2RII Operators Manual Over Serial Number 16000
Contents
1. SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS SECTION 3 OPERATION PUMP PTO CONTROL 1 The Pump PTO Power Take Off is engaged to put the hydraulics in operation The exact location of the Pump PTO control will vary depending on the type truck chas sis style and control panel location The Pump PTO may be engaged by use of a lever rocker switch push pull cable toggle lever or positive control button depending on the style Be sure to read all safety decals associ ated with the Pump PTO before attempting operation SOLENOID ON OFF SWITCH 2 This switch energizes the engine speed up system It is located on the cab control panel exact location depen dent on cab make and style NOTE The engine speed up system consists of the solenoid ON OFF switch a relay and solenoid air cylinder on electronic engines the relay is wired to the engine ECU A speed up push button and speed up switch connected to the operating control linkage on the Operating Valve The function of the speed up system is to speed up the engine and provide more power to the hydraulic pump during operation of the various hydraulic cylinders TAILGATE OPEN LIGHT 3 This warning light located in the cab will illuminate if the tailgate is ajar Having the tailgate ajar will also sound the backup alarm and illuminate the backup lights Operation of the unit with an illuminate2. 2 7 5 1 2 7 SECTION 3 OPERATION General dansa mss 3 1 Description of Operating Controls 3 1 Location Of Operating Controls 3 2 Compaction Cycle Operation 3 5 Operating Procedures 3 6 Pre operating Walk around Inspection 3 6 Walk around Inspection Checklist 3 10 Start Up Operating Instructions 3 11 Positioning Pushout Panel 3 12 TABLE OF CONTENTS SECTION 3 OPERATION continued Loading the 3 13 Attaching a Container to the Packer 3 13 Using a Winch or Container Lift Cylinder 3 14 Using a Container Push Bar 3 15 Packing the 3 15 Pushout Panel Operation During Packing Telescopic 3 16 Disconnecting the Container 3 16 Unloading at Dumpsite 3 17 Lifting the Tailgate 3 17 the 3 18 Lowering the Tailgate 3 18 DOWN urn e440 6 eae ow asas 3 19 GENERAL The 2HII Packmaster has been designed with the oper ator in mind However as with any industrial machinery especially those that are large and apply forces through hydraulic pressures the ultimate responsibility for safe ty rests with you the user An aler
3. INTRODUCTION The main purpose of the 2RIl Packmaster is to safely and effi ciently load compact transport and unload refuse The following describes how the unit performs those tasks in the most basic terms For amore detailed description of the unit and its com ponents read the complete 2811 PACKMASTER SERVICE MANUAL Before going further look at the accompanying full page illustration of the 2RIl Packmaster and become familiar with the terms you will need to know LOADING Refuse is first loaded into the hopper of the tailgate assembly The carrier and packer panels which sweep up and pack the refuse from the hopper will be in the home position PACKER PANEL HOME POSITION Y COMPACTION When the operator starts the packing cycle the carrier and packer panels move rearward over the load CARRIER 8 PACKER PANELS MOVE OVER LOAD CARRIER Next the carrier and packer panel automatically stop at the interrupted cycle position PACKER PANEL INTERRUPTED CYCLE 2 2 The operator again activates the packing cycle The carrier and packer panels move forward and sweep the refuse from the hopper up into the body and pack it against the pushout panel Having completed a cycle the carrier and packer panels are back into the home position and the hopper is cleared for more refuse Also during the compaction cycle considerable hydraulic pressure is applied to the cylind
4. Place the container on a flat level surface For large non moveable containers the driver should back the unit toward the container following all vehicle and refuse body safety restrictions The vehicle should be backed with the latch arms open until the container trunnion bar is between the guide ears and within the latch assembly Center the container on the attachment LATCH ARMS DISCONNECTED After setting the vehicle parking brake the right and left container latch arms must be engaged A WARNING Lifting a container without both latch arms secured can allow the container to swing away from the unit and cause severe injury or death ATTACHED 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 s cure them to the packer 3 13 SECTION 3 OPERATION USING A WINCH OR CONTAINER LIFT CYLINDER Once the container is secured within the latch assem bly the lifting cable should be attached Place the load in the base of the hook with the safety latch closing the throat opening It is important that hooks are used in a proper manner Proper use of a lifting hook not only includes placing the load in the base of the hook but also includes ensuring that the hook is lifting on the proper area of the attachment point The hook must completely encircle the attachment poi
5. 2RII PACKMASTER OPERATORS MANUAL Over Serial Number 16000 BUILDING THE BEST WARRANTY LEACH C O P A Y Refuse bodies manufactured by Leach Company Company are supplied and sold under a Limited Warranty that they are and will remain free of defects in workmanship or material for a period of six 6 months from the date of original sale under reasonable conditions of use and operation providing required planned maintenance services are performed Extended war ranty packages are available for purchase If a failure occurs during said period because of such defect in the opinion of the Company the component or part shall be repaired or replaced by an authorized Leach Distributor at no cost to the customer provided the unit is brought to the distributor s service facility After three 3 months performance of adjustments or the replace ment of wear expendable components is not covered under warranty This limited warranty is the sole and exclusive warranty of the Leach Company THE COMPANY MAKES NO WARRANTY AS TO MERCHANTABILITY FITNESS FOR USE LEGALITY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF ANY KIND OR NATURE THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL OR CON SEQUENTIAL DAMAGES OF ANY KIND OR NATURE OTHER THAN ITS LIMITED WAR RANTY OF REPLACEMENT HEREIN NO OTHER PERSON FIRM OR CORPORATION CAN BIND THE COMPANY TO ANY WARRANTY OTHER THAN HEREIN ABOVE STATED To validate the new unit warr
