Leach 2R-III Maintenance Manual
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Leach 2R-III Maintenance Manual

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2R-III™
M
MAINTENANCE
ANUAL

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Summary of Contents for Leach 2R-III

  • Page 1 2R-III™ MAINTENANCE ANUAL...
  • Page 3 2R-III™ AINTENANCE MANUAL...
  • Page 4 Liability Labrie Enviroquip Group assumes no liability for any incidental, consequential, or other liability that might result from the use of the information contained in this document. All risks and damages, incidental or otherwise, arising from the use or misuse of the information contained herein are entirely the responsibility of the user.

  • Page 7: Table Of Contents

    Table of Contents Liability ..................ii Table of Contents ................ v Introduction ................1 Introducing the 2R-III™ ................................... 1 Terms You Will Need to Know .............................. 1 Waste Handling Process ................................. 3 Loading ......................................3 Packing ......................................3 Unloading ..................................... 4 Container Handling Systems ................................
  • Page 8 Lubricants ......................................41 Hydraulic System ................................... 41 Capacity (approximately) ..............................41 Total System ..................................... 41 Pump ........................................42 Leach Hydraulic Fluid Recommendation ..........................42 Body Dimensions ................................... 43 Hydraulic Fluid ....................................44 Preventive Maintenance ............45 Operating and Maintenance Records ............................. 45 Lubrication Chart ...................................
  • Page 9 Table of Contents vii Hydraulic System ..................................55 Check-Out .................. 57 Checking Hydraulic Tank Fluid Level ............................. 58 Checking Engine Speed Up Switch ............................58 Checking Engine Speed Up Switches (Body) ........................59 Checking Pack Cycle Time ................................60 Checking Pressures ..................................61 Checking Main Line Pressure .............................
  • Page 10 viii Table of Contents Removal of the Tailgate Assembly ..........................129 Inspection of Tailgate ................................. 130 Reassembly and Installation of Tailgate ........................131 Front Control Valve (FCV) ................................. 131 Removal of the Front Control Valve ..........................131 Disassembly and Reassembly of the Front Control Valve ..................132 Reinstallation of the Front Control Valve ........................

  • Page 11: Introduction

    2R-III™ Maintenance Manual. Before going further, you will need to become familiar with specific terms that are used when referring to the 2R-III™ garbage truck. Terms You Will Need to Know Body’s main components are the hopper, the packer...
  • Page 12 2 Introduction TERMS YOU WILL NEED TO KNOW TERMS YOU WILL NEED TO KNOW BODY ASSEMBLY TAILGATE ASSEMBLY HOPPER LOADING EDGE PUSHOUT PANEL HYDRAULIC TANK PACKER PANEL CARRIER PANEL...

  • Page 13: Waste Handling Process

    Introduction 3 Waste Handling Process The waste handling process in a 2R-III™ rear-loader garbage truck is a three-step process: 1. loading; 2. packing; 3. unloading. Take a look at the following illustrations. They will help you understand how these steps relate to one another.

  • Page 14: Unloading

    This causes the refuse to be compacted tightly allowing for a large carrying capacity. Once the body is full, the 2R-III™ can be moved to the dumpsite for unloading. CARRIER PANEL...

  • Page 15: Container Handling Systems

    A drum winch or roof-mounted lifting cylinder for containers with capacities of four (4) or more cubic yards. Drum winches are rated at various pounds of pull. The 2R-III™ drum winch and lifting cylinder are rated at 12,000 lbs. : Leach bodies can be equipped with more than one container handling system.

  • Page 16: Terms You Need To Know

    6 Introduction Terms You Need to Know Hook 1. Throat Opening 2. Back 3. Heel 4. Hook Safety Latch 5. Tip 6. Base ____________________________ Container 1. Trunnion Bar 2. Hook Attachment 3. Lid ____________________________ Container Attachment 1. Loading Sill 2. Arm 3.
  • Page 17 Introduction 7 Winch 1. Control Levers 2. Engine Speed-Up Button 3. Winch Lifting Cable 4. Winch Assembly 5. Container Attachment 6. Stop Bar/Lid Guard ____________________________ Container Lifting Cylinder (CLC) 1. Control Levers 2. Engine Speed-Up Button 3. Cylinder Cable Roller Guide 4.

  • Page 18: Container Handling Process

    8 Introduction Container Handling Process All Leach container handling systems have three (3) basic operation steps: Attaching The first step in container handling is to attach the container to the rear loader by securing it with the latch arms of the container attachment.

  • Page 19: To Contact Labrie Plus

    Introduction 9 To Contact Labrie Plus In the U.S. Address: 1981 W. Snell Road Oshkosh, WI 54904 Toll Free: 1-800-231-2771 Telephone: 1-920-233-2770 General Fax: 1-920-232-2496 Sales Fax: 1-920-232-2498 Parts and warranty: During business hours, 7:00 AM to 7:00 PM Central Standard Time Technical Support Service: Available 24 hours In Canada Address:...
  • Page 20 10 Introduction...

  • Page 21: Safety

    This manual contains safety information that could MPORTANT prevent accidents. Read and thoroughly understand it before using the vehicle. 2R-III™ has been designed with the operator in mind. However, as with any industrial machinery, especially those that are large and apply forces through hydraulic pressures, the ultimate responsibility for safety rests with you - the operator.

  • Page 22: Conventions

    Safety decal categories Keep your decals clean and in good condition at all times. For a list of safety and informative decals for your 2R-III™ unit, refer to the section on Safety and Informative Decals in the related Operator’s Manual.

  • Page 23: Basic Safety Notions

    Basic Safety Notions The following safety notions are related to the use of the 2R-III™. It is important to point out that the safe use of the vehicle remains the user’s responsibility. He must heed all safety notions explained in this manual and on the decals affixed to the vehicle.

  • Page 24: Employee Responsibilities

    To enforce all safety measures to meet the requirements established by the employer. To operate the 2R-III™ only after having received proper instructions and training. To make sure that nobody is near the vehicle before activating any of the controls, and to be prepared to stop at any indication of possible danger.

  • Page 25: Safety Precautions

    Locking Out and Tagging Out the Vehicle on page 28. Proper servicing requires specialized tools and procedures. Service must be performed by authorized personnel only following procedures in the 2R-III™ Maintenance Manual. Walk completely around the vehicle to make sure all...

