise the cylinder may be difficult to take apart ZERK ROD
40. ATUS Truck Off PTO Disengaged 6 Using a lifting device lower the telescopic cylinder until it is resting on the floor of the body 7 Disconnect the hydraulic lines to the cylinder ports Cap the hydraulic lines and the cylinder ports to prevent contamination of the hydraulic system 8 Remove the cylinder case end pin 9 25 116 PUSHOUT LEVER PUSHOUT LEVER NOTE For more information about lifting devices and slings refer to Sec 4 GENERAL REPAIR PRACTICES 9 Attach a sling connected to a suitable lifting device with a minimum lifting capacity of 750 Ibs 341 kg 10 Operate the lifting device slowly and guide the inder out of the body through the side access door Take care during removal to avoid damaging the surrounding components or hydraulic lines SERVICE AND REPAIR TELESCOPIC CYLINDER PACKING REPLACEMENT ROD END 1 Drain the hydraulic fluid from the cylinder Clean the outside of the cylinder prior to working on it to prevent contamination from entering the cylinder Secure the cylinder to the floor or a workbench in a vertical position rod end up 2 Remove the setscrew 1 and plastic plug 2 from the head nut 3 Remove the smallest head nut 3 using a strap or chain wrench If the tube turns with the head nut tighten the next head nut slightly 4 Repeat steps 2 and 3 to remove each head nut TELESCOPIC 5 Using a suitable lifting device attached
41. ER PANEL CARRIER PANEL The two double acting hydraulic cylinders that control CYLINDERS movement of the carrier panel are called the carrier cylinders The two double acting hydraulic cylinders that control movement of the packer panel are called the packer cylinders PACKER PANEL CYLINDERS 9 1 92 TEST FOR LEAKING PACKER PANEL CYLINDERS NOTE Before testing any cylinder make sure the main sys tem pressure is correct as described under MAIN LINE PRESSURE CHECK Sec 7 CHECK OUT PROCE DURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top covers over the operating cylin ders for better accessibility during testing OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 2 Shift the packer panel lever outward to fully extend the packer panel cylinders NOTE Engine speed up only activates when carrier panel le ver is activated Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components OPERATIONAL STATUS Truck Off PTO Disengaged 3 Disconnect and plug the lines to the rod end of one cylinder at a time 93 SECTION 9 SERVICE AND REPAIR PACKER PANEL CYLINDERS SY A CERO PACKER PANEL LEVER 9 2 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS 4 Shift the packer panel lever outward to apply hy draulic pressure to the case end of the packe
42. ERING UNDER TAILGATE 13 SECTION 1 SAFETY PRECAUTIONS DECAL PLACEMENT ENGINE This unit conforms to all American HYDRAU LIC National Standards Institute safety SPEED UP requirements Z 245 1 in effect on FLU ID ONLY the date of manufacture 4 LEACH DRIVER SIGNAL cren ELEMENT CHANGE 7 ensure oil cleanliness and longer machine life change the element at intervals of 20hrs 50hrs and at EJECTION 250hr intervals thereafter EJECTION EJECTION 2O NOT FILL BEYOND THIS LINE gt A DANGER Stand clear when tailgate is in motion amp during unloading cycle Do not stand or TAILGATE legs raised TAILGATE TAILGATE SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW BODY ASSEMBLY TAILGATE ASSEMBLY LOADING EDGE PUSHOUT HYDRAULIC PANTE ug PACKER CARRIER PANEL SECTION 2 INTRODUCTION The main purpose of the Alpha Series III 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 ofthe unit and its components read the complete Alpha Series Ill SERVICE MANUAL Before going further look at the accompanying full page illustration of the Alpha III 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 p
43. ES CARRIER hp MAIN CONTROW VALVE H 2 O 2 i 7 CYLINDER 2 gt s PUSHOUT CYLINDER TAILGATE LIFT CYLINDER CARRIER CYLINDER PACKER CYLINDER 8 15 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM RAISING TAILGATE OPERATOR ACTION Operator opens the packer panel to release pressure Operator loosens and swings away from the body the tailgate clamps Operator depresses the speed up but ton Operator moves the tailgate lift lever rearward HYDRAULIC SEQUENCE Moving the tailgate lift lever rearward shifts a spool in the FCV Front Control Valve causing flow to the tail gate lift cylinders The cylinders extend causing the tailgate to raise Excess fluid flow from the FCV Front Control Valve returns back to tank TAILGATE LIFT CYLINDER VA CARRIER M A 2 cvLINDER gt O 8 16 m SPEED UP BUTTON TAILGATE LIFT LIFT LEVER mn PRESSURE RETURN HYDRAULIC FLUID TANK CYLINDER CARRIER CYLINDER PUMP TAILGATE LIFT CYLINDER SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM EJECTING LOAD OPERATOR ACTION Operator depresses speed up button and moves pushout lever rearward SPEED UP BUTTON HYDRAULIC SEQUENCE Moving the pushout lever rearward shifts a spool in the FCV Front Control Valve causing flow to the telescopic cylinder As the cylinder extends
44. Ibs 3629 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 eet dl 4800 Ibs 2177 kg icd aac cease H 3600 Ibs 1633 kg SI cdam cm I 9600 Ibs 4354 kg WVU RN 2in Length tinsen O raed e a re aae E AES EE depends on type of lifting device used CHAIN AND HARDWARE SPECIFICATIONS Chains should be used to lift and or support the carrier and packer panel pushout panel and tailgate The follow ing specifications should be used to determine the type of chain and hardware to use for lifting Chain Nj D O F Double Branch Oblong Link Foundry Hook Nl 1 2 in ginge 1 2 in ODIO 1 2 47 4 GENERAL REPAIR PRACTICES CAPSCREW MARKING AND TORQUE VALUES Much Used Used at Times Used at Times Capscrew Diameter To Ya 120 000 To Y 140 000 150 000 amp Minimum Tensile To 1 115 000 3 4 133 000 Strength PSI Quality of Material Min Commercial Med Commercial Best Commercial SAE Grade Number 60r 7 CAPSCREW HEAD MARKINGS Manufacturers marks may vary These are all SAE Grade 5 3 line OO Capscrew Body Size
45. N 10 NO PART NO DESCRIPTION EXPLANATION UNIT 1 603667 Pressure Gauge To measure system pressure All except FL104 Beta 2 T SK 793 100 Pin Puller Remove pivot pins All 3 100368 Snap Connector Quick coupling for pressure gauges All 4 6050180 Test Block Test resistance cartridge AL BE DE Series III 5 103081 O Ring Kit 4 to 24 Straight Thread o rings All except FL104 6 972087 ORFS O Ring Kit 4 to 24 ORFS o rings All 7 970004 Plunger Tool Remove install spring loaded plungers on rear loader container attachments 8 7104750 Test Block Test circuit relief cartridges AL BE DE Series Ill 10 2 136 NOTES Part 90350 labrie environmental group Customer Support Center 3596 Stearns Drive Oshkosh WI 54904 1 800 231 2771 Parts Service and Warranty during business hours Technical Support Service 24 hours
46. NGS ZERK ROD HEAD GLAND BUSHING 9 13 104 INSPECTION AND REPLACEMENT 1 Carefully and thoroughly inspect the bore of the cyl inder case for cracks rust scoring or excessive wear Replace if found not to be serviceable Check all other parts for damage 2 Anewwiper rod seal o rings and piston seals must be installed anytime the cylinder is disassembled Pay particular attention to the way the parts are po sitioned before disassembly REASSEMBLY AND INSTALLATION Reassemble and install the cylinder in the approximate reverse order of disassembly NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from enter ing the cylinder PISTON SEALS CASE PISTON SECTION 9 SERVICE AND REPAIR DESCRIPTION OF TAILGATE LIFT E aN CYLINDERS oa gt These two hydraulically operated cylinders mounted on each side of the tailgate lift and lower the tailgate assembly The rod end is pinned to a pivot ear on the body frame near the discharge opening while the cylin der weldment pivot ear is bolted to a mounting hub on the tailgate TAILGATE CYLINDERS TEST FOR LEAKING TAILGATE CYL INDER NOTE This check will require two people OPERATIONAL STATUS 1 Loosen and release swing away the tailgate clamps OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 2 Depress the speed up button and move the tail gate lift
47. ONS O Grease weekly every 40 hrs of operation with MOBILUX EPI SERVICE grease or equivalent Oil weekly every 40 hrs of operation with SAE 10 or equivalent ILLUS LUBE POINT QTY NOTE E Control levers 2 1 2 PTO shaft 2 3 Tailgate lift cylinder 4 top and bottom Tailgate clamps 2 5 Operating cylinders 4 2 top pivots 6 Operating valve 4 1 control lever Not Shown Telescopic cylinder 2 pivot pins 6 2 54 In below freezing climates all grease and fluids should have a cold test rating of at least 20 F ILLUS LUBE POINT NOTE QTY NOTE The packer panel must be in the home position to lubricate the following lube points 9 10 W11 912 Inside amp outside 3 bearing housing Carrier panel cylinder 1 end Packer panel cylinder 2 rod ends Rollers 4 Optional control 2 lever s HCA oylinders 4 3 amp 4 LUBRICATION CHART SECTION 6 PREVENTIVE MAINTENANCE NOTES 1 cm These parts require frequent inspection and lubri cation as necessary to be in prime working condi tion Remove the top cover for access to lube points Move roller track access covers to grease roller Rollers need lubrication roller tracks do not Grease on the tracks will cause the rollers to slide keep tracks clean and dry 55 6 3 SECTION 6 PREVENTIVE MAINTENANCE NT 2257 27 YE are
48. Power Take 71 SECTION 8 TROUBLESHOOTING Generalen O bane 73 Compact P M 73 Dieseling In Hydraulic System 74 Operation Is 2 lt 75 Pump Noise 15 75 Engine Will Not Speed Up When Carrier Panel Lever or Speed Up Button Is 76 Engine Speed Up Will Not Return To Normal When Pack ing Cycle Is Complete or Speed Up Button Is Re ICI 76 Packer Panel Valve Section Shifts Too Slow 76 Carrier Panel Valve Section Shifts To Neutral Too slo eS 77 Packer Panel Valve Section Will Not Shift 77 Carrier Panel Valve Section Will Not Shift To Neutral 77 Packer Carrier Panels Do Not Deliver Full Force To Pack Load Into 77 Loud Squealing Noise When Manually Retracting Tele 78 Load Will Not Push 2 78 Pushout Panel Slides Forward Too Fast While Packing A 78 Pushout Panel Will Not Slide Forward Automatically 78 Carrier And Packer Panels Stop Short Of Home Position After Each 78 Packer Panel Drifts Open While Packing Load Into BOG DN 79 Cycle Time Too Slow iicet certe 79 Tailgate Will Not 79 Contain
49. R 4 MAIN CONTRO VALVE SA VE 6 L PUSHOUT gt CYLINDER P aa Y IN VA lt gt O LP CYLINDER gt O y 2 NN O 2 S TAILGATE OL LIFT CYLINDER DA g L L L L L L L L HYDRAULIC PUMP AN Q NNS 5 91 A PACKER CYLINDER m 8 11 SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM CARRIER amp PACKER PANELS MOVE DOWN TO INTERRUPTED CYCLE POSITION OPERATOR ACTION None MCV Main Control Valve shifts automatically HYDRAULIC SEQUENCE At the end of the packer cylinder stroke pressure builds to Alpha 1800 PSI 124 BAR Beta 2000 PSI 138 BAR Delta 1800 PSI 124 BAR causing the MCV Main Control Valve to shift diverting flow to the case end of the carrier cylinders The cylin ders 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 retraction stroke pressure builds to Alpha 2000 PSI 138 BAR Beta 2100 PSI 145 BAR Delta 2100 PSI 145 BAR causing the MCV Main Control Valve to shift to neu tral TAILGATE LIFT CYLI vae y CARRIER NA 28 CARRIER CYLINDER PACKER CYLINDER 8 12 84 PRESSURE e eee RETURN TRAPPED FLUID PUSHOUT CYLINDER i FRONT CONTRO a VALVE TAILGATE LIFT CYLINDER
50. REPAIR INSPECTION AND REPLACEMENT OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot bearing and roller sur faces for excessive or uneven wear scoring or dam age 2 Check the panel for broken welds bent edges or warpage 3 Inspect the track bar for excessive wear or dam age 4 Replace parts as necessary INSTALLATION OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the carrier panel in the approximate reverse or der of disassembly Pay particular attention to the in stallation of roller and bearing assemblies as described earlier in this section TRACK BAR REPLACEMENT OPERATIONAL STATUS Truck Off PTO Disengaged NOTE Refer to Sec 4 GENERAL REPAIR PRACTICES for welding instructions 1 Remove the old track bar and make sure the track channel is smooth and clean 2 Weld a new track bar in place The surface of the track bar must be at 90 degrees from the side of the tailgate so the roller will run true 9 37 128 CARRIER PANEL CAUTION The Leach track bar is made out of special alloy bar steel Do not substitute a different steel It may cause damage to the tailgate WRONG RIGHT GAP NO GAP SECTION 9 SERVICE AND REPAIR ROLLER REPLACEMENT SHIMMING OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Shift the control levers and cycle the unit several times while observing the rollers and