6. 12 13 14 15 It is the operators responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operators manual and in accordance with all applicable codes including Occupational Safety and Health Act OSHA and American National Standards Institute ANSI reg ulations Do not attempt to operate this equipment without proper training Move the vehicle as slowly as possible without stalling when traveling in reverse Always make sure the area behind the unit is clear before traveling in reverse Do not travel in reverse for distances greater than those dictated by local ordinances If reverse trav el exceeds 10 feet use a spotter or move the vehicle in 10 foot increments only and then check to make sure the area behind the unit is clear between increments Do not attempt to dislodge any material above waist level unless wearing eye protection such as approved side shielded safety glasses or a full face shield Never use the unit to push or tow another vehicle Never unload uphill or against a pile of refuse or into the bank of a hill Never place head body fingers or any limbs into a scissors point or pinch point on the equipment Before operating the vehicle the driver must be thoroughly familiar with the employer s safety pro gram concerning traffic rules warning devices and hand signals Know where to get assistance in the event of an emergency K
7. When the resistance circuit is adjusted to produce maximum load density it may become necessary to manually retract the telescopic pushout cylinder in order to allow the compacted refuse to move forward in the body Also if the packer panel stops short of the home position the carrier panel operating lever may need to be held overridden to allow the refuse to move the pushout panel toward the front of the body When the pushout panel has reached the front of the body neither the packer panel operat ing lever nor the carrier panel lever should be overrid den except to clear the final hopper load ENGINE SPEED UP BUTTON DISCONNECTING THE CONTAINER Once the container is empty it should be lowered to the ground the latch arms released and the cable discon nected DISCONNECTED Wa PUSHOUT LEVER 3 16 SECTION OPERATION UNLOADING AT DUMPSITE Do not unload uphill or against a pile of refuse 1 Apply the brakes engage the PTO and ensure the transmission is in neutral Relieve the pressure on the tailgate by moving the packer panel to the interrupted 1 cycle position E dr A JEN uc 2 Loosen both tailgate clamps and swing them out and Ww E 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 Pus
8. an error Inthe manual Part No Page s It should say Name Address City State ZIP Code Return this form to Thanks for your help Leach Company Service Department P O Box 2608 Oshkosh WI 54903 2608 Fax 920 231 2712 LEACH C O P A Y 2737 Harrison Street Oshkosh Wisconsin 54901 920 231 2770 920 231 2712 FAX Please visit our website www LeachUSA com PRINTED IN U S A April 30 2001 Part Number 105319
9. engaged and the transmission in neutral and the brakes applied depress the speed up push but ton on the forward left street side ofthe body You should hearthe engine speed up Never hold the packer or the carrier panel lever in position by hand Always engage and let go immediately The only exception is at the end of a load PUSHOUT LEVER FRONT CONTROL VALVE TAILGATE ENGINE SPEED UP BUTTON 3 8 SECTION 3 OPERATION 10 Move both the packer panel lever and carrier panel CARRIER PANEL lever inward and let go Check for the following LEVER a Engaging the carrier panel lever will activate an engine speed up switch you should hear PACKER PANEL the engine speed up LEVER 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 working DRIVER SIGNAL PUSH BUTTONS BOTH SIDES OF TAILGAT
10. panel has passed the loading sill the container may be raised to again fill the hopper Hepeat this process until the container is empty ATTACH CONTAINER LOWER TO CHECK CONTENTS CORRECT CONTAINER CONTROL LEVERS NOTE On units with a roof mounted container lifting cylin der the speed of the device is limited during both the up and down movement This speed reduction is for safety considerations LOWER TO GROUND USING A CONTAINER PUSH Once the container is secured within the latch assem bly the container is ready to be dumped After assuring that all persons are standing clear the operator moves the CPB control lever in the direction shown on the in struction decal to raise the container When raiseing a container with the push bar it is normal for the container to first lift upward within the container latch assembly then tip toward the hopper and finally lower or drop to the bottom of the latch slots Do not overfill the hopper After assuring that all persons are standing clear lower the container to check the load condition ofthe container and the hopper Lowerthe 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 pac
11. provides all the instructions necessary to start and operate the 2RII Packmaster including specific instructions for loading packing and unloading the unit NOTE It is important that operators and mechanics understand these procedures PRE OPERATING WALK AROUND INSPECTION Each day before starting the unit perform the following walk around inspection 1 Refer to the decal location illustration in Section 1 SAFETY of this manual and make sure all decals are in place and readable Replace any decals that are not NOTE A decal kit free of charge is available from your local authorized Leach distributor 2 As you are checking for decals also look for fluid leaks on and around the unit Check for fluid leaks at the hydraulic cylinders valves and fittings 3 Inspect the mounting sills and attaching hardware Make sure everything is tight and that there are no bro ken or excessively worn parts Check capscrews and fasteners for looseness visible welds for cracks and control levers for each movement SPRINGS 3 6 4 Make sure the tailgate clamps are in the closed posi tion and securely tightened 5 Check the hydraulic tank gauge to make sure the fluid is in the safe range Add fluid if necessary See Sec 5 SPECIFICATIONS for the correct type of fluid to use The pushout cylinder must be re