  • Page 26: General Operation

    16 Safety General Operation It is the employer’s responsibility to ensure that only qualified employees are assigned to operate this vehicle. It is the operator’s responsibility to ensure that operation of the unit is in accordance with the guidelines contained in the Operator’s Manual and in accordance with all applicable codes including Occupational Safety and Health Act (OSHA) and American National Standards Institute (ANSI) regulations.
  • Page 27 Do not move the vehicle with a container attached. Always set the vehicle parking brake before attaching or lifting a container. Never lift a container which is non-compatible with the Leach container attachment. Never lift a container without first latching both container latch arms.

  • Page 28: Hydraulics

    18 Safety 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 manufacturer’s information on accepted use practices.

  • Page 29: Housekeeping

    Never load ashes or other materials which might be smoldering. These materials could ignite refuse in the packer body. : 2R-III™ vehicles are equipped with a 5-lb fire extinguisher, which is located inside the cab. A 20-lb fire extinguisher may also be installed as an option (see Figure 2-2). Each fire extinguisher must be checked regularly by qualified personnel.

  • Page 30: Safety Features

    20 Safety Safety Features Back Up Alarm The back up alarm sounds when the transmission is put into reverse or when the tailgate opens. Tailgate Safety Props The tailgate safety props are used to support and keep the tailgate open during inspection or maintenance procedures.
  • Page 31 Safety 21 Turn the pump ON. Danger! Prior to raising the tailgate, make sure that no one is standing behind the vehicle and that the body is empty. Using the T lever raise the tailgate about 3 feet (enough to swivel both safety props AILGATE towards the body).
  • Page 32 22 Safety Lower the tailgate until both safety props lean against the body base using the T lever. AILGATE Figure 2-6 Props leaned against body base Putting the Tailgate Safety Props Back in Place (for units with tailgate clamps) To put the tailgate safety props back into their stored position: Start the engine.
  • Page 33 Safety 23 Figure 2-8 Props in stored position Secure each prop using the provided latch. MPORTANT Using the T lever (see Figure 2-4), completely close the tailgate. AILGATE light indicator should turn off. TAILGATE OPEN Figure 2-9 light indicator AILGATE Put the tailgate clamps back in place (see Figure 2-3).
  • Page 34 24 Safety Start the engine. Turn the pump ON. Danger! Prior to raising the tailgate, make sure that no one is standing behind the vehicle and that the body is empty. Using the tailgate unlatch button on the body left-side corner near the access door, unlock the tailgate.

  • Page 35: Camera System

    Camera System 2R-III™ units can be equipped with up to two (2) cameras. These cameras can be installed: on the upper part of the tailgate (standard feature) [see Figure 2-12, right], and on the left-hand side mirror (optional feature) [see Figure 2-12, left].

  • Page 36: Tailgate Open Proximity Switch Test

    26 Safety Figure 2-12 Camera on the left-hand side mirror (left), and on the tailgate (right) Tailgate Open Proximity Switch Test The Tailgate Open Proximity Switch Test should be done daily. Successful completion of this test ensures that your unit is safe to operate. If this test fails, do not operate your unit until the appropriate adjustment or service has been completed (see Adjusting the Tailgate Open Proximity Switch on page 27).
  • Page 37 Safety 27 Put both tailgate clamps back to their lock position. B. For this test, proceed as follows (on units equipped with the optional hydraulic tailgate- locking mechanism): Make sure that the body is empty. Start the truck. Engage the pump. Using the tailgate unlatch button on the body left-side corner near the access door (see Figure 2-10), unlock the tailgate.

  • Page 38: Locking Out And Tagging Out The Vehicle

    To lock out and tag out a 2R-III™ unit: Park the vehicle on safe, level ground and apply the parking brake (see Figure 2-14).

  • Page 39: Shutting Down The Vehicle

    Safety 29 The battery set of the 2R-III™ is equipped with a master switch (see Figure 2-15) that must be turned MPORTANT off. Figure 2-15 Master switch Chock all wheels. Put an “O ” tag on the driver’s wheel and on the front windshield.

  • Page 40: Prior To Start-Up

    30 Safety Figure 2-16 Drain valve on air tank Prior to Start-Up Before starting the vehicle: Make sure no system will engage and/or start to operate as you start the engine. Make sure the shut-off valve on the hydraulic tank is fully open before starting the vehicle (see Figure 2-17).
  • Page 41 Safety 31 Figure 2-18 Hydraulic pump O switch on the dashboard (left), on the console (right) Once the engine is started, wait for air pressure to build up to at least 70 psi. Figure 2-19 Air pressure indicator Do not operate or move the vehicle until air pressure has reached 70 psi. MPORTANT...
  • Page 42 32 Safety...

  • Page 43: General Repair Practices

    General Repair Practices Proper service and repair is important for the safe, MPORTANT reliable operation of all mechanical products. The service procedures recommended and described in this service manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose.

  • Page 44: Replacement Parts

    Labrie Enviroquip 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 substitute parts may effect the operation and performance of the unit and will void the warranty.

  • Page 45: Welding Precautions

    General Repair Practices 35 a. Examination or lubrication of the PTO, pump or drive shafts b. Entering the front of the body c. Entering the tailgate See Locking Out and Tagging Out the Vehicle on page 28 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 beneath the pump and apply a slight pressure, so that when the bolts are removed the pump is supported.

  • Page 46: Removal, Disassembly And Repair

    36 General Repair Practices When preparing to use the torch, make certain that the regulator valves are all the way out to the “off” position before the main tank valves are opened to protect the regulators from sudden impact of tank pressure. When opening the tank valves, stand alongside of the regulators, out of the way, in case they blow out.

  • Page 47: Electrical Testing

    Always check the hydraulic fluid in the hydraulic tank after performing any service or repair of the hydraulic system. Always lubricate components with grease fittings after they have been repaired and reinstalled. Use only Leach/Labrie replacement parts. : See Chapter 8 Service and Repair for specific repair instructions. Electrical Testing The electrical system used on the unit consists of various lights, switches and wiring.

  • Page 48: Welding

    38 General Repair Practices The “|” is “blocking” the power from going against the direction of the arrow as a visual reference for path of flow within the circuit. To test, set the multimeter to resistance or diode test, and put the positive (red) lead on the anode side, and the negative (black) lead on the cathode side.