51. Repair or replace linkage as required Lifting motor or cylinder s by passing hydraulic 7 Repair or replace the defective component fluid Shear pin or key broken between winch shaft and Replace the key or pin drum INCH MOTOR LEAKING POSSIBLE CAUSE REMEDY 1 Shaftseal damaged 1 Replace shaft seal 2 Motor worn internally 2 Replace motor CONTAINER RAISES VERY SLOWLY POSSIBLE CAUSE REMEDY Winch motor by passing 1 Repair or replace motor Rear loader hydraulic system not providing suffi 2 Check and repair rear loader hydraulic system fol cient flow rate or pressure for container handling lowing procedures in Service manual Systems SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM DESCRIPTION OF HYDRAULIC SYS TEM The following is a description with flow diagrams of what happens in the hydraulic system of the telescopic sys tem during the loading packing and unloading opera tions of the unit Operator action is presented and then a description of the hydraulic flow and the interaction of system compo nents i e valves and cylinders follows Before pro ceeding to the flow diagram refer to the illustration and become familiar with the system component nomen clature SYSTEM COMPONENT NOMENCLATURE TAILGATE LIFT CYLINDER HYDRAULIC FLUID TANK PUSHOUT CYLINDER PUMP CARRIER CYLINDER TAILGATE LIFT CYLINDER 81 8 9 TROUBLESHOOTING TELESCOPIC SYSTEM NEUTRAL
52. 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 may also affect compaction Compaction rates of a unit will depend on the season the type of trash the weather and the operation and maintenance of a unit If the unit packs relatively con sistent loads and has been properly maintained accord ing to 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 con tamination air is compressible and contains oxygen It is these two 2 properties of air contamination that pro vide the elements needed to support the phenomenon known as dieseling Dieseling can only occur when the elements of fuel oxygen and heat are all present at the same time In the hydraulic system the hydraulic fluid is the fuel The presence of air provides not only the oxy gen to support combustion but also the means for gen erating sufficient heat to ignite the fuel air mixture When air is rapidly compressed heat is generated A rapid pressure change of only 600 psi may be enough to gen erate the heat required to ignite the fluid and mixture The oxygen in the heated compressed air and the
53. Torque Torque Torque Inches Thread Ft Lb kg m Ft Lb kg m Ft Lb kg m 10 1 38 19 2 63 34 4 70 5 7 61 85 11 76 120 16 60 21 44 20 75 167 23 10 10158 da og 24 280 38 72 86 A 65 440 60 85 a 67 590 Bf 660 91 28 91 28 136 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 48 SECTION 4 GENERAL REPAIR PRACTICES HYDRAULIC FITTING TORQUE VALUES JIC 37 DEGREE FLARED TUBE FITTINGS TUBE SIDE TORQUE TORQUE THREAD INCH LBS FOOT LBS SIZE FLAT FACE O RING ORFS FITTINGS TUBE SIDE TORQUE TORQUE THREAD INCH LBS FOOT LBS SIZE 9 16 18 11 16 16 13 16 16 1 14 1 3 16 12 1 5 16 12 1 7 16 12 1 11 16 12 2 12 2 1 2 12 49 4 7 50 SECTION 5 SPECIFICATIONS BODY DIMENSIONS SINGLE AXLE 16 Cu yd 204 5 182 mm 14 Cu yd 192 4 877 mm 18 Cu yd 2
54. ack to neutral This will take the pres sure off the rod eye when the pin is removed 7 ll 2 yi NOTE For more information about lifting devices and slings refer to Sec 4 GENERAL REPAIR PRACTICES OPERATIONAL STATUS Truck Off PTO Disengaged 3 Remove the capscrews 1 lockwashers 2 and LEVER PACKER PANEL pivot pin 3 from the rod end 4 Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin 123 9 32 SECTION 9 SERVICE AND REPAIR 5 Attach a chain connected to a suitable lifting de vice capable of lifting 1600 Ibs 726 kg to the packer panel as shown Operate the lifting device d to support the weight of the packer panel without causing strain on the bearing and roller assemblies ji i 3 4 Ru Vil y ki M n S i less Sool 6 Remove the pins that attach the packer panel to Sf the carrier panel 35775 KX 7 With the pins removed carefully operate the hoist 7 TUS SE and lift the packer panel out of the hopper Use care z G to avoid damaging the hopper INSPECTION AND REPLACEMENT OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Carefully inspect all pivot surfaces for excessive or uneven we
55. acker panels which sweep up and pack the refuse from the hopper will be in the home position COMPACTION When the operator starts the packing cycle the carrier and packer panels move rearward over the load CARRIER PANEL PACKER PANEL HOME POSITION 1 CARRIER AND PACKER PANELS MOVE OVER LOAD Next the carrier and packer panel automatically stop at the interupted cycle position CARRIER PACKER PANEL INTERUPTED CYCLE 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 Also during the compaction cycle cosiderable hydrau lic 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 Once the body is full the Alpha Beta Delta Series can be moved to the dumpsite for unloading 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 After unloading the tailgate is lowered and latched to the body PUSHOUT PANEL MOVES REARWARD EJECTING THE
56. acking cycle is completed As the carrier cylinders apply force to compact refuse the pressure of the trapped fluid in the TAILGATE LIFT CYLINDER CARRIER ib Q gt 53 NA Y VAL 2 D 4 gt 55 12 CYLINDE 8 14 86 CYLINDER packer cylinders will increase Should this pressure reach 3700 PSI 262 BAR a relief valve will open re ducing the pressure by allowing some trapped fluid to escape and return to the hydraulic tank PRESSURE eeee RETURN TRAPPED FLUID 38838855389 8 9 HYDRAULIC FRONT CONTRO VALVE PUSHOUT CYLINDER PUMP TAILGATE LIFT CYLINDER SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKING REFUSE CONTINUED HYDRAULIC SEQUENCE While the carrier and packer panels are moving up compacting refuse against the pushout panel pressure is building in the case end of the telescopic push out cylinder When this pressure reaches Alpha 222 PSI BAR Beta 2 PSI BAR Delta PSI BAR a relief resistance cartridge opens in the FCV Front Control Valve pushout section allowing some case end pressure from the telescopic pushout cylinder to return to tank This allows the pushout panel to come forward slightly mu PRESSURE e e o RETURN TRAPPED OIL TAILGATE LIFT CYLINDER L L L L L L L L L HYDRAULIC BS VASES TS NN Ml Ay
57. age corrosion stretching or distortion as shown in the wire rope illustration below NOTE important item A lay of rope is that length of rope in which one strand of wire makes a complete revolution about the core b Check the breather cap on the hydraulic tank Clean it weekly and replace it if it cannot be cleaned thoroughly or is missing EVIDENCE OF HEAT NORMAL 1 2 DAMAGE FROM ANY DIAMETER OF CAUSE MORE THAN 3 64 4 REDUCTION FROM WIRE ROPE CHART KINKING CRUSHING OR i DISTORTION OF ROPE STRUCTURE 6 BROKEN WIRES IN ANY ONE LAY OR 3 BROKEN WIRES IN ONE STRAND Ne IN ANY LAY MORE THAN 1 gt BROKEN WIRE AT WEAR GREATER A DEAD END THAN 1 3 DIAMETER CONNECTION OF OUTSIDE INDIVIDUAL WIRES 61 6 9 SECTION 6 PREVENTIVE MAINTENANCE MAINTENANCE RECOMMENDATIONS The packer carrier assembly should be visually inspect ed every forty 40 hours of operation for cracked or fatigued welds loose or broken fasteners worn bear ings pin hubs or pins MONTHLY LIFTING HOOK A thorough inspection of any container lifting hook should be completed once a month consisting of check ing for distortion cracks nicks wear latch engagement and secure end connections Maximum distortion allowable is an 8 percent increase in the throat dimen sion or a 10 degree twist in the hook Cracks nicks and wear must not exceed 10 percent of any dimension Visually inspect before each use for o
58. al of the carrier panel and removal of the pushout panel Procedures for car rier panel and pushout panel removal are different and are covered under REMOVAL OF CARRIER PANEL or REMOVAL OF PUSHOUT PANEL REMOVAL OF THE TAILGATE AS SEMBLY OPERATIONAL STATUS Truck Off PTO Disengaged 1 Release the tailgate clamps and swing away 2 Disconnect and remove the tailgate lift cylinders as described earlier in this section 3 Disconnect and cap the hydraulic lines NOTE See Sec 4 GENERAL REPAIR PRACTICES for de tailed information about the correct use of slings and lifting chains 4 Attach chains connected to a suitable lifting device with a minimum lifting capacity of 7 500 Ibs 3402 kg to the tailgate as shown Operate the lifting device no more than necessary to support the weight of the tailgate 9 17 108 X gt Remove capscrew and locknut not shown to re move retainer 1 and hinge pin 2 Operate the lifting device and or move the truck for ward to free the tailgate from the body Position the tailgate on supports as needed to fa cilitate repairs The supports must be capable of supporting 7 500 Ibs 3402 kg INSPECTION OF TAILGATE 1 Inspect all the sheet metal for bends dents or tears Check the hardware holes for enlargement or breaks in the metal Check threaded holes for stripped or otherwise damaged threads Check the tailgate seal for any sign of deteriora
59. aling parts 4 Lubricate all new sealing parts with clean fresh hy draulic fluid before installation 5 Use care not to damage new sealing parts on reas sembly 6 Use correct torque values when reassembling and installing components See TORQUE SPECIFICA TION CHARTS 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 FS Depot replacement parts NOTE See Section 9 SERVICE AND REPAIR for specific repair instructions ELECTRICAL TESTING The electrical system used on the unit consists of vari ous lights switches and wiring Testing the components and wiring can be accomplished by two simple checks CHECKING FOR VOLTAGE and CHECKING CONTI NUITY CHECKING FOR VOLTAGE A test light is used to check for the presence of electric ity in a live circuit Connect the test light clip to a good ground and the probe at the point where the presence of voltage is to be checked If voltage is present the light will be on if no voltage is present the light will be off WELDING 1 Completely clean out an old weld before rewelding CHECKING CONTINUITY A continuity tester is used to check the ability of a con ductor to allow current to pass A continuity tester uses a self contained power source and should never be used on a live circuit
60. ar scoring or other damage 2 Check the panel for broken welds bent edges or warpage 3 Inspect the packer panel edge for damage Replace a badly worn edge as described below EDGE 4 Replace parts as necessary See Sec 4 GEN ERAL REPAIR PRACTICES 9 33 124 SECTION 9 SERVICE AND REPAIR REPLACEMENT OF PACKER EDGE 1 Remove the old edge with an air arc to obtain clean cut 2 Grind smooth the packer panel where the new edge will be attached 3 Weld a new edge in place INSTALLATION OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the packer panel in the approximate reverse or der of disassembly 125 9 34 SECTION 9 SERVICE AND REPAIR CARRIER PANEL The correct method of operation is thoroughly described in the Alpha Beta Delta Series Operator s Manual Our policy is not to describe the many different ways in which a unit might be incorrectly operated however in an attempt to provide maintenance personnel with clues that may assist in the diagnosing of a reoccurring car rier packer panel concern that might be operator in duced we offer the following Skimming is a result of the operator interrupting the movement of the packer panel and stopping the packer panel before it rotates perpendicular 90 degrees to the carrier panel When the packer panel is not allowed to fully rotate and the carrier is then moved toward the home position a shear load i