12. 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 PUSHOUT LEVER FRONT CONTROL VALVE TAILGATE LIFT LEVER ENGINE SPEED UP BUTTON DX A TAILGATE CLAMPS 3 4 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 operation NOTE The engine speed up system does not engage if only the packer panel lever is shifted The carrier panel lever must also be shifted to engage the engine speed up system B Carrier panel lever 10 The carrier panel operational control lever is lo cated on the right curb side of the tailgate Itis used by the operator to position the carrier panel up or down duri
13. ARTS 2140 3500 9511134 7 DELTA COLOR SPECIFICATIONS 105556 ALPHA SERVICE 2140 3500 9603134 2 AL BE SUGGESTED SPECS 105565 BETA PARTS 0001 2139 9603134 3 DELTA SUGGESTED SPECS 105563 BETA SERVICE 0001 2139 Other Publications 105295 MILLENIUM PARTS 105305 2 LEACH BINDER 105297 MILLENIUM SERVICE 105309 REARLOADER PRE OP GUIDELINE 105296 MILLENIUM OPERATORS 105308 ALL REARLOADER PARTS SERVICE 105616 FL 104 SERIES B PARTS AND OPERATORS CD ROM 105596 FL 104 SERIES B SERVICE 42495293 PAINT COLOR CHART 961134 5 LEACH COLOR SPECIFICATIONS 105590 SAFETY BOOKLET 9603134 1 LEACH SUGGESTED SPECIFICATIONS LSAFE SAFETY WALL POSTERS 6 PER SET 105286 REARLOADER MOUNTING MANUAL 105321 REARLOADER CONTAINER HANDLING SYSTEMS 105605 CHASSIS REQUIREMENTS MANUAL Send this form by Fax or Mail to Leach Company Attention Service Department P O Box 2608 Oshkosh WI 54903 2608 Fax 920 231 2712 REWARD 2RII PACKMASTER 2RIIPACKMASTER 2RII PACKMASTER PARTS MANUAL SERVICE MANUAL OPERATORS MANUAL Over Serial Number 16000 Over Serial Number 16000 Over Serial Number 16000 BUILDING THE BEST BUILDING THE BEST BUILDING THE BEST One genuine Leach hat to the first person to notify us of an error in any of our publications If you find what you believe to be an error in any of our publications please complete the requested information an return the form to us by fax or mail If you are the first you will receive a hat by return mail believe found
14. E 13 Back the unit up a few feet to ensure that the back up alarm is working properly TAILGATE 14 Loosen the tailgate clamps and swing out Raise the tailgate approximately 6 and check to see if the tailgate ajar light on the dash is on and if the backup alarm is audible Do not have the unit in reverse 3 9 SECTION 3 OPERATION Do not operate a unit that is in need of service or repair 15 Report any problems found during the pre opera tion walk around inspection to the maintenance supervisor for service or repair place a tag on the steering wheel using a non reusable fastener stating the unit is inoperative and remove the keys WALK AROUND INSPECTION CHECKLIST Lh Decals in place and readable 2 Look for any fluid leaks 3 Mounting hardware tight and in place 4 Tailgate clamps closed and tightened 5 Hydraulic fluid reservoir at correct level 6 All operating levers in neutral positions 7 Pushout panel area clear of debris 8 Engine warmed up according to manufacturer s instructions 9 All operating and running lights functioning 10 Engine speed up buttons operational 11 Packing cycle operates properly 12 Driver signal alarm can be heard 13 Back up alarm and tailgate ajar light are operable 14 Report any problems to proper personnel 3 10 SECTION 3 OPERATION START UP OPERATING INSTRUCTIONS 1 Inspect and start the truck as described in the pr
15. OL OUTWARD FOR CARRIER DOWN FOR CARRIER UP MOY CONTROL INWARD MOVE CONTROL OUTWARD FOR PACKER OPEN FOR PACKER CLOSE Be all persons are clear of hopper opening before operating controls STROBE LIGHT IA WARNING A WARNING TAILGATE Do not transport container Do not operate OPEN OHM INECHANIENE 7 vehicle in excess Transporting a container could result in personal of 20 mph from the injury or property damage stand up position WARNING Stand facing truck side Use both hands on grab handles Riding step shall not be used when Speeds are expected to exceed 10 mph or when distance traveled without stopping will exceed 2 tenths of one mile Vehicle is moving backward Do not mount or dismount riding step when vehicle is in motion Do not ride on loading sill or on container attachment 1 9 SECTION 1 SAFETY PRECAUTIONS ENGINE This unit conforms to all American HYDRAULIC National Standards Institute safety SPEED UP requirements Z 245 1 in effect on FLU D ONLY the date of manufacture LEACH DO NOT FILL BEYOND THIS LINE DRIVER SIGNAL FILTER ELEMENT CHANGE To anger TEACH COMPANY NEAR SAFE RANGE machine life change the element a OSHKOSH WI OR ALL CYLS RETRACTE CTED intervals of 20hrs 50hrs and at RR EJECTION 250hr intervals thereafter EJECTION EJECTION ADD HYDRAULIC FLUID WA R N N G DANGER side Use b
16. RM LATCH one 1 to ten 10 cubic yard capacity The standard container for use with the Leach rear loader must have an ANSI Standard 11 4 134 diameter trunnion bar which is between 7712 78 end to end This trun A nion bar length will center the container between the o o o ears and prevent the container from moving side A ways The latch arms must be manually raised and secured by the arm latch The container arms when properly latched together with the guide ears will secure the container to the packer L IM m Only containers that meet the American National Standards Institue ANSI regulations ARMS should be used in conjuction with Leach Container Handling Systems CONTAINER HANDLING SYSTEMS To lift or dump a container several systems are avail able A hydraulically operated container push bar is available to handle containers of 1 to 3 cubic yard capacity The handling of containers with capacities of four 4 or more cubic yards requires the use of a drum winch or roof mounted container lifting cylinder Drum winches are rated at various pounds of pull Leach Company offers winches with 8 000 12 000 and heavy duty 12 000 Ib ratings The Leach container lift cylinder is rated at 12 000 pounds NO TE Leach bodies are capab le of being equipped with more than one container handling system LA vane 3 Sp em ER ES II LIFTING 5 CYLINDER 2 4 SECTION 2 INT