  • Page 49: Capscrew Marking And Torque Values

    General Repair Practices 39 Capscrew Marking and Torque Values Usage Much Used Used at Times Used at Times Capscrew Diameter - 120,000 - 140,000 150,000 & Minimum Tensile To 1 - 115,000 - 133,000 Strength PSI Quality of Material Min. Commercial Med.

  • Page 50: Hydraulic Fitting Torque Values

    40 General Repair Practices Hydraulic Fitting Torque Values JIC 37 DEGREE FLARED TUBE FITTINGS TORQUE TORQUE TUBE SIDE DASH INCH LBS. FOOT LBS. THREAD SIZE SIZE 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1200 1 5/16-12 1400 1 5/8-12 1900...

  • Page 51: Specifications

    Specifications Lubricants SAE #10 or equivalent Grease Multiservice (quality grade) Hydraulic System Capacity (approximately) Fluid Tank 50 gallons Total System System Pressure 2350 PSI (162 BAR) Settings Type of Fittings Steel Tubing w/ Brazed Fittings: Reinforced Rubber Hose w/ Crimped Full-Flow ORFS Fittings, O-Ring Fittings Filtration...

  • Page 52: Pump

    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 the fluid to an ISO 46 specification (higher viscosity).

  • Page 53: Body Dimensions

    Specifications 43 Body Dimensions 147.75" 184" BODY DIMENSIONS 20 Cu. yd. 25 Cu. yd. 32 Cu. yd. AF After Frame (52” Beam) 52” 52” 52” 1270mm 1270mm 1270mm Overall Length 249” 270” 316” 6325mm 6858mm 8026mm CA To Centerline of Trunion (Note2) 130”...

  • Page 54: Hydraulic Fluid

    Stability over a wide range of temperatures and under agitation is very important. Premium hydraulic fluids should be used in Leach hydraulic systems. In addition to the above characteristics, selected additives should be incorporated to provide additional resistance to wear, corrosion, oxidation, decomposition and foaming.

  • Page 55: Preventive Maintenance

    Preventive Maintenance The 2R-III has been designed for long periods of efficient uninterrupted operation. Careful attention to proper preventive maintenance, as described in this chapter, will ensure and extend trouble-free operation of the unit. Particular attention to correct lubrication of the unit and maintenance of the return filter, are probably the two most vital areas of preventive maintenance required.

  • Page 56: Lubrication Chart

    46 Preventive Maintenance Lubrication Chart Recommended Lubricants Any lithium-based commercial multi-purpose grease may be used for all lube points, except control levers. Lubrication of the control levers on the tailgate must be done weekly (every 40 hours of operation) using lubricating oil SAE 10 or equivalent. Caution! In below freezing climates all grease and fluids should have a cold test rating of at least -20°F (-29°C).

  • Page 57: Hydraulic System Service

    If low, fill the hydraulic tank to the “NORMAL FILL LEVEL” with hydraulic fluid as specified in the Leach Hydraulic Fluid Recommendation section on page 42 according to operating and weather conditions.
  • Page 58 48 Preventive Maintenance Figure 5-1 Hydraulic tank w/ return filter...

  • Page 59: Check/Replace Return Line Filter Element

    Preventive Maintenance 49 Check/Replace Return Line Filter Element The return line filter is a vital component of the hydraulic system. Without proper filtration, problems are bound to occur among the hydraulic system components. Stick to the strict maintenance schedule for this item. Time lapse recommendations for element replacement: After the first five days of unit operation.

  • Page 60: Contamination

    Daily Preventive Maintenance Each day perform the following maintenance: Inspection Perform the pre-operational inspection as described in Chapter 4 Operating the 2R-III™ in the Operator’s Manual. Danger! Never go under the vehicle with the engine running. Death or serious injury could result.

  • Page 61: Lubrication

    Preventive Maintenance 51 Lubrication Frequent inspection of grease points will indicate when lubrication is needed. 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 inspection: Check the condition and operation of the container latch assemblies.

  • Page 62: Inspection

    Check all pivot points for wear and smooth operation. Carrier Cylinder Pivot Maintenance Correct location of the carrier cylinder pivot is critical on the Leach 2R-III to ensure proper carrier roller positioning and thorough engagement of the carrier cylinder pivot into the carrier hub. The items locating the carrier cylinder pivot must be inspected during every weekly planned maintenance cycle.

  • Page 63: Wire Rope (Cable)

    Preventive Maintenance 53 Split sleeves & clamp Cylinder pivot locator roll pin Wire Rope (Cable) A detailed inspection of all wire rope (cable) should be made weekly or every 40 hours of use - which includes checking the wire rope for damage, deterioration and secure end connections. Damage or deterioration requiring replacement of wire rope is indicated by broken wires, excessive wear, heat damage, corrosion, stretching or distortion as shown in the wire rope illustration below.

  • Page 64: Maintenance Recommendations

    54 Preventive Maintenance Maintenance Recommendations The packer/carrier assembly should be visually inspected every forty (40) hours of operation for cracked or fatigued welds, loose or broken fasteners, worn bearings, pin hubs or pins. The four (4) torque tube bearing straps should be lubricated a minimum of every forty (40) hours of operation.

  • Page 65: Yearly Preventive Maintenance

    Preventive Maintenance 55 Yearly Preventive Maintenance Hydraulic System Once a year drain, flush and refill the hydraulic tank as described in Flushing Hydraulic System / Cleaning Hydraulic Strainer (Yearly) on page 49. Once a year remove, clean and inspect the suction strainer as described in Flushing Hydraulic System / Cleaning Hydraulic Strainer (Yearly) on page 49.
  • Page 66 56 Preventive Maintenance...

  • Page 67: Check-Out

    Check-Out 2R-III™ has been designed to provide long periods of trouble-free operation. Performing the check-out procedures below, at regular weekly intervals, will help prevent unscheduled downtime. Warning! Make sure you know and observe all safety precautions listed in Chapter 2 before performing any of the following check-out procedures.

  • Page 68: Checking Hydraulic Tank Fluid Level

    58 Check-Out Checking Hydraulic Tank Fluid Level To check the hydraulic tank fluid level, do the following: Make sure the tailgate is down and clamped securely. Position the packer and carrier panels to the “INTERRUPTED CYCLE” position. Pull the pushout lever to position the pushout cylinder in the retract position. The fluid level should be between the safe range marks on the sight gauge.

