Page 1 A Subsidiary of Federal Signal Corporation 2R-III SERVICE MANUAL Over Serial Number 30000 BUILDING THE BEST...
Page 3 WARRANTY A Subsidiary of Federal Signal Corporation 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.
Page 4 FOREWARD Leach Company has been a leader in the refuse industry for over 115 years. Leach refuse bod- ies are the industry standard for both quality and performance. Leach Company is justifiably proud of the quality engineering, material and workmanship that goes into each and every packer we produce.
Page 5: Table Of Contents
TABLE OF CONTENTS SECTION 3 - OPERATION (continued) WARRANTY..............I FORWARD..............II Attaching a Container to The Packer.....3-13 TABLE OF CONTENTS..........III Using a Winch or Container Lift Cylinder....3-14 Using a Container Push Bar........3-15 SECTION 1 - SAFETY PRECAUTIONS Packing The Load..........3-15 Pushout Panel Operation During Packing....3-16 General..............1-1 Disconnecting The Container.........3-16 Danger, Warning and Caution Decals......1-1...
Page 6: Table Of Contents
TABLE OF CONTENTS SECTION 8 Continued SECTION 7 - CHECK-OUT Ejecting Load............8-17 General..............7-1 Retracting Pushout Panel........8-18 Check Hydraulic Tank Fluid Level......7-1 Lowering Tailgate..........8-19 Check Engine Speed-Up Switch (Cab)....7-2 Check Engine Speed-Up Switches (Body)....7-2 SECTION 9 - SERVICE AND REPAIR Check Pack Cycle Time........7-3 General..............9-1 Check Pressures..........7-3 Description Of Operating Cylinders......9-1...
Page 7 TABLE OF CONTENTS SECTION 9 Continued Installation Of Hydraulic Pump......9-39 New Pump Preparation.........9-39 Testing A New Pump..........9-39 Description Of Electrical System......9-40 Testing..............9-40 Repair..............9-40 Inspection.............9-40 Schematics............9-40 SECTION 10 - SERVICE TOOLS Service Tools............10-1...
Page 9: Section 1 - Safety Precautions
SECTION 1 SAFETY PRECAUTIONS GENERAL Publication of these precautions does not imply or in The 2R-III has been designed with the operator in mind. any way represent an all inclusive list. It is the opera- However, as with any industrial machinery, especially tors responsibility to be familiar with and ensure that those that are large and apply forces through hydraulic operation is in accordance with safety requirements and...
Page 10: Prior To Start Up
SECTION 1 SAFETY PRECAUTIONS PRIOR TO START UP Never operate machinery while wearing jewelry or 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 in- ing the unit.
Page 11: General Operation
SECTION 1 SAFETY PRECAUTIONS GENERAL OPERATION Turn on appropriate warning lights, put on a safety vest, protective glasses and protective shoes. It is the operator’s responsibility to ensure that op- All service opening covers and access doors must eration of the unit is in accordance with the guide- be maintained and latched in place while operating lines contained in the Operator’s manual and in ac- equipment.
Page 12 SECTION 1 SAFETY PRECAUTIONS Do not move the vehicle with a container attached. To avoid possible bodily injury or equipment dam- age, lower the tailgate slowly. Always set the vehicle parking brake before attach- ing or lifting a container. Never enter the body unless the telescopic ejec- tion cylinder pressure is released, PTO disengaged Never lift a container which is non-compatible with and ignition key removed and placed in your pocket.
Page 13: Hydraulics
SECTION 1 SAFETY PRECAUTIONS HYDRAULICS In case of injury seek proper medical treatment im- Hydraulic fluid operates under high temperatures. mediately. Avoid contact with piping, hoses or cylinders to pre- vent burns. Never use hands to check for leaks. Hydraulic fluid escaping under pressure may cause injury.
Page 14 SECTION 1 SAFETY PRECAUTIONS - DECAL PLACEMENT CART TIPPER CONTROL DOWN DOWN...
Page 15 SECTION 1 SAFETY PRECAUTIONS - DECAL PLACEMENT CART TIPPER CONTROL DOWN DOWN...
Page 16 SECTION 1 SAFETY PRECAUTIONS - DECAL PLACEMENT 10 13 15 16 18 20 21 22 14 23...
Page 17 SECTION 1 SAFETY PRECAUTIONS - DECAL PLACEMENT TAILGATE PROP OPERATION INSTRUCTIONS ENGAGE TAILGATE PROPS ENGAGE TAILGATE PROPS 1.) SLIDE TG PROP ALL OF THE WAY OUT UNTIL IT REACHES THE STOP. 2.) LIFT THE PROP INTO POSITION. 1.) UNLATCH TAILGATE, RAISE TAILGATE SLOWLY UNTIL ENOUGH ROOM IS AVAILABLE TO DEPLOY PROPS. 3.) REINSTALL PROP RETAINER PIN AND CLEVIS.
Page 18 SECTION 1 SAFETY PRECAUTIONS - DECAL PLACEMENT 20 30 43 6 21 34 44 TAILGATE PROP OPERATION INSTRUCTIONS ENGAGE TAILGATE PROPS ENGAGE TAILGATE PROPS 1.) SLIDE TG PROP ALL OF THE WAY OUT UNTIL IT REACHES THE STOP. 2.) LIFT THE PROP INTO POSITION. 1.) UNLATCH TAILGATE, RAISE TAILGATE SLOWLY UNTIL ENOUGH ROOM IS AVAILABLE TO DEPLOY PROPS.