17. RODUCTION GENERAL TERMS YOU NEED TO KNOW The main purpose of a refuse body is to load compact Before going further become familiar with the contain transport and unload refuse To assist in loading of er handling terms you will need to know refuse in containers various container handling sys tems are available to be mounted on Leach rear load ers A refuse container may be a mobile residential one 1 cubic yard container with casters or a ten 10 cubic yard stationary commercial container The equipment required to lift and empty these containers will vary according to the container s type and size HOOK 1 Throat Opening 2 Back 3 Heel 4 Hook Safety Latch 5 Point 6 Base CONTAINER 1 Trunnion bar 2 Hook point 3 Lid CONTAINER ATTACHMENT 1 Loading sill 2 Arm 3 Latch 4 Guide ear 2 5 SECTION 2 INTRODUCTION WINCH 1 Control lever 2 Engine speed up button 3 Cable 4 Winch assembly 5 Container attachment 6 Stop bar Lid guard CONTAINER LIFTING CYLINDER CLC 1 Control lever 2 Engine speed up button 3 Roller guide 4 Cable 5 Lifting cylinder assembly 6 Container attachment 7 Stop bar Lid guard CONTAINER PUSH BAR CPB 1 Control lever 2 Push bar 3 Lift roller 4 Container dumping cylinder 5 Stop bar Lid guard 6 Container attachment 2 6 SECTION 2 INTRODUCTION BASIC OPERATION All Leach container handling systems have
18. SH BAR CARRIER HYD PUSH BAR MU Ss 1 HYD PUSH BAR LEACH COMPANY OSHKOSH WI TA WARNING Hotating power take off shaft hazard DO NOT FILL BEYOND THIS LINE Do not enter under chassis unless engine is stopped and key removed EJECTION EJECTION EJECTION 12 000 LB CAPACITY 1 T a d SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW TAILGATE ASSEMBLY LOADING EDGE CARRIER PUSHOUT PANEL PANEL PACKER HYDRAULIC PANEL ur a tee ee amp oe g gt a um m m m mm m mn s eee 4 gt one v tw on E gt EP gt a x lt EP E EP E 1 1 a D gt a wt m ni e s E a 4 LI e Hs 1 ni o a E a a d o PEN a a oo a 1 END toa au 1 1 n 1 ara of 34 on PR a r eos n t e e un Ta e gt oy Pai T m ir m P FERE EN ww s gt et s De Sa ia u ES t vs ae i Pes 2 Li LI Pa a a EL ae P e PX 2 PO oe SS a PE 2 1 SECTION 2
19. anty an authorized Leach Distributor must have completed a pre delivery inspection before the unit is placed into service and the delivery report form signed by both the customer and the distributor must be submitted to the Leach Service Department Because Company products are engineered to work only with genuine Company parts this limited warranty will be void and of no effect if a Company products are modified other than as done at its factory or as authorized to be done by the factory in writing or b Parts or assem blies of any other manufacturer are used as substitutes for genuine Company parts Genuine Leach replacement parts components and assemblies are also sold under a Limited Warranty to be free from defects in workmanship or material for a period of six 6 months This is a replacement only warranty and the item must be returned to the Leach distributor for exchange The labor to replace or repair the part shall be the responsibility of the customer There is no warranty on expendable items wear components or used parts Leach Company reserves the right to redesign and or discontinue the manufacture of parts components and assemblies at any time FOREWARD Leach Company has been a leader in the refuse industry for over 110 years Leach refuse bodies are the industry standard for both quality and performance Leach Company is justifi ably proud ofthe quality engineering material and workmanship that goes into each and ever
20. d or defec tive warning system can result in personal injury and or equipment damage 3 3 SECTION 3 OPERATION ENGINE SPEED UP PUSH BUTTON 4 When depressed this push button switch will cause the engine to speed up and supply more power to the hy draulic system Located on the lower front left side of the body itis depressed by the operator when operating either the pushout lever or tailgate lift lever NOTE Additional speed up control buttons may be installed with optional winches and container attachments FRONT CONTROL VALVE The front control valve is located behind the access door on the front left hand side ofthe body The control levers for this valve extend out through a cutout in the door This valve controls the ejection pushout panel and the lifting of the tailgate PUSHOUT LEVER 5 The upper lever controls the movement of the pushout panel Moving the control lever rearward toward the tail gate will move the pushout panel to the rear Moving the control lever forward toward the cab will move the pushout panel to the front TAILGATE LIFT LEVER 6 The lower lever controls the tailgate Moving the lever rearward toward the tailgate will raise the tailgate Mov ing the lever forward toward the cab will lower the tail gate 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
21. e 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 ENGINE SPEED UP YSTEM ON mE OFF 3 11 SECTION 3 OPERATION POSITIONING PUSHOUT PANEL To load the unit the pushout panel must be positioned toward the rear of the body 1 Check the tailgate clamps to make sure both are Ae CEAMES securely tightened nm 2 Depress and hold the speed up push button SPEED UP BUTTON 3 Push the pushout lever rearward until the pushout cylinder is fully extended NOTE On units with a telescopic pushout cylinder the pushout panel is now in position for loading PUSHOUT LEVER 4 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed 5 Repeat steps 2 3 and 4 until the pushout panel is as far back as it will go and then pull forward on the pushout lever to fully retract the pushout cylinder Now extend the cylinder a few inches to reset the clamp SPEED UP BUTTON 3 12 SECTION 3 OPERATION LOADING THE HOPPER SS oo VIN OO 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 notload refuse higher than the loading edge Always follow proper loading procedures ATTACHING A CONTAINER TO THE PACKER
22. ers which control movement of the carrier and packer panels This causes the refuse to be compacted tightly allowing for a large carrying capacity On units with the standard clamp pushout system the operator must manually release the pushout panel clamping system to allow movement of the pushout panel Once the body is full the 2RIl Packmaster 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 on telescopic units the tailgate is low ered and latched to the body On clamp style units the the pushout cylinder is retract ed and then the clamp is set by extending the cylinder a couple of inches The tailgate is then lowered and latched to the body PUSHOUT PANEL MOVES REARWARD EJECTING THE LOAD PACKER CARRIER PACKER PANEL SECTION 2 INTRODUCTION PUSHOUT PANEL CARRIER PANEL COMPACTION POSITION PANEL PUSHOUT PANEL MOVES FORWARD TAILGATE TAILGATE RAISED TAILGATE PUSHOUT PANEL 2 3 SECTION 2 INTRODUCTION CONTAINER ATTACHMENT The Leach Container Attachment system consists of a loading edge with a latch assembly and a guide ear ear on each side of the packer tailgate The latches and ears are installed to accomodate containers from A