  • Page 69: Checking Engine Speed Up Switches (Body)

    Check-Out 59 If engine speeds up: OPERATIONAL STATUS Truck Running PTO Disengaged The system is grounded. Locate the short and repair as described in the Electrical System section on page 156. Checking Engine Speed Up Switches (Body) To check engine speed up switches located on the body: OPERATIONAL STATUS Truck Running PTO Engaged...

  • Page 70: Checking Pack Cycle Time

    60 Check-Out If not: OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or switch and repair. See Electrical System on page 156. Activate carrier panel lever. Engine should speed up. If not: OPERATIONAL STATUS Truck Off PTO Disengaged Locate the fault in the wiring or switch and repair.

  • Page 71: Checking Pressures

    Check-Out 61 complete cycle should take 23 to 26 seconds. If not: The engine ECU (Electronic Control Unit) may have to be programmed by an authorized chassis dealer. : It is important the cycle time is correct before performing the following pressure checks. Checking Pressures The pressure checks provided below will indicate the operating condition of the hydraulic system.

  • Page 72: Checking Main Line Pressure

    62 Check-Out Checking Main Line Pressure OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral Warning! Make sure the area above the tailgate is clear before raising the tailgate. To check the main line pressure: Release the tailgate clamps. Depress speed-up button.
  • Page 73 Check-Out 63 Pressure should be 2350 +/- 50 PSI. If not: 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 relief cartridge and turn the adjusting screw out (rotate counter-clockwise) to reach the correct pressure.

  • Page 74: Checking Packer And Carrier Panel Shift (Knockout) Pressures

    64 Check-Out Checking Packer and Carrier Panel Shift (Knockout) Pressures OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral To check packer and carrier panel shift (knockout) pressures: Install a 0-3000 PSI (0-207 BAR) pressure gauge at the quick disconnect coupler on the front control valve.

  • Page 75: Checking Resistance Cartridge Pressure

    Check-Out 65 OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral While observing the pressure gauge, slowly increase the main relief valve setting. The pressure indicator will increase until the knockout pressure setting is reached and the Main Control Valve spool returns to neutral.
  • Page 76 66 Check-Out Figure 6-2 Hydraulic gauge Install LabriePlus part # HYF13701 plug (see above illustration) on the hydraulic hose connected to the extension side of the cylinder. Install hydraulic connectors as shown below.
  • Page 77 Check-Out 67 Connect manual pump (see Figure 6-3) to the empty quick-connect (FD56). Figure 6-3 Hydraulic manual pump (example) Unlock the adjustment nut, then loosen the resistance cartridge pressure set-screw by some turns to reduce resistance. Use the manual pump to reach a reading of 1800 PSI on the gauge. If pressure stops going up before reaching that value, tighten the pressure set-screw by a quarter of a turn and repeat pumping operation.

  • Page 78: Checking Packer High Pressure (Circuit) Relief Cartridge

    68 Check-Out Checking Packer High Pressure (Circuit) Relief Cartridge OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture and test as shown on illustration. Attach port-a-power When the adjusted with 0-6000 psi pressure is reached gauge to port (3800 psi), fluid will marked “P2”...

  • Page 79: Checking Accessory (Circuit) Relief Cartridge

    Check-Out 69 Checking Accessory (Circuit) Relief Cartridge OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture and test as shown on illustration. Attach port-a-power When the adjusted with 0-3000 psi pressure is reached gauge to port (1700 psi), fluid will marked “P2”...

  • Page 80: Checking Pushout Panel Shoes

    70 Check-Out Checking Pushout Panel Shoes OPERATIONAL STATUS Truck Off PTO Disengaged 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 Pushout Panel on page 140. WEAR SHOES Power Take Off (P.T.O.)

  • Page 81: Troubleshooting

    Troubleshooting Troubleshooting is a matter of quickly and logically isolating the cause of a problem and taking corrective action. Factory trained mechanics, experienced operators, a thorough understanding of the information in this manual and accurate maintenance records are the best troubleshooting tools available. Occasionally it may be best for a service person, who is trying to isolate a problem, to go “on the route”...

  • Page 82: Dieseling In Hydraulic Systems

    72 Troubleshooting Preventive maintenance. A properly maintained unit will achieve higher compaction rates than one that is poorly maintained. The condition of the hydraulic system, pump, main relief setting and the condition of the operating cylinder seals will all have an effect on unit performance and compaction.

  • Page 83: Troubleshooting Tables

    Speed up system operating erratically Check electrical system. See Chapter 8 Service and Repair. Hydraulic fluid too hot Check for proper grade of fluid (see Leach Hydraulic Fluid Recommendation on page 42). Hydraulic fluid level too low Check fluid level. Add fluid if necessary.
  • Page 84 Improper grade of hydraulic fluid (fluid Replace with proper grade of hydraulic fluid (see foaming) Leach Hydraulic Fluid Recommendation on page 42). Air entering the system Tighten the suction hose. Replace the pump shaft seal. Replace the suction hose.
  • Page 85 Troubleshooting 75 ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR SPEED-UP BUTTON IS ENGAGED Possible cause Remedy Relay or switch is defective Check for and replace defective parts. See Electrical System on page 156. Electrical system not grounded properly Check all ground connections for corrosion or breaks.
  • Page 86 76 Troubleshooting PACKER PANEL VALVE SECTION WILL NOT SHIFT Possible cause Remedy Packer panel cylinder leaking Perform test for leaking cylinder. See Chapter 8 Service and Repair. Packer panel valve section shift pressure Perform pressure check as described in Checking Pressures on page 61.
  • Page 87 Troubleshooting 77 PACKER/CARRIER PANELS DO NOT DELIVER FULL FORCE TO PACK LOAD INTO BODY Possible cause Remedy Hydraulic pump is defective and will not Replace pump. See Hydraulic Pump on page 152. deliver full pressure Operating cylinder piston seal is leaking Perform test for leaking cylinder. See Chapter 8 Service and Repair.
  • Page 88 78 Troubleshooting PUSHOUT PANEL WILL NOT SLIDE FORWARD AUTOMATICALLY Possible cause Remedy Resistance setting too high Reduce resistance setting Packer/carrier panels not applying full Check pressures. force to move pushout panel forward Check pump. CARRIER AND PACKER PANELS STOP SHORT OF HOME POSITION AFTER EACH CYCLE Possible cause Remedy Unit full...
  • Page 89 Operating cylinder piston seals leaking Perform test for leaking operating cylinder seals and repair as required. Refill with proper grade of hydraulic fluid (see Leach Incorrect grade of hydraulic fluid for current operating conditions Hydraulic Fluid Recommendation on page 42).
  • Page 90 80 Troubleshooting CONTAINER WON’T LIFT Possible cause Remedy Linkage binding or restrictive Repair or replace linkage as required. Lifting motor or cylinder(s) by-passsing Repair or replace the defective component. hydraulic fluid Shear pin or key broken between winch Replace the key or pin. shaft and drum WINCH MOTOR LEAKING Possible cause...