61. bvious damage LATCH THROAT OPENING a AN POINT BACK HEEL V BASE YEARLY PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM a Once a year drain flush and refill the hydraulic tank as described under HYDRAULIC SYSTEM SERVICE in this section b Once a year remove clean and inspect the suction strainer as described under HYDRAULIC SYSTEM SERVICE in this section c Once a year replace the hydraulic tank air breather 6 10 i GENERAL The Alpha Beta Delta Series III have been designed to provide long periods of trouble free operation Perform ing the check out procedures below at regular weekly intervals will help to prevent unscheduled downtime Make sure you know and observe all safety precau tions listed in Sec 2 before performing any of the following check out procedures Use extreme cau tion to avoid coming near any moving parts Never enter the body of the unit when the truck is run ning 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 Speed Up On CHECK HYDRAULIC TANK FLUID LEVEL 1 Make sure the tailgate is down and clamped se curely 2 Move the carrier and packer panel levers to posi tion the carrier and packer cylinders in the retract position 3 Pull the
62. cautions Prior to Service or Repair 44 Safety During Service And 44 Welding 44 Oxy Acetylene 2 11 cete reser ied 45 Reassembly And Installation 46 Electrical Testing ceste 46 Checking For 46 Checking Continuity esses 46 1 46 Lifting Instructions i redirent eerte 47 Capacity of Lifting 47 Sling Strap 2 47 Chain And Hardware 47 Capscrew Marking And Torque Values 48 Hydraulic Fitting Torque Values 49 SECTION 5 SPECIFICATIONS Body Specification 51 E briGarnits 52 Hydraulic System sssrinin sirrinin sinea 52 y joe aaia 52 Hydraulic Fluid 52 SECTION 6 PREVENTIVE MAINTENANCE 53 Operating and Maintenance Records 53 Lubrication Chart 54 Hydraulic System 57 Checking Fluid Level 57 Clean Tank
63. cess Cleaning will occasionally uncover trouble sources Tools instruments and parts needed for the job should be gathered before work is started Inter rupting a job to locate tools or parts is a needless delay Special tools required for a specific job are listed in Sec tion 10 REPLACEMENT PARTS Of growing concern to the Labrie Environmental Group is the use of counterfeit will fit or substitute parts Leach replacement parts are designed and manufactured to exacting standards The use of counterfeit will fit or sub stitute parts may effect the operation and performance of the unit and will void the warranty Insure maximum reliability and protect your investment insist on Leach original factory replacement parts TECHNICAL SERVICE BULLETINS In addition to the information provided in this Service Manual TechnicalService Bulletins are issued when needed to cover interim changes or to provide supple mentary information necessary for maintaining the refuse unit in a proper safe operating condition Check with your authorized Leach distributor 43 SECTION 4 GENERAL REPAIR PRACTICES 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 1999 It is important to note that deviating fr
64. ch secure the valve sections and covers Separate carefully noting the location of o ring seals 3 Thoroughly clean the o ring counterbores ground surfaces of each section KNOCKOUT SECTION 9 SERVICE AND REPAIR 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 sections to avoid dis lodging o rings from the counterbores 2 Secure tie bolts and tighten evenly to 25 ft Ibs 33 8 Nm 3 Torque 3800 PSI relief cartridge to 20 ft Ibs 27 Nm POSITIONER _ y CARRIER SECTION PACKER SECTION TIE BOLT CONTAINER HANDLING SECTION 115 9 24 SECTION 9 SERVICE AND REPAIR REMOVAL OF TELESCOPIC CYLIN DER OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Move the pushout lever to position the pushout panel approximately midway in the body 2 Weld a lifting eye to the roof of the body OPERATIONAL STATUS Truck Off PTO Disengaged 3 Attach a sling connected to a lifting device capable of lifting 750 lbs 341 kg to the telescopic cylin der 4 Remove the nuts and bearing block halves con necting the pushout panel to the cylinder OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 5 Move the pushout lever to slowly retract the tele scopic cylinder until it is completely retracted OPERATIONAL ST
65. ctive Main relief cartridge out of adjustment or broken Tailgate lift cylinders leaking or defective Restriction in tailgate cylinder hose Set engine RPM to achieve 23 to 26 second cycle time Must be done by authorized dealer Fill to proper level See Sec 6 Preventive Mainte nance Service filter See Section 6 Preventive Mainte nance Service breather See Sec 6 Preventive Mainte nance Replace pump See Sec 9 Service and Repair Perform test for leaking operating cylinder seal and repair as required Refill with proper grade of hydraulic fluid See Sec 5 Specifications Repair or replace as required See Sec 9 Service and Repair Disconnect clamps and swing free of tailgate Check main relief pressure See Sec 7 Check Out Replace pump See Sec 9 Service and Repair Adjust or replace main relief cartridge as neces sary See Sec 9 Service and Repair Repair or replace as required Remove and clean hose SECTION 8 TROUBLESHOOTING CONTAINER WON T LIFT POSSIBLE CAUSE REMEDY Insufficient hydraulic pressure Check pressures as described in Sec 7 Check Out Cable broken Replace cable Cable loose from the lifting device drum cylinder Secure cable to lifting device Container overload Reduce weight of material in container Container frozen to the ground Do not use lifting device to break container loose from the ground Linkage binding or restrictive
66. d paint exposed metal surfaces to remove and prevent the formation of rust 2 INSPECTION a In addition to the body mounting hardware which is checked daily inspect all other acces sible mounting hardware and fittings for tight ness Refer to the CAPSCREW MARKING AND TORQUE VALUE CHART provided in Sec 4 GENERAL REPAIR PRACTICES b Check electrical wiring and insulation for frays breaks and loose connections 3 LUBRICATION Refer to the LUBRICATION CHART in this section and service those items which require weekly lubri cation 4 HYDRAULIC SYSTEM a The return line filter element is vital to the ser vice life of the hydraulic system Check the replacement indicator on the filter assembly weekly Refer to HYDRAULIC SYSTEM SER VICE for more detailed information about this CHECK OUT PROCEDURES Each week perform the CHECK OUT PROCE DURES listed in Sec 7 of this manual CONTAINER HANDLING SYSTEM HARDWARE Check all container handling system hardware to make sure that no damage exists and that all fas teners are secure PIVOT POINTS Check all pivot points for wear and smooth opera tion WIRE ROPE CABLE A detailed inspection of all wire rope cable should be made weekly or every 40 hours of use which includes checking the wire rope for damage dete rioration and secure end connections Damage or deterioration requiring replacement of wire rope is indicated by broken wires excessive wear heat dam
67. der or riders are on riding steps ADANGER A DANGER A WARNING TIE To prevent possible serious injury or death do not use this refuse collection vehicle to tow other equipment It is not intended designed or equipped Stand clear when fortowing tailgate is in motion amp during unloading cycle Do not stand cross under raised tailgate Stand clear when packer panel is in motion ENIE SOLENDID MUST BE OFF WHEN This vehicle requires 7 TRUCK iS PARKED ot overhead eal ON OFF Clearance as originally mounted Be sure all persons are clear of hopper WARNING 79 STROBE LIGHT ON OFF WARNING TAILGATE Do not operate OPEN Do not transport container on lift mechanism vehicle in excess Transporting a container of 20 mph from the could result in personal stand up position injury or property damage A WAR N NG TAILGATE PROP OPERATION INSTRUCTIONS ENGAGETALGKEFEORI a site Use both hands an 4 Riding step shall no be used when lt Speeds nre expected to exceed 10 mph or when dislance traveled withoul stopping wlll exceed 2 tenths of one mile Vehicle ig mong backwa Do not mount or dismount riding slep when vehicle is in mouon gt Da not ride on loadin ran container ANWARNING ENGAGE BOTH TAILGATE PROPS BEFORE ENT
68. duce maxi mum load density it may become necessary to manu ally retract the telescopic pushout cylinder in order to allow the compacted refuse to move forward in the body Also if the packer panel stops short of the home posi tion the carrier panel operating lever may need to be held overridden to allow the refuse to move the pushout panel toward the front of the body When the pushout panel has reached the front of the body neither the packer panel operating lever nor the carrier panel lever should be overridden except to clear the final hopper load ENGINE SPEED UP BUTTON DISCONNECTING THE CONTAINER Once the container is empty it should be lowered to the ground the latch arms released and the cable discon nected DISCONNECTED 38 SECTION 3 OPERATION UNLOADING AT DUMPSITE Do not unload uphill or against a pile of refuse 1 Apply the brakes engage the PTO and ensure the transmission is in neutral Relieve the pressure on the tailgate by moving the packer panel to the interrupted cycle position 2 Loosen both tailgate clamps and swing them out and forward as far as they will go LIFTING THE TAILGATE Stand clear when the tailgate is raised If you need to clean debris from the edges use a pole while standing to the side 1 Depress and hold engine speed up button 2 Push the tailgate lift lever rearward and hold until the tailgate is fully raised TAILGATE
69. e sure none are missing and that there are no burned out bulbs AWARNING The tailgate open warning light should be off Do not operate the unit if the light is illuminated Never place hands in or near the packer panel dur ing operation 9 With the engine running the speed up solenoid switch ON the PTO engaged and the transmission in neutral and the brakes applied depress the speed up push but ton on the forward left street side of the body You should hear the engine speed up FRONT CONTROL 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 VALVE ENGINE SPEED UP BUTTON 30 10 Move both the packer panel lever and carrier panel lever inward and let go Check for the following a Engaging the carrier panel lever will activate an engine speed up switch you should hear the engine speed up b Observe the carrier and packer panel move ment it should be smooth The panels should stop automatically at the interrupted cycle position 11 Move both the packer panel lever and carrier panel lever outward and let go Observe the carrier and packer panel movement it should be smooth The panels should stop automatically at the home position 12 Depress the two driver signal push buttons located on both sides of the tialgate to make sure that the au dible alarm located in the cab is wo
70. e containers the driver should back the unit toward the container following all vehicle and refuse body safety restrictions The vehicle should be backed with the latch arms open until the container trunnion bar is between the guide ears and within the latch assembly Center the container on the attachment LATCH ARMS DISCONNECTED After setting the vehicle parking brake the right and left container latch arms must be engaged Lifting a container without both latch arms secured ATTACHED can allow the container to swing away from the unit and cause severe injury or death NOTE If the container is equipped with wheels it should be rolled into position only after the vehicle parking brake has been set Even small containers must use the latch arms to se cure them to the packer 35 SECTION 3 OPERATION USING A WINCH OR CONTAINER LIFT CYLINDER Once the container is secured within the latch assem bly the lifting cable should be attached Place the load in the base of the hook with the safety latch closing the throat opening It is important that hooks are used in a proper manner Proper use of a lifting hook not only includes placing the load in the base of the hook but also includes ensuring that the hook is lifting on the proper area of the attach ment point The hook must completely encircle the attachment point Equally as important at the time load is applied to the base of the hook t