23. g before operating controls CARRIER CARRIER 44 DANGER CONTAINER FALLING SWINGING HAZARD While container is off the ground E Insure both container latch arms are latched Do not operate packing cycle Do not stand or cross under Latches will secure straight container trunnion pivot bars which meet ANSI Z245 6 container dimensions shown below Stand clear when y container dumping The con er attachment on this compactor mechanism is in ally mounted is compatible with as original H ANSI Z245 6 containers motion a A 1 6 SECTION 1 SAFETY PRECAUTIONS 4 ZN 12 000 LB CAPACITY 3 NOTE N j A ji 29852 xu i Am Both container latch arms must be in place and latched before raising container 2 SECTION 1 SAFETY PRECAUTIONS PACKER PACKER ENGINE PACKER DRIVER SIGNAL BEACON LIGHT ON OFF CARRIER WARNING CARRIER Rotating power take off shaft hazard CARRIER a Do not enter under 5 chassi assis unless engin is stopped and key oved PTO A WARNING YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS You are qualified by training and experience i of this machine e Traini A CAUTION Serious pump damage will result if pump is run dry Disconnect pump drive to run engine Serious pump damage will result if vehicle ce in the safe aperalion is operated at highway
24. h the tailgate lift lever rearward and hold until the tailgate is fully raised TAILGATE ENGINE SPEED UP BUTTON 3 17 The tailgate open light and backup lights should illuminate The backup alarm should also sound SECTION 3 OPERATION EJECTING THE LOAD PUSHOUT LEVER 1 Depress and hold engine speed up button push the pushout lever rearward and hold until the pushout panel stops N NOTE SPEED UP On units with a telescopic pushout cylinder this will i BUTTON eject the entire load go on to step 4 2 Release the speed up button and pull the pushout lever forward until the pushout cylinder is fully retract ed WARNING 3 Repeat steps 1 and 2 until the pushout panel is as far back as it will go completely ejecting the load Never drive the unit more than 10 feet with the tailgate in a raised position 4 Slowly pull the unit ahead to clear the refuse pile when the tailgate is lowered 6 Pull the pushout lever forward to completely retract the pushout cylinder Now push the pushout lever 5 Clear debris from the edges with a pole while stand rearward extending the pushout cylinder a few inches ing clear off to one side thus clamping the bar to the pushout panel With the telescopic circuit the pushout cylinder remains fully extended If the unit is going to travel over one mile empty completely retract the cylinder When packing is about to resume extend the cylinder and
25. ker panel and the carrier panel by mov ing both the packer panel lever and the carrier panel lever inward toward the tailgate then let go The packer panel will open and the packer panel lever will automati cally shift to neutral The carrier panel will then move down to above the loding edge stop in the interrupted cycle position and the carrier panel lever 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 3 15 SECTION 3 OPERATION CONTAINER CONTROL LEVER Releasing the CPB control handle when the container begins to tip will allow the container trunnion bar to lower within the latch slots with ease CARRIER PANEL LEVER N PACKER PANEL LEVER CARRIER PANEL LEVER PACKER PANEL LEVER SECTION 3 OPERATION PUSHOUT PANEL OPERATION DURING PACKING TELESCOPIC PUSH OUT The 2RII Packmaster telescopic pushout cylinder will normally move toward the front of the body automati cally
26. nance Perform a pre operation walk around inspection of the truck chassis in accordance with the chassis manufacturer s guidelines Perform a walk around 8 Before operating the vehicle the driver must be inspection of the refuse packer in accordance with thoroughly familiar with the employer s safety pro the checks listed in Section 3 Operation of the gram concerning traffic rules warning devices and Operators Service manual Never start or operate hand signals any equipment found to have malfunctions a Report any malfunctions immediately to the 9 Be sure to know where to get assistance in the proper authorities event of an emergency b Prior to leaving any malfunctioning unit the parking brakes must be set the PTO system 10 Know your machine Know the location and func disengaged the engine turned off the ignition tion of all controls gauges instruments and pro key removed and using a non reusable fasten tective devices ing device place a sign on the steering wheel indicating the unit is inoperative 11 Should the height of a refuse collection vehicle be Proper servicing requires specialized tools and pro cedures Service must be performed by authorized personnel only following procedures in the 2RIl Service manual altered by installing a container handling system be sure the overall height is rechecked and overall height plus 3 inches is noted on the decals LEACH OPERATION GENERAL 10 11
27. ner without first latching both con tainer latch arms 52 53 54 55 56 57 58 59 60 61 62 63 64 65 Raise the container with a smooth even movement Do not bounce the container Do not slam the container against the packer tail gate or bump bar Do not attach the hook to any lift point which will not be completely encircled by the hook with the safe ty latch closed Do not remove the hook safety latch Read and obey all container decals issued by the container manufacturer Read and follow container manufacturers informa tion on accepted use practices Do not attempt to lift overloaded containers Center the container on the attachment All containers should be inspected for serviceabili ty and repaired if not in a safe usable condition Do not use a non standard or damaged trunnion bar Never cross under a raised container Stand clear when dumping containers Before attempting to lift a container below 32 F 0 C make sure it is not frozen to the ground When using an eye type container attachment point the base of the hook must be positioned to lift on the inside of the eye Place the container on a flat level surface 1 4 SECTION 1 SAFETY PRECAUTIONS HYDRAULICS 1 Hydraulic fluid operates under high temperatures 3 In case of injury seek proper medical treatment Avoid contact with piping hoses or cylinders to immediately prevent burns 2 Neve