  • Page 91: Hydraulic System

    Troubleshooting 81 Hydraulic System The following is a description with flow diagrams of what happens in the hydraulic system of the telescopic system during the loading, packing and unloading operations of the unit. Operator action is presented and then a description of the hydraulic flow and the interaction of system components (i.e., valves and cylinders) follows.

  • Page 92: Transmission In Neutral (With Packer And Carrier Panels In The "Home" Position)

    82 Troubleshooting Transmission in Neutral (with Packer and Carrier Panels in the “Home” Position) Operator Action Operator starts the truck and engages the PTO/pump and speed-up system. Hydraulic Sequence Hydraulic fluid flows from the tank, by gravity, to the pump; from there, it is pumped to the FCV (Front Control Valve).

  • Page 93: Packer Panel Sweeps Back Over Load

    Troubleshooting 83 Packer Panel Sweeps Back Over Load Operator Action The operator moves the control levers inward to start the compaction cycle. Hydraulic Sequence Operator action causes the MCV (Main Control Valve) to shift, diverting flow to the rod end of the packer panel cylinders.

  • Page 94: Carrier & Packer Panels Move Down To "Interrupted Cycle" Position

    84 Troubleshooting Carrier & 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 1950 PSI (134 BAR) causing the MCV (Main Control Valve) to shift, diverting flow to the rod end of the carrier cylinders.

  • Page 95: Packer Panel Sweeps Hopper

    Troubleshooting 85 Packer Panel Sweeps Hopper Operator Action Operator shifts the control levers outward to start compaction. Hydraulic Sequence Fluid flows through the MCV (Main Control Valve) packer section to the case end of the packer panel cylinders. As the cylinders extend, the packer panel sweeps the load forward in the hopper. As the packer cylinders extension stroke continues, pressure builds to 1950 PSI (134 BAR) causing the MCV (Main Control Valve) to shift.

  • Page 96: Packing Refuse (1)

    86 Troubleshooting Packing Refuse (1) Operator Action None. MCV (Main Control Valve) shifts automatically. Hydraulic Sequence Fluid flows from the MCV (Main Control Valve) to the case end of the carrier panel cylinders. The cylinders extend, moving the carrier and packer panels up, packing refuse against the pushout panel. When the pressure reaches 2150 PSI (148 BAR), the MCV (Main Control Valve) shifts into neutral and the packing cycle is completed.

  • Page 97: Packing Refuse (2)

    Troubleshooting 87 Packing Refuse (2) 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 carrier cylinders. This pressure is also building in a pilot line from the carrier valve section to the FCV (Front Control Valve) pushout section.

  • Page 98: Raising Tailgate

    88 Troubleshooting Raising Tailgate Operator Action Operator opens the packer panel to release pressure. Operator loosens and swings away from the body the tailgate clamps. Operator depresses the speed-up button, then moves the tailgate lift lever rearward. SPEED UP BUTTON TAILGATE LIFT LIFT LEVER Hydraulic Sequence...

  • Page 99: Ejecting Load

    Troubleshooting 89 Ejecting Load Operator Action Operator depresses speed-up button and moves pushout lever rearward. SPEED UP BUTTON PUSHOUT LEVER 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, the load is ejected from the body.

  • Page 100: Retracting Pushout Panel

    90 Troubleshooting Retracting Pushout Panel Operator action Operator releases speed-up button and moves the pushout lever forward. : Speed-up may have to be used to retract pushout panel if engine RPM drops too far. SPEED UP BUTTON PUSHOUT LEVER Hydraulic Sequence Moving the pushout lever forward shifts a spool in the FCV (Front Control Valve) causing flow to the telescopic cylinder.

  • Page 101: Lowering Tailgate

    Troubleshooting 91 Lowering Tailgate Operator Action Operator moves the tailgate lift lever forward. SPEED UP BUTTON TAILGATE LIFT LIFT 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.
  • Page 102 92 Troubleshooting...

  • Page 103: Service & Repair

    Service & Repair This chapter contains the instructions necessary for repair and replacement of the main components of the unit. Before attempting any repair of the unit, become thoroughly familiar with the operation instructions (see Chapter 4 of the Operator’s Manual) and general repair practices (see Chapter 3 of this manual).

  • Page 104: Test For Leaking Packer Panel Cylinders

    94 Service & Repair All four cylinders are the same (except for tag axle units). The two packer panel cylinders mount in the opposite direction of the carrier panel cylinders and the pivot mountings are different. er panels during the PACKER perating cylinders”.
  • Page 105 Service & Repair 95 PACKER PANEL CYLINDERS : Engine speed-up only activates when carrier panel lever is activated. Caution! Loosen the hydraulic fittings slowly to release any trapped pressure. Watch for inadvertent movement of components. OPERATIONAL STATUS Truck Off PTO Disengaged Disconnect and plug the lines to the rod end of one cylinder at a time.
  • Page 106 96 Service & Repair Shift the packer panel lever outward to apply hydraulic pressure to the case end of the packer panel cylinders. Hold the lever and observe the fluid flow from the open port on the rod end of the cylinder.