71. e 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 drive shaft to ward the PTO or engine 6 Remove the key from the pump shaft keyway 7 Remove the attaching hardware The pump assem bly may now be removed from the mounting bracket 9 41 132 d O of DRIVE SHAFT BALL VALVE INSTALLATION OF HYDRAULIC PUMP OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install pump in the reverse order of removal 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 2 Be sure to install any shaft guards that may have been removed NEW PUMP PREPARATION Before installing a new pump refer to Sec 6 PRE VENTIVE MAINTENANCE and the following This will prevent contamination of the new pump 1 Remove and clean the hydraulic 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 ring 4 TESTING A NEW PUMP OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On After installing a new pump
72. e packer panel lever and carrier panel lever to place the packer panel in the home position 2 Put all controls in neutral 3 Set parking brake 4 Disengage PTO 5 Shut off engine 6 Shut of solenoid dashboard switch 7 Remove key 8 Lock truck 41 42 Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these ser vice operations require the use of tools specially designed for the purpose These special tools should be used when and as recommended Since Leach Company could not possibly know evaluate and advise the service trade of all possible ways in which service might be done or of the possible haz ardous consequences of each way we have not ac cordingly anyone who uses a service procedure or tool PREPARATION FOR SERVICE Proper preparation is very important for efficient safe service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and reduce the 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 pres sure equipment and strong chemicals Follow the manufacturer s instructions and precautions during this pro
73. e proper support and may cause accidental equipment movement Make sure the backup alarm is working properly Always ensure that all persons are clear before rais ing or lowering the tailgate It is the operator s re sponsibility to warn all persons not to stand or cross under a raised tailgate Do not move the vehicle with the tailgate raised exept during unloading and then only as necessary to clear the load before lowering Stand clear when the tailgate is being raised or low ered and during the unloading cycle If it is neces sary to manally clear the debris from the hopper use a long metal probe and DO NOT stand under the tailgate Never Load the hopper above the loading sill Never allow material to extend outside of the hop per when packing Allow the packer panel control lever and carrier panel control lever to shift automatically SECTION 1 SAFETY PRECAUTIONS 31 32 37 41 42 To avoid possible bodily injury or equipment dam age lower the tailgate slowly Never enter the body unless the telescopic ejec tion cylinder pressure is released PTO disengaged and ignition key removed and placed in your pocket Do not attempt to load refuse into the hopper after the packing cycle has begun The packer panel must be in the home position and stopped before loading the hopper The dashboard speed up switch must be OFF between pickups or when parked This prevents i
74. e pushout panel Any time the carrier panel lever is shifted the engine speed up automatically engages The packing cycle may be stopped at any point by moving both oper ating levers to neutral The packer or carrier panel can be moved independently CONTAINER HANDLING CONTROL LEVERS SECTION 3 OPERATION OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the Alpha Beta Delta Series III including specific instructions for loading pack ing and unloading the unit NOTE It is inportant 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 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 move ment LR REAR MOUNT HARDWARE SPRINGS 28
75. ealer 3 Packer panel valve section pressure too low 3 Perform pressure checks as described in Sec 7 Check Out 76 SECTION 8 TROUBLESHOOTING CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON Perform pressure check as described in Sec 7 Check Out PACKER PANEL VALVE SECTION WILL NOT SHIFT POSSIBLE CAUSE REMEDY 1 Packer panel cylinder leaking Perform test for leaking cylinder See Sec 9 Ser vice and Repair 1 Carrier panel valve section pressure too low 1 2 Packer panel valve section pressure too high Perform pressure check as described in Sec 7 Check Out 3 Linkage binding or restrictive Inspect and free linkage as necessary CARRIER PANEL VALVE SECTION WILL NOT SHIFT TO NEUTRAL 1 Carrier panel cylinder leaking 1 Perform test for leaking cylinder See Sec 9 Ser 2 Carrier panel valve section pressure too high 3 Linkage binding or restrictive PACKER CARRIER PANELS DO NOT DELIVER FULL FORCE TO PACK LOAD INTO BODY Hydraulic pressure incorrect Hydraulic fluid in tank is low Tank strainer screen is dirty this condition will starve pump and cause noise in the system Wrong type of hydraulic fluid in system Main relief section of Front Control Valve opens too soon Hydraulic pump is defective and will not deliver full pressure Operating cylinder piston seal is leaking Operating valve pressures are too low Air in hydraulic lines vice and Repair Perform
76. ence dealing with information provided in any Labrie Environmental Group manual please refer to the part number of that manual The manuals provided with the unit are considered a permanent part of the unit and should be included in the event of a re sale Additional manuals are available from your local authorized Labrie Environmental Group 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 800 231 2771 We are here to be of service to you our valued customers TABLE OF CONTENTS FORWARD 5 e oe x RR nue 1 TABLE OF 2 SECTION 1 SAFETY PRECAUTIONS 3 Danger Warning and Caution Decals 3 Prior To Start Up iii 4 General 5 Hydraulics 7 Fire 2 000 0 0 000000 7 Housekeeping 3 CE ee odds 7 SOU WO ioooocccncncnnccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnns 7 Decal Locations ier itte 8 SECTION 2 INTRODUCTION Terms You Will Need To 13 A 14 14 Unloading
77. er Won t 80 Winch Motor 2 42 4422 80 Container Raises Very 2 80 Description Of Hydraulic 81 System Component Nomenclature 81 82 Packer Panel Sweeps Back Over Load 83 Carrier And Packer Panels Move Down To Interrupted Cycle PositlOh ec iet eerte deat genas 84 Packer Panel Sweeps 85 Packing Refuse eee Redde 86 Raising 87 SECTION 8 Continued Ejecting LOA 89 Retracting Pushout 90 Lowering Tailgate cocti cicer Deer 91 SECTION 9 SERVICE AND REPAIR M 92 Description Of Operating Cylinders 92 Test For Leaking Packer Panel Cylinders 93 Test For Leaking Carrier Panel Cylinders 95 Removal Of Packer Panel Cylinders 98 Removal Of Carrier Panel Cylinders 100 Disassembly Of Packer Panel Cylinders Alpha Delta Ih e 101 Disassembly Of Packer Panel Cylinders Beta 102 Disassembly Of Carrier Panel Cylinders Alpha icm 103 Disassembly Of Carrier Panel Cylinders Delta 104 Description Of Tailgate Lift Cylinders
78. f the Op erators 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 park ing brakes must be set the PTO system disengeged the engine turned off the ignition key removed and using a non reusable fas tening device place a sign on the steering wheel indicating the unit is inoperative Proper servicing requires specialized tools and pro cedures Service must be performed by authorized personnel only following procedures the 2RIII Service manual 10 11 Walk completly around the vehicle to make sure all persons and obstructions are clear before start ing the unit The container handling system is a critical compo nent of the unit Use only the proper replacement parts Inspect all hooks chains and cables daily to en sure serviceable condition Replace damaged or worn parts See Section 5 Preventive Mainte nance Before operating the vehicle the driver must be throughly familiar with the employer s safety pro gram concerning traffic rules warning devices and hand signals Be sure to know where to get assistance in the event of an emergency Know your machine Know the location and func tion of all controls gauges instruments and pro tective devices Should the height of a refuse collection vehicle be altered by installing a container handling system
79. g a particular operation or service that may be hazardous if performed incorrectly or carelessly DANGER Immediate haz ards 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 un safe practices which could result in minor personal injury or property or prod uct damage Strict compliance to these safety alerts combined with common sence 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 SECTION 1 SAFETY PRECAUTIONS 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 in jury Wear proper safety equipment as required by your employer Never operate machinery while under the influence of alcohol narcotics or other mood altering sub stances Workers who operate machinery while un der the influence are a hazard to themselves and others Perform a 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 o
80. g the cylinder Secure the cylinder to the floor or a workbench ina vertical position rod end up 3 Remove the setscrew 1 plastic plug 2 and head nut 3 Insert a long thin screwdriver under the end of the retaining ring 6 prying it out of the groove Using another screwdriver place it behind the retaining ring and work your way around the cylin der prying the ring out of the groove as you go When you are opposite the starting point hang one of the clips on the edge of the tube so that the long end of the clip is between the ring and the groove in the cylinder Continue to use the screwdrivers as pry bars and hang the remaining clips The clips CASE END should be equally spaced around the retaining ring 4 Using an appropriate lifting device raise the tube completely out of the cylinder The retaining ring 6 will come out with the tube 5 Clean inspect and replace the guide and piston rings 7 as necessary When installing new rings o the ends should be positioned on opposite sides of the tube to prevent leakage 6 After the tubes have been installed back into the case the retaining rings 6 should be installed packings 4 replaced and the head nuts 3 rein stalled 9 27 118 DESCRIPTION OF PUSHOUT PANEL Refuse is compacted against and ejected from the body by the Pushout Panel The telescopic system uses one multi stage cylinder that is attached to the pushout panel
81. gate will move the pushout panel to the rear Moving the control lever forward toward the cab will move the pushout panel to the front TAILGATE LIFT LEVER 6 The lower lever controls the tailgate Moving the lever rearward toward the tailgate will raise the tailgate Mov ing the lever forward toward the cab will lower the tail gate TAILGATE CLAMPS 7 Tailgate clamps are located on each side of the tailgate at the bottom where the tailgate rests against the body They are used to secure the tailgate to the body during operation They must be manually loosened and swung away from the body before raising the tailgate Before attempting to loosen the tailgate clamps pressure against the tailgate must be relieved by opening the packer panel to the interrupted cycle stop position TAILGATE CLAMPS 26 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 PACKER AND CARRIER PANEL OPERATIONAL LEVERS 9 10 A Packer panel lever 9 The packer panel operational control lever is lo cated on the right curb side of the tailgate It is used by the operator to position the packer panel open or closed during the compaction cycle o