28. ng 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 A refuse vehicle may have none one or two control levers de pending on the configuration of the unit 3 5 SECTION 3 OPERATION DRIVER SIGNAL PUSH BUTTONS CARRIER PANEL LEVER PACKER PANEL 7 LEVER COMPACTION CYCLE OPERATION Both the packer panel lever and the carrier panel lever are shifted simultaneously inward to open the packer panel and lower the carrier panel to the interrupted cycle position Both levers are shifted outward to sweep the load from the hopper and pack it against the pushout panel Any time the carrier panel lever is shifted the engine speed up automatically engages The packing cycle may be stopped at any point by moving both oper ating levers to neutral The packer or carrier panel can be moved independently CONTAINER HANDLING CONTROL LEVERS AN SECTION 3 OPERATION OPERATING PROCEDURES This section of the manual
29. now your machine Know the location and func tion of all controls gauges instruments and pro tective devices Wear your seat belt Start the engine following the manufacturer s rec ommended procedure Always set the parking brake before leaving the cab 16 Turn on appropriate warning lights put on a safety 17 18 19 20 21 ee 2 24 25 26 27 28 29 30 31 32 33 SECTION 1 SAFETY PRECAUTIONS vest protective glasses and protective shoes All service opening covers and access doors must be maintained and latched in place while operating equipment Ensure all co workers are in view before operating or moving any controls or the unit Ensure that there is sufficient overhead clearance before operating the unit Ride only in the cab or on riding platforms designed for that purpose Riding steps shall not be used when speeds are expected to exceed 10 mph or when distance traveled without stopping will exceed o of one mile Do not mount or dis mount riding step when vehicle is in motion Never allow anyone to ride on the steps when the vehicle is backing up Stop the vehicle immediately if warning lights for the TAILGATE AJAR system come on Never use controls or hoses for hand holds when mounting or dismounting Controls and hoses are movable They do not provide proper support and may cause accidental equipment movement Make sure the backup alarm i
30. nt Equally as important at the time load is applied to the base of the hook the positioning must be correct to prevent the hook from dislodging When using an eye type attachment point the base of the hook must be positioned to lift on the inside of the eye The diagrams show both correct and incorrect positioning of the hook For the safety of yourself as well as others always ensure that a hook is positioned properly as slack is removed from the chain cable before lifting Slack should be removed from the cable without the use of the engine speed up button by moving the winch con trol lever in the direction shown on the instruction decal to raise the container When the cable is tight the speed up button should be depressed and held to provide suf ficient hydraulic power to lift the container The container should be raised until the contents begin to slide into the hopper of the packer or until it is resting against the container bump bar Do not overfill the hopper After assuring that all per sons are standing clear lower the container to check the load condition of the container and the hopper Lower the container enough to see between the con tainer and the tailgate while standing on the ground without placing yourself between them When the hopper is full lower the container to the ground assure all persons are standing clear and then engage the packer mechanism See Sec 3 Operation Packing Load After the packer
31. ompliance to these safety alerts combined with common sense operations are important accident pre DANGER Immediate hazards which WILL result in severe personal injury or death vention measures The word NOTE is also used throughout the manual It precedes information that provides special emphasis or clar WARNING Hazards or unsafe practices which COULD result in severe personal injury or death ification on a specific operation or procedure CAUTION Hazards or unsafe practices which could result in minor personal injury or prop erty or product damage SECTION 1 SAFETY PRECAUTIONS PRIOR TO START UP Never operate machinery while wearing jewelry or 5 Walk completely around the vehicle to make sure loose clothing These items may become caught by all persons and obstructions are clear before start or entangled in the machinery causing serious ing the unit injury Wear proper safety equipment as required by your employer 6 The container handling system is a critical compo nent of the unit use only the proper replacement Never operate machinery while under the influence parts of alcohol narcotics or other mood altering sub stances Workers who operate machinery while under the influence are a hazard to themselves and 7 Inspect all hooks chains and cables daily to others ensure serviceable condition Replace damaged or worn parts See Section 5 Preventive Mainte
32. oth hands on YOU MUST NOT OPERATE OR SERVICE THIS MACHINE UNLESS h or when WAR N N G his ma Training includes complete knowledge ol your employer s work DO NOT ENTER UNLESS rules all gavernmental regulations and manufacturer s operator cort and salety manuals relative to this machines safe use All pressure against ejector h b AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO panel been relieved DEATH DA SERIOUS INJURY Engine is stopped and key removed Stand clear when tailgate is in motion amp during unloading cycle TAILGATE Do not stand or AWARN NG cross under raised TAILGATE tailgate aiman TAILGATE Do not operate vehicle at speeds in excess of 10 mph for distances over 2 tenths mile or in reverse gear when rider or riders are on riding steps SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL PACKER PACKER CONTAINER DUMP CONTROL PACKER HYDRAULIC FLUID ONLY Both container latch arms must be in _ place and latched before raising container FILTER ELEMENT CHANGE This unit conforms to all American To ensure oil cleanliness and Ion ass ger National Standards Institute safety hina life requirements Z 245 1 in effect on DRIVER SIGNAL intervals of 20hrs 50hrs and at cate ol manufacture D 250hr intervals thereafter CE LEACH BEACON LIGHT CARRIER E nn CARRIER HYD PU