  • Page 107: Test For Leaking Carrier Panel Cylinders

    Service & Repair 97 OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral Shift the packer panel lever inward to apply hydraulic pressure to the rod end of the packer panel cylinder. Hold the lever and observe the fluid flow from the port on the case end of the cylinder. The flow of hydraulic fluid should be no more than 2 fluid ounces per minute.
  • Page 108 98 Service & Repair OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral Shift the carrier panel lever outward to fully extend the carrier panel cylinders (“home position”). CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged Disconnect and plug the lines that connect to the rod end of one cylinder. PLUG Caution! Loosen the hydraulic fittings slowly to release any trapped pressure.
  • Page 109 Service & Repair 99 OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral Shift the carrier panel lever outward to apply hydraulic pressure to the case end of the carrier cylinders. Hold the lever and observe the fluid flow from the open port on the rod end. The flow of hydraulic fluid should be no more than 2 fluid ounces per minute.
  • Page 110 100 Service & Repair CARRIER PANEL LEVER OPERATIONAL STATUS Truck Off PTO Disengaged Disconnect and plug the hydraulic lines which connect to the case end of the carrier panel cylinder. PLUG Caution! Loosen the hydraulic fittings slowly to release any trapped pressure. Watch for inadvertent movement of components.

  • Page 111: Removal Of Packer Panel Cylinders

    Service & Repair 101 CARRIER PANEL LEVER OBSERVE FLUID FLOW OPERATIONAL STATUS Truck Off PTO Disengaged If the cylinder does not leak, reconnect the hydraulic lines to the case end of the carrier panel and tighten to 110 ft-lbs. Removal of Packer Panel Cylinders Procedure: OPERATIONAL STATUS Truck Off...
  • Page 112 102 Service & Repair Secure a nylon sling around the cylinder as shown and attach to a suitable lifting device with a capacity of 500 lbs (227 kg). Operate the hoist to make the lifting cable snug without applying strain on the cylinder. See Chapter 3 General Repair Practices for more detailed information about the correct use of slings and...
  • Page 113 Service & Repair 103 OPERATIONAL STATUS Truck Off PTO Disengaged Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin. OPERATIONAL STATUS Truck Running PTO Engaged Speed Up Off Shift the packer panel lever inward to completely retract the cylinder. OPERATIONAL STATUS Truck Off PTO Disengaged...

  • Page 114: Removal Of Carrier Panel Cylinders

    104 Service & Repair Remove capscrew (1), lockwashers (2), and nut (3) securing the pivot pin retainer (4) and remove the retainer. Remove the pivot pin. Check for bent pivot pins and inspect pin hubs for broken welds and elongated holes. Removal of Carrier Panel Cylinders Procedure: OPERATIONAL STATUS...
  • Page 115 Service & Repair 105 CARRIER PANEL LEVER OPERATIONAL STATUS Truck Off PTO Disengaged Secure chains or a sling to the upper and lower end of the carrier panel. Attach the other end to a suitable lifting device with a minimum lifting capacity of 1600 lbs (726 kg). Adjust the hoist so that it will support the panel once the roller assembly and pivot pin are removed, but not so tight that it changes the position of the carrier panel.
  • Page 116 106 Service & Repair Secure a nylon sling around the cylinder and attach to a lifting device with a lifting capacity of 500 lbs (227 kg). Operate the hoist to snug the lifting cable without applying strain to the cylinder. OPERATIONAL STATUS Truck Running PTO Engaged...

  • Page 117: Disassembly Of Operating Cylinders

    Service & Repair 107 Disconnect both the case end (1) and rod end (2) pressure tubes from the carrier cylinder. Immediately plug the pressure tubes and cap the cylinder ports to keep fluid in and dirt out. Remove capscrew (1), nut (2) and lockwashers (3) securing the cylinder pivot pin retainer (4) and remove retainer.

  • Page 118: Inspection And Replacement Of Operating Cylinders

    (6) must be installed any time the cylinder is disassembled. Pay particular attention to the way parts are positioned for correct assembly. Parts that must be replaced together are available as a repair kit from your authorized Leach distributor.

  • Page 119: Reassembly And Installation Of Operating Cylinders

    Service & Repair 109 Reassembly and Installation of Operating Cylinders Reassemble and install the operating cylinders in the approximate reverse order of disassembly. Description of the Packer Panel The packer panel works in conjunction with the carrier panel and four operating cylinders to make up the compaction mechanism.

  • Page 120: Bearing Placement

    110 Service & Repair Bearing Placement For this task, apply the following procedure: OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral Move the packer panel lever outward to fully extend the packer panel cylinders and put the panel in the “home position”.

  • Page 121: Roller Replacement

    Service & Repair 111 stall the bearing housing over the packer panel be and secure to the carrier panel channel with w through-bolts, shims and nuts. Torque to 900 . Lbs. (1221 Nm.) then tack weld the nuts to the lts.
  • Page 122 112 Service & Repair OPERATIONAL STATUS Truck Running PTO Engaged Speed Up Off Shift the control levers and cycle the panels as necessary to align the upper and lower rollers with track holes. TRACK HOLES 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.
  • Page 123 Service & Repair 113 OPERATIONAL STATUS Truck Off PTO Disengaged Remove one roller at a time. Replace any roller that is excessively worn, cracked or out of round. Inspect the condition of the track bar. Replacement rollers should be installed with the original shims or the same amount of new shims (see Carrier Roller Adjustment &...

  • Page 124: Carrier Roller Adjustment & Maintenance

    114 Service & Repair Once alignment is correct, lubricate each roller as described in the “Lubrication Chart” on page Using the capscrews (1), lockwashers (2) and spacers (3) secure the cover weldment (4) over the four track holes. Carrier Roller Adjustment & Maintenance The purpose of adjusting the carrier rollers is to provide for smooth upward and downward travel of the carrier and packer panels with a minimum of side travel.
  • Page 125 Service & Repair 115 The rollers align the carrier by means of slight contact with the inside vertical face of the track channels (also known as the “web” of the track), and should never be allowed to apply excess force to the point of distorting the web.

  • Page 126: Wear Shoe Replacement

    116 Service & Repair Example The upper right roller is removing paint to the point of scuffing the track web. Also, the carrier shifts to the left about 5/8” while being retracted. To adjust, the upper right roller should have 2-3 shims removed.
  • Page 127 Service & Repair 117 : Wear shoe replacement is not required if the wear is confined only to the top or bottom chromium plate of the wear shoe assembly (see Figure 8-2). In such a case, only replace the plate that shows signs of wear. To replace wear shoes, proceed this way: OPERATIONAL STATUS Truck Running...
  • Page 128 118 Service & Repair TRACK HOLES Before proceeding with the replacement of a wear shoe, you will need to slightly lift the carrier and packer panel assembly with a lifting crane to take the weight off the wear shoes and gain access to the shoes.
  • Page 129 Service & Repair 119 : If you only need to replace worn-out chromium plates, you will have some unwelding and rewelding to do. But before doing so, take all the necessary measures to ensure your safety. Check the track bar for cracks and wear. 4 f.