82. he hydraulic system 8 3 TROUBLESHOOTING ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR SPEED UP BUTTON IS ENGAGED POSSIBLE CAUSE REMEDY 1 Short in electrical wiring 1 Repair broken wire See Sec 9 Electrical System Service and Repair 2 Blown fuse on speed up relay 2 Replace fuse and check electrical system for shorts See Sec 9 Electrical System Service and Repair 3 Relay or switch is defective 3 Checkforand replace defective parts as described in Sec 9 Electrical System Service and Repair 4 Electrical system not grounded properly 4 Check all ground connections for corrosion or breaks Clean or repair as described in Sec 9 Elec trical System Service and Repair 5 Carrier panel lever speed up switch or linkage de 5 Repair replace or adjust as required fective ENGINE SPEED WILL NOT RETURN TO NORMAL WHEN PACKING CYCLE IS COMPLETE OR SPEED UP BUTTON IS RELEASED POSSIBLE CAUSE REMEDY 1 Short circuit in electrical system 1 Check for and repair short in system as described in Sec 9 Electrical System Service and Repair 2 Carrier panel lever speed up switch is defective 2 Repair replace or adjust as required PACKER PANEL VALVE SECTION SHIFTS TOO SLOW POSSIBLE CAUSE REMEDY 1 Objectin hopper that the packer panel cannot move 1 Recycle unit Rearrange or remove refuse if nec essary 2 Cycle time too fast 2 Havechassis ECU reprogrammed by an authorized chassis d
83. he 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 en sure that a hook is positioned properly so that any slack is removed from the 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 speed up button should be depressed and held to pro vide 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 con tainer enough to see between the container and the tail gate while standing on the ground without placing your self between them When the hopper is full lower the container to the ground assure all persons are standing clear and then engage the packer mechanism See Sec 3 Operation Packing Load After the packer panel has passed the loading sill the container may be raised to again fil
84. his sec tion 4 Disconnectthe telescopic pushout cylinder from the pushout panel 5 Weld an eye to the center of the panel and attach a chain to prevent the panel from tipping over upon removal 6 The pushout panel can now be removed from the body The method of removal will depend on the equipment available Whatever method is used the equipment must be capable of lifting a minimum of 2800 Ibs 1270 kg and the panel should be se cured safely to the removal device 9 29 120 Truck Off PTO Disengaged 1 Install the pushout panel into the body of the unit 2 Install the tailgate and tailgate lift cylinders 3 Slowly extend the telescopic cylinder until the case end is beneath the crossmember of the pushout panel where the lifting eye is welded NOTE Do not allow the cylinder to become stuck or wedged while it is being extended 4 Attach a lifting device capable of supporting 750 Ibs 341 kg to the cylinder and the lifting eye welded to the crossmember 5 Raise the cylinder and slowly extend it until it can be attached to the pushout panel with the bearing clamp halves and nuts SECTION 9 SERVICE AND REPAIR INSTALLATION OF PUSHOUT PANEL OPERATIONAL STATUS 9 30 121 SECTION 9 DESCRIPTION OF CARRIER AND PACKER PANELS The carrier and packer panels operate as a single unit to sweep the refuse from the hopper and to pack it against the push
85. hy draulic 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 oc cur 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 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 suspen sion 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 restric tion or an orifice The resulting pressure decreases can be sufficient to allow trapped air to separate from the fluid 8 2 74 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 lu brication 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 Th
86. hydraulic fluid should be no more than 2 fluid ounces per minute A flow greater than 2 ounces CARRIER indicates an excessive piston seal leak If the cylin PANEL der does not leak excessively continue test LEVER OPERATIONAL STATUS Truck Off PTO Disengaged If the cylinder does not leak reconnect hydraulic lines to the rod end of cylinder and tighten to 110 Ft Lbs Repeat steps 3 5 for other cylinder OBSERVE FLUID FLOW 9 5 96 OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 6 Shift the carrier panel lever inward to retract the car rier panel cylinder Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components OPERATIONAL STATUS Truck Off PTO Disengaged 7 Disconnect and plug the hydraulic lines which con nect to the case end of the carrier panel cylinder OPERATIONAL STATUS 8 Shift the carrier panel lever inward to apply hydraulic pressure to the rod end of the carrier panel cylin ders Hold the lever and observe the fluid flow from the open 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 Disas semble the cylinder and replace the piston seal OPERATIONAL STATUS Truck Off PTO Disengaged 9 Ifthe cylinder does not leak reconnect the hydrau lic lines to the case end of the ca
87. ing should be done in a well venti lated area 4 44 When working on the unit always use the service tools listed in Section 10 SERVICE TOOLS if so directed by the instructions in Section 9 SERVICE AND REPAIR Whenever dismantling any hydraulic line valve or cylinder be sure to turn off the hydraulic fluid flow relieve the pressure and slowly crack or loosen the fittings When it becomes necessary to raise the tailgate for maintenance or repair do not enter the area beneath the tailgate unless the proper bracing has first been applied All bracing and supports must be able to support 8 000 Ibs 3629 kg Never enter the body when the load is under com paction pressure Bring the packer panel to the in terrupted cycle stop position and retract the pushout panel slightly The radiation given off by the arc will destroy the retina of the eye Wear an approved welder s hel met Welding radiation will produce severe burns on un protected skin similar to sunburn so wear heavy clothing Use natural fiber or leather avoid syn thetic fiber clothing SECTION 4 GENERAL REPAIR PRACTICES OXY ACETYLENE TORCHES 1 REMOVAL DISASSEMBLY AND REPAIR 1 Acetylene is a highly explosive gas which should be treated with the greatest care At pressures above 15 psi acetylene will explode by decompo sition without the presence of air No other indus trial gas has such a wide explosive range Oxygen will spon
88. is recirculates the fluid air and al lows for the separation of even more air In cases where the seals in cylinders appear to be burnt or melted consider the possibility of air ingestion The following suggestions may help in eliminating this prob lem 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 sys tem Replace if the seal is suspect 3 Check for air ingestion around the packings on the ball valve stem Replace the ball valve if suspect 4 Excessive system flow rate cycle time too fast can agitate the hydraulic fluid Set the cycle time ac cording to specifications 5 Do not thin hydraulic fluid with diesel fuel lowers the flash point Weather permitting use a higher flash point fluid After making any repairs on the hydraulic system bleed the system at reduced engine speed and pressure to remove any trapped air Depending on the size of the component e g cylinder hose it may be necessary to cycle the unit several times Of course the larger the air pocket the more cycles are needed To avoid potential problems thoroughly bleed all hydraulic systems and ensure that all inlet connections are tight and not in gesting air TROUBLESHOOTING OPERATION IS ERRATIC POSSIBLE CAUSE REMEDY Speed up system operating erratically Check electrical system See Sec
89. iscard Using a long screwdriver or pick remove the re taining ring from the inside of the cylinder between the case and the rod Use care to avoid damage to the case or rod surfaces Slide the retaining ring off of the rod and discard Slide the rod assembly out of the case der rod and discard Remove the wiper from the head gland cylinder is not to be installed immediately keep the port sealed to prevent contamination 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 the bleeder port In stall the bleeder screw Fully extend and retract the cylinder twice clamp the tailgate in the down position and once again remove the bleeder screw Operate the control le ver After all air has exited the cylinder install the bleeder screw Check for any external leaks on the cylinder and connecting fittings PORT 9 16 SECTION 9 SERVICE AND REPAIR DESCRIPTION OF THE TAILGATE ASSEMBLY The tailgate assembly consists of the operating cylin ders carrier and packer panels and the hopper where refuse is first loaded into the unit The tailgate is lifted for unloading and lowered by the tailgate lift cylinders which are actuated by the tailgate lift lever located at the front of the body The need to remove the tailgate is rare and limited to repair of the hopper area remov
90. ker panel lever and carrier panel lever Using a stopwatch time a complete cycle Acomplete cycle should take Alpha 26 to 28 seconds Beta 29 to 31 seconds Delta 23 to 26 seconds IF NOT 2 The engine ECU Electronic Control Unit may have to be programmed by an authorized chassis dealer NOTE It is important the cycle time is correct before perform ing the following pressure checks LEVER CARRIER LEVER CHECK PRESSURES The pressure checks provided below will indicate the operating condition of the hydraulic system Detailed adjustment procedures are provided later in this sec H tion and are referenced at the appropriate check out procedure Prior to performing pressure checks OPERATIONAL STATUS Truck Off PTO Disengaged 1 Install a gauge capable of reading at least 3000 PSI 207 BAR on the test coupling 2 Start the unit engage PTO PUMP and turn speed up switch on TEST COUPLING 65 7 3 SECTION 7 CHECK OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Make sure the area above the tailgate is clear be fore raising the tailgate 1 Release the tailgate clamps SPEED UP BUTTON TAILGATE LIFT 2 Depress speed up button LEVER 3 Move tailgate control lever to fully raise the tailgate ES 4 Hold lever and read gauge Pressu
91. l Control Levers 25 Compaction Cycle Operation 25 Container Handling Control Levers 25 Operating Procedures ences 26 Pre Operating Walk Around Inspection 26 Walk Around Inspection Check List 30 Start Up Operating Instructions 31 Positioning the Pushout 32 Loading the 33 SECTION 3 OPERATION continued Attaching a Container to The 33 Using a Winch or Container Lift Cylinder 34 Using a Container Push 35 Packing The Load arsino 35 Pushout Panel Operation During Packing 36 Disconnecting The 36 Unloading At 37 Lifting The Tailgate sicrie ennie 37 Ejecting 0 38 Lowering The Tailgate eonim emen 38 Shut 39 SECTION 4 GENERAL REPAIR PRACTICES Preparation For 43 Replacement 43 Technical Service 43 Safety Pre
92. l the hopper Repeat this process until the container is empty ATTACH CONAINER LOWER TO CHECK CONTENTS CORRECT 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 con siderations LOWER TO GROUND 36 SECTION 3 OPERATION USING A CONTAINER PUSH BAR CPB Once the container is secured within the latch assem bly the container is ready to be dumped After assuring that all persons are standing clear the operator moves the CPB control lever in the direction shown on the in struction 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 con tainer enough to see between the container and the tail gate while standing on the ground without placing your self between them PACKING THE LOAD NOTE The compaction cycle can be stopped at any time by moving both the packer panel lever and the carrier panel lever to the center neutral 1 Cycle the packer panel and the carrier panel by mov ing both
93. lever to raise the tailgate and hold 3 Visual inspection of the tailgate cylinders is the only leakage test necessary 105 9 14 SECTION 9 SERVICE AND REPAIR REMOVAL OF TAILGATE LIFT CYL INDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 With the tailgate closed attach a sling connected to a suitable lifting device with a capacity of 500 Ibs 227 kg to the tailgate lift cylinder NOTE See Sec 4 GENERAL REPAIR PRACTICES for more detailed information about the correct use of slings and lifting chains 2 Disconnect the hydraulic line 1 at the cylinder port in the case end and cap the line 3 Remove the capscrew 2 washer and cover from the cylinder case end 4 Remove capscrew 3 lockwasher retainer and pin from the rod end DISASSEMBLY OF TAILGATE LIFT CYLINDER 1 Wash the outside of the cylinder assembly com pletely to prevent contamination and or damage to the cylinder components Secure the case end of the cylinder to a workbench or floor mount and the rod end to an overhead lift ing device with a minimum lifting capacity of 500 Ibs 227 kg Remove the plug from the port and drain all fluid Remove the 1 4 socket head setscrew from the side of the cylinder case and discard Remove the bleeder screw and gasket from the end of the cylinder rod Save these for reassembly Unscrew the head gland from the cylinder case completely Slide the head gland off of the rod