33. r use hands to check for leaks Hydraulic fluid escaping under pressure may cause injury FIRE PROTECTION 1 Keep a fire extinguisher accessible at all times as recommended by the Bureau of Motor Carrier Safety 2 Never use lighted smoking materials open flame or sparks around when working with flammable mate rials such as fuel tanks or storage batteries 3 Never have an open flame as a light source 4 Never load ashes or other materials which might be smoldering These materials could ignite refuse in the packer body HOUSEKEEPING Good housekeeping habits are a major factor in acci 3 Rubbish scrap paper and litter are highly com dent prevention bustible Such material should be stored in metal containers entirely clear of sparks and flames 1 Keep handrails and steps clean and free of grease or debris 2 Do not store brooms or other equipment where they could inadvertently activate the packer con trols SHUTDOWN 1 Put all controls in neutral 2 Set parking brake 3 Disengage PTO 4 Shut off engine 5 Shut off solenoid dashboard switch 6 Remove key 7 Lock vehicle SECTION 1 SAFETY PRECAUTIONS CART TIPPER CONTROL PACKER ENGINE PACKER SPEED UP 281 PACKING OPERATION INSTRUCTIONS READ AND NOTE Both container latch arms must bein place and latched before raising container Be sure all persons are clear of hopper R R openin
34. s working properly Always ensure that all persons are clear before raising or lowering the tailgate It is the operator s responsibility to warn all persons not to stand or cross under a raised tailgate Do not move the vehicle with the tailgate raised except during unloading and then only as neces sary to clear the load before lowering Stand clear when the tailgate is being raised or lowered and during the unloading cycle If it is nec essary to manually clear debris from the hopper use a long metal probe and DO NOT stand under the tailgate Never load the hopper above the loading sill Never allow material to extend outside of the hop per when packing Allow the packer panel control lever and carrier panel control lever to shift automatically To avoid possible bodily injury or equipment dam age lower the tailgate slowly Never enter the body unless the pushout panel clamp or the telescopic ejection system cylinder is released PTO disengaged and ignition key removed and placed in your pocket Do not attempt to load refuse into the hopper after SECTION 1 SAFETY PRECAUTIONS 34 35 36 37 38 39 40 41 42 4 44 54 46 47 48 49 50 51 the packing cycle has begun The packer panel must be in the home position and stopped before loading the hopper The dashboard solenoid switch must be OFF between pickups or when parked This prevents inadvertent engine
35. speed up if the tailgate carrier panel control lever is shifted The tailgate clamps must be tightened securely before starting to load Do not step on the throttle pedal while the speed up system is engaged Vehicles with automatic transmissions require the shift lever to be in gear to engage the PTO and then shifted to neutral to activate the PTO pump Never use a rear loader to transport a container Follow all safety directions listed in the refuse body Operator and Service manual under SAFETY PRE CAUTIONS Never use container handling chains or cable for towing or pulling When not handling containers keep the container attachment closed and latched Do not operate the rear loaders packing mecha nism with a container off the ground If it is necessary to manually free debris from the container use a long metal probe while the con tainer is on the ground and DO NOT place yourself between the container and the packer body Attach hook to the tailgate and take up the excess slack when not in use Never hold the hook on an attachment point while taking up slack Take up excess cable slack before moving the vehi cle Check overhead clearance before dumping a con tainer Do not move the vehicle with a container attached Always set the vehicle parking brake before attach ing or lifting a container Never lift a container which is non compatible with the Leach container attachment Never lift a contai
36. speed with pu anm includes complete knowledge ol your empl es all go i engaged Move unit with pump engaged vernmental regulations and manufact oyer s work only as required to perform its function as L clurer s operator a refuse collection compaction vehicle at and safety manuals relative to this machines safe use h speeds less than 10 mph N UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO EATH OR SERIOUS INJURY if tank valve is required to be closed or if oil tank is not at proper fill level D SECTION 1 SAFETY PRECAUTIONS AWARNING Falling hazard Do not operate vehicle at speeds in excess of 10 mph for distances over 2 tenths mile or in reverse gear when rider or riders are on To prevent possible serious injury or riding steps un death do not use this refuse collection qu vehicle to tow other equipment It is sped Stand clear when intended designed or equipp a or towing tailgate is in motion amp during unloading cycle Stand clear when Do not stand or packer panel is cross under raised in motion tailgate SOLENOID BEFORE OPERATING THIS MACHINE BE SURE TO READ AND UNDERSTAND OPERATION MANUALS SUPPLIED WITH THIS UNIT REPLACEMENT MANUALS CAN BE OBTAINED FROM A LEACH DISTRIBUTOR A SS MUST BE OFF WHEN EMEN T ba D TRUCK IS PARKED is vehicle requires gt of overhead 0 N 0 F F TM e sto rs to neutra MOVE CONTROL INWARD E MOVE CONTR
37. start packing PUSHOUT LEVER LOWERING THE TAILGATE 1 Pull forward on the tailgate lift lever slowly and in small increments to lower the tailgate a little at a time AVOID SLAMMING SHUT the tailgate TAILGATE LIFT 2 Place the tailgate clamps in the closed position and tighten securely NOTE The tailgate open light backup lights and backup alarm should be off after closing the tailgate SECTION 3 OPERATION SHUT DOWN 1 Move the packer panel lever and carrier panel lever to place the packer panel in the home position 2 Put all controls in neutral 3 Set parking brake 4 Disengage PTO 5 Shut off engine 6 Shut of solenoid dashboard switch 7 Remove key 8 Lock truck LEACH C A N Y CUSTOMER SUPPORT MANUAL LITERATURE ORDER FORM SHIP TO LEACH INTERNAL USE ONLY NO TITLE QTY NO TITLE QTY Current Production Units Previous Production Units 2RII 105291 2RII PARTS 9719 16000 105313 2RII PARTS OVER 16000 105615 2RII SERVICE 9719 16000 105318 2RII SERVICE OVER 16000 105546 2RII PARTS 8993 9718 105319 2RII OPERATORS OVER 16000 105549 2RII SERVICE 8993 9718 ALPHA BETA DELTA 105567 2RII PARTS 6972 8993 105284 PARTS OVER 3500 105544 2RII SERVICE 6972 8993 105282 SERVICE OVER 3500 105600 2RII PARTS 0001 6972 105283 OPERATORS OVER 3500 105601 2RII SERVICE 0001 6972 951134 5 ALPHA COLOR SPECIFICATIONS 9511134 8 BETA COLOR SPECIFICATIONS 105557 ALPHA P