  • Page 130: Wear Shoe Adjustment

    120 Service & Repair Replacement wear shoes should be installed with the original shims or the same amount of new shims (see Wear Shoe Adjustment on page 120). A grease fitting should be installed in the replacement wear shoe. OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On...
  • Page 131 Service & Repair 121 The purpose of adjusting the carrier panel wear shoes (see Figure 8-3) is to provide for smooth upward and downward travel of the carrier and packer panels with a minimum of side travel. In essence, the wear shoes are adjusted to align the carrier panel to the carrier operating cylinder stroke positions, and by shimming the wear shoes in a diagonal fashion, the carrier may be adjusted to allow for fabrication variances of the many components of the tailgate assembly.
  • Page 132 122 Service & Repair The wear shoes should always be shimmed to allow the carrier to travel in the direction of the side to side movement, thus aligning the carrier with the cylinders. If the carrier shifts to the right at the bottom wear shoes, then the following adjustments would be made, depending upon the looseness of the wear shoes inside the tracks: Add shim(s) to the left bottom wear shoe...
  • Page 133 Service & Repair 123 Shift the control levers and cycle the panels as necessary to align the upper and lower wear shoes with the track holes. TRACK HOLES OPERATIONAL STATUS Truck Off PTO Disengaged Adjust any wear shoe that needs to be adjusted. Remove all 4 screws that secure the plastic plates to the wear shoe assembly (see Figure 4 a.

  • Page 134: Tailgate Lift Cylinders

    124 Service & Repair : This procedure may have to be repeated multiple times to achieve proper adjustment of the wear shoes. Again, remember that the wear shoes are better left a little loose than too tight. OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Transmission Neutral...

  • Page 135: Test For Leaking Tailgate Cylinders

    Service & Repair 125 TAILGATE LIFT CYLINDERS Test for Leaking Tailgate Cylinders : This check will require two people. For this task, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged Loosen and release (swing away) the tailgate clamps. CLAMPS OPERATIONAL STATUS Truck Running...

  • Page 136: Removal Of Tailgate Lift Cylinders

    126 Service & Repair Removal of Tailgate Lift Cylinders For this task, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged With the tailgate closed, attach a sling connected to a suitable lifting device with a capacity of lbs (227 kg) to the tailgate lift cylinder. See Chapter 4 General Repair Practices for more detailed information about the correct use of slings and...

  • Page 137: Draining Fluid From Tailgate Lift Cylinder

    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.

  • Page 138: Tailgate Assembly

    128 Service & Repair  D Tailgate Assembly The tailgate assembly consists of the operating cylinders, 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.

  • Page 139: Removal Of The Tailgate Assembly

    Service & Repair 129 Removal of the Tailgate Assembly For this task, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged Release the tailgate clamps and swing away. Disconnect and remove the tailgate lift cylinders (see Removal of Tailgate Lift Cylinders on page 126).

  • Page 140: Inspection Of Tailgate

    130 Service & Repair Remove capscrew and locknut (not shown) to remove retainer (1) and hinge pin (2). Operate the lifting device and/or move the truck forward to free the tailgate from the body. Position the tailgate on supports as needed to facilitate repairs. The supports must be capable of supporting 7500 lbs (3402 kg).

  • Page 141: Reassembly And Installation Of Tailgate

    Service & Repair 131 Check the tailgate seal for any sign of deterioration. Check handles for looseness. Replace any defective or worn part. Follow all safety precautions pertaining to welding described in Chapter 2 Safety. See Chapter 3 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.

  • Page 142: Disassembly And Reassembly Of The Front Control Valve

    132 Service & Repair Disassembly and Reassembly of the Front Control Valve For these tasks, refer to the valve manufacturer’s manual for detailed instructions. The following illustrations show the various components that make up the front control valve. : Service should be limited to seal replacement, cartridges and individual valve sections. Field repairs of the spool assemblies are not recommended.

  • Page 143: Reinstallation Of The Front Control Valve

    Service & Repair 133 SPOOL COLLAR BONNET CAPSCREW TIE BOLT Reinstallation of the Front Control Valve For this task, apply the following procedure: Secure the valve to the mounting bracket with the appropriate hardware. Remove plugs and caps, then attach hydraulic lines with new ORFS o-rings. Torque all hydraulic lines per torque chart as described in Chapter 3 General Repair Practices.

  • Page 144: Removal Of The Main Control Valve

    134 Service & Repair MAIN CONTROL VALVE Removal of the Main Control Valve For this task, apply the following procedure: Place the packer and carrier panels in the “interrupted cycle” position. INTERRUPTED CYCLE POSITION CARRIER PANEL PACKER PANEL Move the packer panel control lever outward to sweep the packer panel through the hopper toward the home position.

  • Page 145: Disassembly And Reassembly Of The Main Control Valve

    Service & Repair 135 PACKER PANEL LEVER 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 contamination. : The Main Control Valve assembly weighs approximately 100 lbs (45.3 Kg). Use appropriate lifting procedures and techniques when handling this assembly.

  • Page 146: Main Control Valve Resealing

    SECTION CONTAINER HANDLING SECTION Main Control Valve Resealing The following work instructions outline the procedure to reseal the main control valve on a 2R-III™ unit. : These repairs should be performed only by trained, experienced technicians. Tools Required : Ratchet ¾”...
  • Page 147 Service & Repair 137 Nylon sling, minimum 500 lb. rating Lint free rags Petroleum jelly Parts Required: LabriePlus part # HYJ4104 - Section Seal Kit, one kit required for each section (does not include plug or port relief seals) LabriePlus part # HYJ04107 - Inlet Section Seal Kit, one kit required per valve assembly Thoroughly clean the valve, connecting hoses and the area directly surrounding the valve.
  • Page 148 138 Service & Repair Using an o-ring pick, remove and discard the o-rings and back-up rings from the spool and/or valve body. Clean and inspect the valve spool, the bore and seal seats in the valve body, as weel as the seal and dust boot retaining plates for cracks, abnormal wear, rust, or uneven surfaces.