94. line element Inspect the mounting hardware The springs should be compressed to 3 1 2 inches 1 8 inch The mounting bolts should be torqued to 700 ft Ibs and inspected daily 2 CLEANING Hose the entire unit inside and out with clean water Make sure no refuse is lodged in the body trough or behind the pushout panel especially near the telescopic pushout cylinder area or rear of the tank 3 LUBRICATION Frequent inspection of grease points will indicate when lubrication is needed LATCHES 6 8 60 4 CONTAINER HANDLING EQUIPMENT In addition to performing the daily vehicle and packer body pre operation inspection also check the container handling system Each day perform the following inspec tion 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 Avisual inspection of the wire rope cable should identify any broken wires or obvious damage A vi sual inspection of the chains should identify any damage 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 sys tem The lifting mechanism should move smoothly with no jerkiness or binding SECTION 6 PREVENTIVE MAINTENANCE WEEKLY PREVENTIVE MAINTENANCE 1 CLEANING Clean an
95. ly 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 ob servance of all known safe operating practices are the best ways to prevent accidents Before operating the unit it is the operator s responsi bility to be thoroughly familiar with the instructions con tained in the Operator s Manual 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 au thority at once 3 Replacement decals can be ordered free of charge from your local authorized Leach distributor DANGER WARNING AND CAUTION SECTION 1 SAFETY PRECAUTIONS Publication of these precautions does not imply or in any way represent an all inclusive list It is the opera tors responsibility to be familiar with and ensure that operation is in accordance with safety requirements and codes including all applicable Occupational Safety amp Health Act OSHA and American National Standards Institute ANSI regulations DANGER AWARNING A 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 concernin
96. nadvertent engine speed up if the tailgate carrier panel control lever is shifted The tailgate clamps must be tightened securely before starting to load Do not step on the throttle pedal while the speed up system is engaged Never use a rear loader to transport a container Follow all safety directions listed in the refuse body Operator and Service manual under SAFETY PRE CAUTIONS Never use container handling chains or cable for towing or pulling When not handling containers keep the container attachment closed or latched Do not operate the rear loader s packing mecha nism with a container off the ground If it is necessary to manually free debris from the container use a long metal probe while the con tainer is on the ground and DO NOT place your self between the container and the packer body Attach hook to the tailgate and take up the excess slack when not in use Never hold the hook on an attachment point while taking up slack Take up excess cable slack before moving the ve hicle Check overhead clearance before dumping a con tainer 4T 49 51 52 57 59 61 62 Do not move the vehicle with a container attached Always set the vehicle parking brake brfore attach ing or lift a container Never lift a container which is non compatible with the Leach container attachment Never lifta container without first latching both con
97. nction of the speed up system is to speed up the engine and provide more power to the hydraulic pump during operation of the various hydraulic cylinders TAILGATE OPEN LIGHT 3 This warning light located in the cab will illuminate if the tailgate is ajar Having the tailgate ajar will also sound the backup alarm and illuminate the backup lights Operation of the unit with an illuminated or defec tive warning system can result in personal injury and or equipment damage 25 SECTION 3 OPERATION ENGINE SPEED UP SYSTEM OFF ON SECTION 3 OPERATION ENGINE SPEED UP PUSH BUTTON 4 When depressed this push button switch will cause the engine to speed ip and supply more power to the hy draulic system Located on the lower front left side of the body it is depressed by yhe operator when operat ing either the pushout lever or tailgate lift lever NOTE Additional speed up control buttons may be installed with optional winches and container handling attachments FRONT CONTROL VALVE The front control valve is located behind the access door on the front left 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 ENGINE SPEED UP LIFT PUSHOUT LEVER 5 BUTTON LEVER The upper lever controls the movement of the pushout panel Moving the control lever rearward toward the tail
98. ned before disassembly 2 Secure the case end of the cylinder to the floor or workbench 3 Secure the rod end of the cylinder to an overhead hoist device with a minimum lifting capacity of 500 Ibs 227 kg REASSEMBLY AND INSTALLATION Reassemble and install the cylinder in the approximate 4 Remove the setscrew from the gland retainer reverse order of disassembly 5 Remove the gland retainer NOTE If the cylinder is not to be installed immediately keep the ports sealed to prevent contamination from enter ing the cylinder 6 Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder ZERK PISTON SEALS ROD WIPERS sa NS ZERK SEALS O RINGS BUSHING GLAND RETAINER GLAND PISTON 103 9 12 SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF CARRIER PANEL CYLINDERS DELTA 1 Remove grease fitting clean parts drain fluid and follow all other applicable guidelines for disassem bly provided in Sec 4 GENERAL REPAIR PRAC TICES 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 Ibs 227 kg 4 Remove the set screw that retains the gland 5 Remove the gland 6 Slowly operate the lifting device to carefully pull the piston rod assembly out of the cylinder ROD WIPERS SEALS O RI
99. o identical samples should be taken One for labora tory analysis and one for your own preliminary analysis while you are waiting for the lab report We recommend the use of commercial laboratory ser vices for analysis of routine fluid samples taken on a regularly scheduled basis The most important analy sis are particle count Spectro chemical analysis water content and viscosity IN HOUSE HYDRAULIC FLUID TEST ING After your sample has been allowed to stand for 20 to 30 minutes to eliminate air bubbles hold the bottle up to the light to check whether the fluid is clear or cloudy Any visible debris is an indication of a severe solid con tamination problem the source of which must be lo cated and corrected immediately Common sources of this kind of contamination may be component wear undersealed reservoir covers or dirty air breather fil ters If the sample is the least bit cloudy it is an indication 59 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
100. om these procedures could cause damage to the unit or ren der it unsafe However please remember that these procedures are not all inclusive labrieplus SERVICE PARTS SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR 1 2 SAFETY DURING SERVICE AND REPAIR 1 5 2 Set the parking brake Put the vehical in park or if equipped with a manual transmission put the unit in gear and remove the ignition key Place an OSHA approved chock block in front and behind the front tire If steel supports are to be used to support the tail gate place them as shown in Section 9 SERVICE AND REPAIR under TAILGATE REPAIR Always wear safety glasses Disengage the PTO turn off the ignition and re move 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 Always check to make sure the body access door is locked shut before entering the cab Pump removal due to the weight and location of the pump it is advisable to place a floor jack be neath 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 manufac turers specifications 3 All electric weld
101. orm test for leaking cylinder and repair 2 Resistance setting too low 2 Adjust resistance cartridge See Sec 7 Check Out PUSHOUT PANEL WILL NOT SLIDE FORWARD AUTOMATICALLY POSSIBLE CAUSE REMEDY 1 Resistance setting too high 1 Reduce resistance setting 2 Packer carrier panels not applying full force to move 2a Check pressures pushout panel forward 2b Check pump CARRIER AND PACKER PANELS STOP SHORT OF HOME POSITION AFTER EACH CYCLE POSSIBLE CAUSE REMEDY 1 Unit full 1 Emptyunit 2 Resistance setting too high 2 Reduceresistance setting 3 Packer carrier panels do not deliver full force 3 See Sec 8 Troubleshooting SECTION 8 TROUBLESHOOTING PACKER PANEL DRIFTS OPEN WHILE PACKING LOAD INTO BODY POSSIBLE CAUSE REMEDY 1 Packer panel cylinder seal leaking 2 Packer panel valve section pressure too low Perform test for leaking cylinder See Sec 9 Ser vice and Repair Perform pressure test as described in Sec 7 Check Out CYCLE TIME TOO SLOW Engine RPM too low Hydraulic fluid level too low Hydraulic fluid filter needs servicing Hydraulic tank breather dirty Hydraulic pump worn or defective Operating cylinder piston seals leaking Incorrect grade of hydraulic fluid for current operat ing conditions Wiring defective AILGATE WILL NOT RAISE POSSIBLE CAUSE REMEDY Tailgate clamps still engaged Insufficient hydraulic pressure Hydraulic pump is defe
102. ot to be misconstrued as operat ing 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 Series III It is impor tant that you know the location and function of each control before attempting to operate the unit Refer to the accompanying illustrations for their location 23 AE E Ba 9 y 49 BN MA 4 sa ASA SU A K SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS PUMP PTO CONTROL 1 The Pump PTO Power Take Off is engaged to put the hydraulics in operation The exact location of the Pump PTO control will vary depending on the type truck chas sis style and control panel location The Pump PTO may be engaged by use of a lever rocker switch push pull cable toggle switch or positive control button depending on the style Be sure to read all safety decals associ ated with the Pump PTO before attempting operation ENGINE SPEED UP ON OFF SWITCH 2 This switch energizes the engine speed up system It is located on the cab control panel exact location depen dent on cab make and style NOTE The engine speed up system consists of the ON OFF switch a relay the relay is wired to the engine ECU a speed up push button and speed up switch connected to the operating control linkage on the Main Control Valve MCV The fu
103. out panel Their movement through the different cycles is controlled by the operating cylinders The two panels are connected together by pins Move ment of the panels within the body is kept in alignment by the roller assemblies located at the upper and lower corners of the carrier panel The rollers ride inside a roller track on each side of the hopper PACKER PANEL 9 31 122 SERVICE AND REPAIR This section focuses on some factors that need to be taken into consideration when performing packer car rier repairs The packer carrier assemblies and interre lated components are designed for relatively trouble free use however they are subject to reduced service life due to the lack of or ineffective maintenance Methods of operation other than for which the unit was designed can also affect the longevity of these components CARRIER PANEL CYLINDERS PACKER PANEL CYLINDERS SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 IF THE CARRIER PANEL IS ALSO TO RE MOVED remove all four operating cylinders as described earlier in this section and proceed to step 5 or Q OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 2 IF THE CARRIER PANEL IS NOT TO BE RE MOVED Move the packer panel operating lever in ward to bring the packer panel up When the panel reaches a vertical position bring the packer panel control lever b