38. t conscientious attitude and observance of all known safe operating practices are the best ways to prevent accidents Before operating the unit it is the operator s responsibil ity to be thoroughly familiar with the instructions con tained in the Operator s Manual DANGER WARNING AND CAUTION DECALS See the accompanying illustration for the location and label content of all safety decals 1 These decals must be obeyed at all times 2 These decals must be in place at all times Report any damaged or missing decals to the proper authority at once 3 Replacement decals can be ordered free of charge from your local authorized Leach distributor DANGER WARNING AND CAUTION 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 4 Health Act OSHA and American National Standards Institute ANSI regulations 44 DANGER AWARNING CAUTION Throughout this manual DANGER WARNING and CAUTION notations accompanied by the International Hazard Symbol are used to alert the operator and mechanics to special instructions concerning a particular operation or service that may be hazardous if performed incorrectly or carelessly AWARNING Strict c
39. three 3 basic steps for operation ATTACH The first step in container handling is to attach the con tainer to the rear loader by securing it with the latch arms of the container attachment ATTACH CONTAINER DUMP A container handling system is used to raise the con tainer and empty the refuse into the hopper of the rear loader DISCONNECT When the container is empty it is lowered to the ground the latch arms released and the truck is moved forward DISCONNECT 2 GENERAL This section will provide all ofthe instructions necessary to operate the 2RII Packmaster However prior to attemting any operation of the unit make sure you are familiar with all of the safety information contained in Section 1 SAFETY PRECAUTIONS A E um yy DESCRIPTION OF OPERATING CONTROLS The following information is for descriptive purposes only It is not to be misconstrued as operating in structions For operating instructions refer to OP ERATING PROCEDURES later in this section There are only a few controls required for the complete and efficient operation of the 2RII Packmaster It is im portant that you know the location and function of each control before attempting to operate the unit Refer to the accompanying illustrations for their location 3 1 SECTION 3 OPERATION
40. tracted the tail gate down the carrier and packer panels in the inter rupted cycle position to check the hydraulic fluid level 1 1 2 i 6 Make sure all operating levers are in the neutral posi tion Check a packer panel lever b Carrier panel lever c Pushout lever d Tailgate lift lever Never operate the 2RII Packmaster with any part of the control system or levers removed or serious damage will result Never under any circumstances enter the body if the truck is running Open the packer panel and release the pushout panel clamp before entering the body Always make sure the truck engine is off and the keys are in your pocket before entering the body 3 SECTION 3 OPERATION 4 TAILGATE CLAMPS PUSHOUT LEVER FRONT CONTROL VALVE TAILGATE LIFT LEVER ENGINE SPEED UP BUTTON CARRIER PANEL LEVER N PACKER PANEL 7 LEVER SECTION 3 OPERATION 7 Start the truck according to the manufacturers instruc tions and while it is warming up continue the walk around inspection 8 Check all of the operating and running lights Make sure none are missing and that there are no burned out bulbs AWARNING The tailgate open warning light should be off Do not operate the unit if the light is illuminated Never place hands in or near the packer panel dur ing operation 9 With the engine running the speed up solenoid switch ON the PTO
41. ve comments or suggestions concerning this manual please contact us at 920 231 2770 We are here to be of service to you our valued customer FOREWORD IH TABLE OF CONTENTS IV SECTION 1 SAFETY PRECAUTIONS E scene hang che hoes het Pee ese ws 1 1 Danger Warning and Caution Decals 1 1 Prior To Start Up 1 2 1 3 FIYALAUICS en ah 1 5 Fire 1 5 Housekeeping 1 5 sario an a re Grace 1 5 Decal lt 1 6 SECTION 2 INTRODUCTION Terms You Will Need To Know 2 1 LOAN G ERPRDC oo eee 2 2 Compaction 2 2 2 3 Container Attachment 2 4 Container Handling Systems 2 4 2 5 Terms You Need to KNOW 2 5 HOOK en He man ae 2 5 2 5 Container Attachment 2 5 VDE a an a ee oe 2 6 Container Lifting Cylinder CLC 2 6 Container Push 2 6 Basic 2 7 Attach 2 7 DUMP
42. y packer we produce This commitment to quality extends to the best parts service and distribu tor organization in the industry One area of great importance to us is your safety This unit was built in accordance with the American National Standards Institute ANSI standard for Mobile Refuse Collection and Com paction Equipment Safety Requirements ANSI Z245 1 1992 Before operating this unit please read and understand the safety precautions found in Section 2 of this manual They are important and are provided to assist you in the safe operation of the unit This manual was produced with the intention of providing clear concise instructions for the proper operation maintenance and service of your 2RII refuse packer It was produced with the latest information available at the time of publication We do however reserve the right to redesign and or discontinue the manufacture of parts components or assemblies at any time Leach Company has an aggressive manual and product improvement program In any conver sation or correspondence dealing with the information provided in any Leach manual please refer to the part number of that manual The manuals provided with the unit are considered a permanent part of the unit and should be included in the event of a re sale Additional manuals are available free of charge from your local authorized Leach distributor These manuals should be kept readily available for easy reference We ask that if you ha
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