  • Page 149: Telescopic Cylinder

    Service & Repair 139 Telescopic Cylinder Removal of Telescopic Cylinder For this task, apply the following procedure: OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Move the pushout lever to position the pushout panel approximately midway in the body. Weld a lifting eye to the roof of the body.

  • Page 150: Pushout Panel

    140 Service & Repair OPERATIONAL STATUS Truck Off PTO Disengaged Attach a sling connected to a lifting device capable of lifting 750 lbs (341 kg) to the telescopic cylinder. Remove the nuts and bearing block halves connecting the pushout panel to the cylinder. OPERATIONAL STATUS Truck Running PTO Engaged...

  • Page 151: Wear Block Replacement

    Service & Repair 141 PUSHOUT PANEL WEAR BLOCKS Wear Block Replacement The wear blocks should be replaced before there is metal to metal contact between the pushout panel and the trough floor. To replace wear blocks under the pushout panel, proceed this way: OPERATIONAL STATUS Truck Off PTO Disengaged...

  • Page 152: Removal Of Pushout Panel

    142 Service & Repair WEAR BLOCKS Removal of Pushout Panel For this task, apply the following procedure: 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. PUSHOUT LEVER Remove the tailgate lift cylinders as described on Page 126.

  • Page 153: Installation Of Pushout Panel

    Service & Repair 143 The pushout panel can now be removed from the body. The method of removal will depend on the equipment available. Whatever method is used, the equipment must be capable of lifting a minimum of 2800 lbs (1270 kg) and the panel should be secured safely to the removal device. Figure 8-4 Pushout panel Installation of Pushout Panel...

  • Page 154: Carrier And Packer Panels

    144 Service & Repair 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 pushout panel. Their movement through the different cycles is controlled by the operating cylinders.

  • Page 155: Packer Panel

    Service & Repair 145 PACKER PANEL CARRIER PANEL CYLINDERS CYLINDERS CARRIER PANEL PACKER PANEL Packer Panel Removal of Packer Panel To remove the packer panel, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged (If the carrier panel is also to be removed) - Remove all four operating cylinders (see Removal of Packer Panel Cylinders on page 101 and Removal of Carrier Panel Cylinders on page 104) proceed to step 6.
  • Page 156 146 Service & Repair : For more information about lifting devices and slings, refer to Chapter 3 General Repair Practices. OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Move the packer panel operating lever inward to bring the packer panel up. When the panel reaches a vertical position, bring the packer panel control lever back to neutral.
  • Page 157 Service & Repair 147 Make sure the cylinder weight is securely supported by the hoist and carefully remove the pivot pin. Attach a chain connected to a suitable lifting device, capable of lifting 1600 lbs (726 kg) to the packer panel as shown. Operate the lifting device to support the weight of the packer panel without causing strain on the bearing and roller assemblies.

  • Page 158: Inspection And Replacement Of Packer Panel

    148 Service & Repair Remove the outside bearing assemblies (see Bearing Placement on page 110). With the bearing assemblies removed, carefully operate the hoist and lift the packer panel out of the hopper. Use care to avoid damaging the hopper. Inspection and Replacement of Packer Panel For these tasks, apply the following procedure: OPERATIONAL STATUS...

  • Page 159: Installation Of Packer Panel

    Carrier Panel The correct method of operation is thoroughly described in the 2R-III™ 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...

  • Page 160: Removal Of Carrier Panel

    150 Service & Repair Anytime a repaired area has a repeat failure, suspect that the core problem, whether it is mechanical or operator, has not been adequately addressed. Removal of Carrier Panel For this task, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged Remove top sheet supports for better accessibility.

  • Page 161: Inspection And Replacement Of Carrier Panel

    Service & Repair 151 Inspection and Replacement of Carrier Panel For these tasks, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged Carefully inspect all pivot, bearing and roller surfaces for excessive or uneven wear, scoring or damage. Check the panel for broken welds, bent edges or warpage. Inspect the track bar for excessive wear or damage.

  • Page 162: Track Bar Replacement

    WRONG RIGHT NO GAP 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. 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.

  • Page 163: Removal Of Hydraulic Pump

    Service & Repair 153 PUMP DRIVE SHAFT Removal of Hydraulic Pump For this task, apply the following procedure: OPERATIONAL STATUS Truck Off PTO Disengaged Shut the ball valve at the underside of the hydraulic fluid tank. BALL VALVE Remove the hose clamp. Remove the pump suction line and allow the fluid to drain.

  • Page 164: Installation Of Hydraulic Pump

    154 Service & Repair Loosen the setscrew (1) and free the yoke (2) from the pump shaft by telescoping the drive shaft toward the PTO or engine. Remove the key from the pump shaft keyway. Remove the attaching hardware. The pump assembly may now be removed from the mounting bracket.

  • Page 165: Testing A New Pump

    Service & Repair 155 Procedure to be applied in the preparation of a new pump: Remove and clean the hydraulic strainer (1). Change the filter element (2). Drain and flush the hydraulic tank as described on page 49. Clean the magnetic ring (4). Testing a New Pump OPERATIONAL STATUS Truck Running...

  • Page 166: Electrical System

    156 Service & Repair 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 suspected components (see Electrical Testing on page 37).
  • Page 167 Service & Repair 157 PART NO. DESCRIPTION PURPOSE UNIT HYJ00910 Pressure Gauge To measure system pressure All except FL104/Beta HYJ05190 ORFS O-Ring Kit #4 to #24 ORFS o-rings HYF10195 Snap Connector Quick coupling for pressure gauges HY010000 Plunger Tool Remove/install spring loaded plungers on rear loader container attachments HYV50000...
  • Page 168 Our office in the U.S. Our office in Canada 1981 W. Snell Road 175A Route Marie-Victorin Oshkosh, WI 54904 Levis, QC G7A 2T3 Toll Free: 1-800-231-2771 Toll Free: 1-877-831-8250 Telephone: 1-920-233-2770 Telephone: 1-418-831-8250 General Fax: 1-920-232-2496 Service Fax: 1-418-831-1673 Sales Fax: 1-920-232-2498 Parts Fax: 1-418-831-7561 Mailing Address Mailing Address...

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