104. peration NOTE The engine speed up system does not engage if only the packer panel lever is shifted The carrier panel lever must also be shifted to engage the engine speed up system B Carrier panel lever 10 The carrier panel operational control lever is lo cated on the right curb side of the tailgate It is used by the operator to position the carrier panel up or down during the compaction cycle NOTE The engine speed up system automatically engages any time the carrier panel lever is shifted CONTAINER HANDLING CONTROL LEVERS 11 12 These control levers are provided when container han dling attachments drum winch reeving cylinder or con tainer push bar are added to the unit They are used to raise and lower the container causing the refuse to be deposited in the hopper for compaction The levers are located on the right curb side of the tailgate directly above the packer and carrier panel control levers Arefuse vehicle may have none one or two control levers de pending on the configuration of the unit 27 SECTION 3 OPERATION eo OJ DRIVER SIGNAL PUSH BUTTONS CARRIER PANEL LEVER PACKER PANEL 7 LEVER COMPACTION CYCLE OPERATION Both the packer panel lever and the carrier panel lever are shifted simultaneously inward to open the packer panel and lower the carrier panel to the interrupted cycle position Both levers are shifted outward to sweep the load from the hopper and pack it against th
105. pool collar to 10 ft Ibs 13 6 Nm Torque the bonnet and handle bracket capscrews to 10 ft Ibs 13 6 Nm Replace work sections and covers with the tie bolts in the same order in which they were removed NOTE Use care in replacing the work section to avoid dislodg ing o rings from the counterbores 111 RETAINER PLATE RESISTANCE CARTRIDGE MAIN RELIEF TIE BOLT 9 5 A 8 A A 75 SPOOL COLLAR BONNET CAPSCREW 9 20 SECTION 9 SERVICE AND REPAIR 6 Torque tie bolts to 32 ft 165 43 Nm RESISTANCE CARTRIDGE If tie bolts are not tightened to the proper torque valve spools may bind or stick or cause section seals to extrude 7 Torque value of the resistance main relief cartridge will be 20 ft Ibs 27 2 Nm MAIN RELIEF REINSTALLATION OF FRONT CON TROL VALVE 1 Secure the valve to the mounting bracket with the appropriate hardware FRONT CONTROL 2 Remove plugs and caps then attach hydraulic lines VALVE with new ORFS o rings Torque all hydraulic lines SS per torque chart as described in Sec 4 GENERAL REPAIR PRACTICES Do 0 e 0 9 21 112 SERVICE AND REPAIR MAIN CONTROL VALVE MCV X CIR LAS NY NE 3 D Z 22 LB t J 9 I E SS 7 5950458 cw nN oe 05529 ou cea VANES C
106. port any problems to proper personnel 32 SECTION 3 OPERATION START UP OPERATING INSTRUCTIONS On 1 Inspect and start the truck as described in the pre operational walk around inspection 2 Engage the Pump PTO control to start the hydraulic pump 3 Place the engine speed up switch in the ON position SPEED UP SYSTEM OFF 33 SECTION 3 OPERATION POSITIONING THE 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 TAILGATE CLAMPS 2 Depress and hold the speed up push button 3 Push the pushout lever rearward until the pushout cylinder is fully extended PUSHOUT LEVER ENGINE SPEED UP BUTTON 34 LOADING THE HOPPER SECTION 3 OPERATION There are only a few but important points to remember during loading of refuse 1 Load the hopper evenly on both sides 2 Load heavy objects in the center of the hop per 3 Do not load refuse higher than the loading edge AWARNING LAW Always follow proper loading procedures ATTACHING A CONTAINER TO THE PACKER Place the container on a flat level surface For large non moveabl
107. pressure check as described in Sec 7 Check Out Inspect and free linkage as necessary Perform pressure check as described in Sec 7 Check Out Add fluid to correct level See Sec 6 Preventive Maintenance Service system as described in Sec 6 Preventive Maintenance Drain and refill with correct type of hydraulic fluid See Sec 5 Specifications Adjust main relief setting on Front Control Valve See Sec 7 Check Out Replace pump See Sec 9 Service and Repair Perform test for leaking cylinder See Sec 9 Ser vice and Repair Perform pressure check as described in Sec 7 Check Out Cycle packer 6 or 7 times to bleed air out of sys tem SECTION 8 TROUBLESHOOTING TELESCOPIC PUSHOUT SYSTEM LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING TELE SCOPIC CYLINDER POSSIBLE CAUSE REMEDY 1 Excessive fluid flow being forced through the main 1a Release speed up button relief in the Front Control Valve 1b Only partially pull feather the Front Control Valve control handle LOAD WILL NOT PUSH OUT 1 Less than full pressure in telescopic cylinder 1a Perform test for leaking cylinder and repair 1b Adjust main relief pressure See Sec 7 Check Out 2 The operator is trying to push the load out against 2 Move the unit forward to finish unloading a pile of refuse dirt or bank of a hill PUSHOUT PANEL SLIDES FORWARD TOO FAST WHILE PACKING REFUSE POSSIBLE CAUSE REMEDY 1 Cylinder bypassing 1 Perf
108. r 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 re duced Replace the filter element regardless of elapsed time if the suction indicator is in the red zone 57 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 Extended operation of the unit without proper fil tration will result in reduced service life of hydrau lic system components FLUSHING HYDRAULIC SYSTEM CLEAN ING HYDRAULIC STRAINER YEARLY 1 Drain all fluid from the hydraulic tank into a suitable container Dispose of it properly 2 Unscrew and remove strainer 7 3 Clean strainer thoroughly in a suitable cleaning sol vent 4 Wipe off the magnetic ring 8 and wipe out the bottom of the tank 5 Reinstall the strainer 7 6 Fill the hydraulic tank with fresh fluid as specified in sec 5 SPECIFICATIONS according to operat ing and weather conditions 7 S
109. r panel cylinders Hold the lever and observe the fluid flow from the open port on the rod 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 If the cylinder does not leak excessively continue test OPERATIONAL STATUS Truck Off PTO Disengaged 5 Reconnect the hydraulic lines to the end of cylin der and tighten to 110 Ft Lbs Repeat steps 3 5 for the other cylinder OPERATIONAL STATUS 6 Shift the packer panel lever inward to retract the packer panel cylinder to the interrupted cycle position OPERATIONAL STATUS Truck Off PTO Disengaged 7 Disconnect and plug the hydraulic lines which con nect to the case end of a packer panel cylinder Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement of components 9 3 94 PACKER PANEL LEVER OBSERVE FLUID FLOW SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On PACKER 8 Shift the packer panel lever inward to apply hydraulic PANEL pressure to the rod end of the packer panel cylin LEVER der 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 Disas
110. re should be d M LX oe Alpha 2150 2200 PSI 148 152 BAR Beta 2300 2400 PSI 157 165 BAR ALPHA BETA DELTA Delta 2300 2350 PSI 157 162 BAR IF NOT 5 If the pressure is below the appropriate setting loosen the lock nut on the relief cartridge and turn the adjusting screw in rotate clockwise to reach the correct pressure If the pressure is above the appropriate setting loosen the lock nut on the re lief cartridge and turn the adjusting screw out ro tate counter clockwise to reach the correct pres sure After readjusting retighten the lock nut Re peat steps 1 through 4 TAILGATE RAISED MAIN RELIEF CARTRIDGE CHECK PACKER AND CARRIER PANEL SHIFT KNOCKOUT PRES SURES OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On 1 Install a 0 3000 PSI 0 207 BAR pressure gauge at the quick disconnect coupler on the front control valve Check the main relief pressure as described in Section 7 Check Out of this manual 2 Reduce main relief setting to below 1000 PSI 69 BAR OPERATIONAL STATUS Truck Off PTO Disengaged Using a screwdriver remove the button plugs from the end of the Main Control Valve packer and car rier sections Shift the packer and carrier linkage to the detented position and release leaving the valve spools in the detented position
111. rking DRIVER SIGNAL PUSH BUTTONS BOTH SIDES OF TAILGATE 13 Back the unit up a few feet to ensure that the back up alarm is working properly 14 Loosen the tailgate clamps and swing out Raise the tailgate approximately 6 and check to see if the tailgate ajar light on the dash is on and if the backup alarm is audible Do not have the unit in reverse 31 SECTION 3 OPERATION CARRIER PANEL LEVER PACKER M c LEVER TAILGATE CLAMPS SECTION 3 OPERATION Do not operate a unit that is in need of service or repair 15 Report any problems found during the pre operation walk around inspection to the maintenance supervi sor 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 hardwarew 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 in structions 9 Alloperating 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 Re
112. rrier panel and tighten to 110 Ft Lbs 97 SECTION 9 SERVICE AND REPAIR CARRIER PANEL CARRIER PANEL LEVER OBSERVE FLUID FLOW 9 6 SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top sheet to provide better accessibility to the packer panel 2 Secure anylon sling around the cylinder as shown and attach to a suitable lifting device with a capacity of 500 Ibs 227 kg Operate the hoist to make the lifting cable snug without applying strain on the cyl inder OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Shift the packer panel lever inward to partially re tract the packer panel cylinders Disengage the le ver when the panel is vertical This relieves the weight of the panel from the cylinder rod end OPERATIONAL STATUS Truck Off PTO Disengaged 4 Remove the capscrews 1 from the pivot pin 5 sure cylinder weight is securely supported by the hoist and carefully remove the pivot pin 2 9 7 98 PACKER PANEL M CYLINDERS it ee ee Pe mo ANE TD SS 8 IN d HET B o i
113. s induced to the lower channel of the carrier panel The carrier panel lower channel is designed for compression or tension not shear loads If the lower channel on the carrier panel cracks suspect that the unit is being skimmed REMOVAL OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove top sheet supports for better accessibility 2 Remove the packer panel as previously described 3 Remove the operating cylinders as previously de scribed 4 Remove the tubing to the Main Control Valve MCV Cap the lines and plug the ports in the valve to pre vent contamination 5 Remove the carrier panel 9 35 126 Short cycling is when the carrier panel is stopped be fore it completely lowers The operator then attempts to penetrate down through the refuse that is in the hopper with the packer panel This incorrect method of opera tion results in much the same kind of failures as skim ming because the lower carrier channel is put into a shear situation This incorrect method of operation will also adversely affect the hopper bottom because the force of the packer panel cylinders is being dissipated down through the refuse and into the hopper structure Anytime a repaired area has a repeat failure suspect that the core problem whether it is mechanical or op erator has not been adequately addressed REMOVE TOP SHEETS CARRIER PANEL 127 SECTION 9 9 36 SECTION 9 SERVICE AND
114. semble the cylinder and replace the piston seal as described OBSERVE later in this section FLUID FLOW OPERATIONAL STATUS Truck Off PTO Disengaged 9 Ifthe cylinder does not leak reconnect the hydrau lic lines to the cylinder and tighten to 110 Ft Lbs Repeat steps 7 9 for the other cylinder TEST FOR LEAKING CARRIER PANEL CYLINDERS dis i CARRIER PANEL testing any cylinder make sure e main line CYLINDERS pressure is correct as described under MAIN LINE PRESSURE CHECK Sec 7 CHECK OUT PROCE DURES OPERATIONAL STATUS Truck Off PTO Disengaged 1 Remove the top covers over the operating cylin ders for better accessibility during testing 95 9 4 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On CARRIER 2 Shift the carrier panel lever outward to fully extend PANEL the carrier panel cylinders home position LEVER OPERATIONAL STATUS Truck Off PTO Disengaged 3 Disconnect and plug the lines that connect to the rod end of one cylinder PLUG ACAUTION Loosen the hydraulic fittings slowly to release any trapped pressure Watch for inadvertent movement Truck Running PTO Engaged Speed Up On 4 Shift the carrier panel lever outward to apply hydrau of components lic 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
115. stment COMPACTION Before troubleshooting a unit it is important to remem ber that the compaction may vary with the following conditions 1 of refuse Tree branches dry leaves furni ture and any other items loaded into the body that take up relatively large amounts of space will re duce 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 ratio 3 Operation of 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 are learned skills that will affect the compaction ratio of a unit 73 SECTION 8 TROUBLESHOOTING Hydraulic flow diagrams are provided in this section These diagrams can be helpful in determining which parts are associated with a particular function Problems in the hydraulic system may be found by per forming the PRESSURE CHECKS found in Sec 7 CHECK OUT PROCEDURES 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 condi tion of the operating cylinder seals will all have an effect on unit performance and compaction
116. taneously ignite in the presence of oil and grease The hoses torch handles and regulators must be kept free of petroleum products Before using the equipment inspect it for cleanli ness and for leaks Hoses cannot be safely repaired when they show signs of deterioration they should be replaced Return regulators periodically to the distributor for inspection Store gas bottles upright and out of the sun Do not attempt to repair or make internal ad justments on the regulators yourself Cleanliness is very important dirt is the number one cause of wear in bearings bushings and espe cially in hydraulic components Inspect hydraulic components for leaks before cleaning The dirt buildup on the component can aid in tracing fluid leaks Clean hydraulic connections before removal to pre vent dirt from entering the component Loosen hydraulic fittings slowly to release pressure Cap hydraulic fittings immediately after removal to prevent fluid from leaking Clean the component in non flammable solvent before disassembly Inspect the component after cleaning for signs of wear or external damage 45 10 8 10 11 12 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 COM BINING WITH IT AND EXPLODING When preparing to use the torch make certain that the regulator valves are all the wa
117. tart the unit and operate all hydraulic levers as described in Sec 3 OPERATION Leave all hy draulic cylinders in the retracted position and shut down unit 8 Recheck the fluid level and add fluid as necessary to bring level to the NORMAL FILL LEVEL on the sight gauge 6 5 58 SECTION 6 PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM SERVICE CONTAMINATION It is estimated that as much as 90 of all hydraulic problems may be traced directly to the fluid It is of ut most importance that all foreign matter be kept from the hydraulic fluid Invisible quantities of abrasive type contamination may cause serious pump wear malfunc tioning of pumps and valves and sludge accumulations within the system in relatively short periods of time It is also essential that moisture and water be kept from the hydraulic fluids and system COMMERCIAL HYDRAULIC FLUID TESTING Hydraulic fluid samples should be taken periodically for laboratory analysis The actual sampling method is criti cal 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 reser voir when the fluid is at operating temperature and placed in a clean dry glass bottle with a nonshedding screw on cap The bottle should be labeled with the date type of fluid model and serial number of the machine Tw
118. 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 VISCONSITY aeterne AGMA NO Gravity API Flash Degree Pour Point Viscosity SSU 100 Degrees SSU 210 Degrees cSt 40 Degrees C cSt 100 Degrees C Viscosity Index ASTM Oxidation Test Hours to 2 0 Neut No ASTM Rust Test A amp B Foam Test Vickers Vane Pump Test Dielectric Strength ASTM 877 180 Degrees F Do not use engine oil automatic transmission fluid ATF or add diesel A CAUTION fuel or kerosene to the hydraulic fluid Service life of all hydraulic system components may be adversely affected HYDRAULIC FLUID To serve its purpose and give long and satisfactory service hydraulic fluid must possess desirable physical and chemical characteristics Stability over a wide range of temperatures and under agitation is very important Premium hydraulic fluids should be used in Leach hydraulic systems In addition to the above characteristics selected additives should be incorporated to provide additional resistance to wear corrosion oxidation decom position and foaming All additive blending should be done by the lubricant supplier so that they are compatible with each o
119. the packer panel lever and the carrier panel lever inward toward the tailgate then let go The packer panel will open and the packer panel lever will automati cally shift to neutral The carrier panel will then move down to above the loding edge stop in the interrupted cycle position and the carrier panel lever will automati cally shift to neutral 2 To finish the cycle move both the packer panel lever and the carrier panel lever outward away from the tail gate then let go The packer panel will sweep the hop per and the packer panel lever will automatically shift to neutral The carrier panel will then move up into the body and stop in the home position and the carrier panel lever will automatically shift to neutral Stand clear of the hopper area during the packing cycle 3 Repeat steps 1 and 2 each time the hopper is filled to but not above the loading edge 37 CONTAINER CONTROL LEVER Releasing the CPB control handle when the container begins to tip will allow the container trunnion bar to lower within the latch slots with ease CARRIER PANEL LEVER PANEL 7 LEVER CARRIER PANEL LEVER N PACKER PANEL LEVER SECTION 3 OPERATION PUSHOUT PANEL OPERATION DURING PACKING TELESCOPIC PUSH OUT Alpha Series III telescopic pushout cylinder will nor PUSHOUT LEVER mally move toward the front of the body automatically When the resistance circuit is adjusted to pro
120. ther 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 5 2 52 SECTION 6 PREVENTIVE MAINTENANCE GENERAL The Alpha Beta Delta Series Ill have been designed for long periods of efficient uninterrupted operation Care ful attention to proper preventive maintenance as de scribed 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 preven tive maintenance required The objective of preventive maintenance is to anticipate and prevent operational difficulties before they require extended shut down for costly repairs OPERATING AND MAINTENANCE RECORDS Prepare and adhere to a maintenance schedule Keep detailed records of all maintenance performed Regu larly inspect operating and maintenance records for de viations from normal operating conditions Analyze the records for indications of potential trouble NOTE Occasionally distributors 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 53 SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART INSTRUCTI
121. tion Check handles for looseness Replace any defective or worn part Follow all safety precautions pertaining to welding described in Sec 1 SAFETY See Sec 4 GENERAL REPAIR PRACTICES for information pertaining to welding repairs REASSEMBLY AND INSTALLATION OF TAILGATE Reassemble and install the tailgate in the approximate reverse order of disassembly and removal 109 SECTION 9 SERVICE AND REPAIR 9 18 SECTION 9 SERVICE AND REPAIR FRONT CONTROL VALVE The Front Control Valve FVC is located behind the access door in the front left hand side of the body It is manually activated and controls the raising and lower ing of the tailgate and the operation of the pushout panel This valve also contains the main pressure relief for the hydraulic system REMOVAL OF THE FRONT CON TROL VALVE OPERATIONAL STATUS Truck Off PTO Disengaged 1 Disconnect the hydraulic lines to the valve Cap the lines and plug the valve ports to prevent dirt from entering the valve and the hydraulic system 2 Remove the capscrews lockwashers nuts and re move the valve DISASSEMBLY AND INSPECTION OF FRONT CONTROL VALVE 1 Wash the valve body with solvent to prevent con tamination 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 four 4
122. u 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 acci dent prevention 1 Keep handrails and steps clean and free of grease or debris 2 Donotstore brooms or other equipment where they could inadvertently activate the packer controls SHUTDOWN 1 Putall 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 3 3 SECTION 1 SAFETY PRECAUTIONS In case of injury seek proper medical treatment im mediately Rubbish scrap paper and litter are highly combus tible Such material should be stored in metal con tainers entirely clear of sparks and flames SECTION 1 PACKER PACKER PACKER CARRIER CARRIER CARRIER SPEED UP Both container latch arms must be in place and latched before raising container A WARNINGEZ A DANGER l lt Stand clear when container dumping mechanism is in motion SECTION 1 SAFETY PRECAUTIONS DECAL PLACEMENT 5 O 12 000 LB CAPACITY S
123. with packer and carrier panels in the home position OPERATOR ACTION Operator starts the truck and engages the PTO Pump and speed up system ENGINE SPEED UP SYSTEM OFF ON HYDRAULIC SEQUENCE Hydraulic fluid flows from the tank by gravity to the pump from there it is pumped to the FCV Front Con trol Valve Flow continues through the valve to and through the MCV Main Control Valve and then back to the tank During packer operation if pressure increases to the main relief setting excess flow will be diverted m PRESSURE from the front control valve back to tank e eee RETURN TAILGATE LIFT CYLINDER FRONT CONTRO VALVE SN V AS E RES RR coo lt gt Q JE PUSHOUT CYLINDER CYLINDER TAILGATE LIFT CYLINDER CYLINDE 8 10 m SECTION 8 TROUBLESHOOTING TELESCOPIC SYSTEM PACKER PANEL SWEEPS BACK OVER LOAD OPERATOR ACTION The operator moves the control levers inward to start the compaction cycle ox HYDRAULIC SEQUENCE Operator action causes the MCV Main Control Valve to shift diverting flow to the rod end of the packer panel cylinders The packer panel cylinders retract causing the packer panel to sweep rearward over the load Re turn fluid flow from the cylinder is back to tank PRESSURE eee o RETURN TAILGATE LIFT AW 2 ES a SN ce if e Wis SN DN gu FRONT CONTRO CARRIE
124. y out to the off position before the main tank valves are opened to protect the regulators from sudden inpact of tank pressure When opening the tank valves stand alongside of the regulators out of the way in case they blow out Backfiring or machine gunning at the torch is very dangerous and can lead to a major explosion Welding should be done in a location well away from flammable materials When disassembling a component note the posi tion of each part as it is removed to aid in reassem bly During disassembly note the condition of each part as it is removed to aid in diagnosing problems and to help prevent them in the future Clean and inspect disassembled parts for wear cracks dirt etc After cleaning and inspection reusable hydraulic parts should be immediately coated with clean fresh hydraulic fluid to prevent rust formation If these parts are not going to be reinstalled immediately they should be wrapped in a clean lint free cloth or paper to prevent nicks or scratches When resealing a cylinder or valve replace all seals and o rings that are disturbed during repair The price of a few seals is very little compared to a re turn repair job SECTION 4 GENERAL REPAIR PRACTICES REASSEMBLY AND INSTALLATION 1 Assemble parts in the same position as removed 2 Align parts accurately before mating 3 Inspect o ring and seal grooves for sharp edges nicks or burrs before installing new se

2RIII Maintenance Manual - Superior Truck Equipment Inc.

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