Page 19: Section 2 - Introduction
SECTION 2 INTRODUCTION TERMS YOU WILL NEED TO KNOW BODY ASSEMBLY TAILGATE ASSEMBLY HOPPER LOADING EDGE PUSHOUT PANEL HYDRAULIC TANK PACKER PANEL CARRIER PANEL...
Page 20: Loading
SECTION 1 INTRODUCTION The main purpose of the 2R-III is to safely and effi- ciently: load, compact, transport and unload refuse. The following describes how the unit performs those tasks in the most basic terms. For a more detailed descrip- tion of the unit and its components, read the complete 2R-III SERVICE MANUAL.
Page 21: Unloading
SECTION 2 INTRODUCTION The operator again activates the packing cycle. The PACKER carrier and packer panels move forward and sweep the PANEL PUSHOUT refuse from the hopper up into the body and pack it PANEL against the pushout panel. Having completed a cycle, the carrier and packer panels are back into the “home”...
Page 22: Container Attachment (Latch And Ears)
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 ARM LATCH one (1) to ten (10) cubic yard capacity.
Page 23: General
SECTION 2 INTRODUCTION GENERAL TERMS YOU NEED TO KNOW The main purpose of a refuse body is to load, compact, Before going further, become familiar with the transport and unload refuse. To assist in loading of container 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.
Page 24: Winch
SECTION 2 INTRODUCTION WINCH 1. Control lever 2. Engine speed up button Cable Winch assembly Container attachment Stop bar/Lid guard CONTAINER LIFTING CYLINDER (CLC) 1. Control lever 2. Engine speed-up button 3. Roller guide Cable Lifting cylinder assembly Container attachment Stop bar/Lid guard CONTAINER PUSH BAR (CPB) 1.
Page 25: Basic Operation
SECTION 2 INTRODUCTION BASIC OPERATION All Leach container handling systems have three (3) basic steps for operation. ATTACH The first step in container handling is to attach the con- tainer to the rear loader by securing it with the latch arms of the container attachment.
Page 26 SECTION 2...
Page 27: Section 3 - Operation
SECTION 3 OPERATION GENERAL This section will provide all of the instructions neces- sary to operate the 2R-III. However, prior to attempting any operation of the unit, make sure you are familiar with all of the safety information contained in SECTION 1, SAFETY PRECAUTIONS.
Page 28: Location Of Operating Controls
SECTION 3 OPERATION LOCATION OF OPERATING CONTROLS 11 12 9 10...
Page 29: Pump/Pto Control
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.
Page 30: Engine Speed-Up Push Button
SECTION 3 OPERATION ENGINE SPEED-UP PUSH BUTTON (4) When depressed, this push button switch will cause the engine to speed-up and supply more power to the hy- draulic system. Located on the lower front left side of the body, it is depressed by the operator when operat- ing either the pushout lever or tailgate lift lever.
Page 31: Driver Signal Buttons
SECTION 3 OPERATION DRIVER SIGNAL PUSH BUTTONS (8) These two push buttons, one located on each side of the tailgate, are connected to a buzzer mounted under the drivers seat or under the dash in the chassis cab. The operator depresses one of these push buttons to signal the driver when the loading operation is completed and the truck is ready to be moved.
Page 32: Operating Procedures
SECTION 3 OPERATION OPERATING PROCEDURES This section of the manual provides all the instructions necessary to start and operate the 2R-III, including spe- cific instructions for loading, packing and unloading the unit. NOTE It is important that operators and mechanics understand these procedures.
Page 33 SECTION 3 OPERATION 4. Make sure the tailgate clamps are in the closed posi- tion and securely tightened. 5. Check the hydraulic tank gauge to make sure the fluid is in the “safe” range. Add fluid, if necessary. (See SECTION 5, SPECIFICATIONS for the correct type of fluid to use.) The pushout cylinder must be retracted, the tailgate down, the carrier and packer panels in the “interrupted cycle”...
Page 34 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.
Page 35 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.
Page 36: Walk Around Inspection Checklist
SECTION 3 OPERATION Do not operate a unit that is in need of service or repair. 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, stat- ing the unit is inoperative and remove the keys.
Page 37: Start Up (Operating Instructions)
SECTION 3 OPERATION START UP (OPERATING INSTRUCTIONS) 1. Inspect and start the truck as described in the pre- operational walk-around inspection. 2. Engage the Pump/PTO control (to start the hydraulic pump). 3. Place the engine speed up switch in the ON position. ENGINE ENGINE SPEED-UP...
Page 38: Positioning The Pushout Panel
SECTION 3 OPERATION POSITIONING THE PUSHOUT PANEL To load the unit, the pushout panel must be positioned toward the rear of the body. Check the tailgate clamps to make sure both are securely tightened. TAILGATE CLAMPS Depress and hold the speed-up push button. Push the pushout lever rearward until the pushout cylinder is fully extended.
Page 39: Loading The Hopper
SECTION 3 OPERATION LOADING THE HOPPER There are only a few but important points to remember during loading of refuse. 1. Load the hopper evenly on both sides. 2. Load heavy objects in the center of the hopper. 3. Do not load refuse higher than the loading edge.
Page 40: Using A Winch Or Container Lift Cylinder
SECTION 3 OPERATION USING A WINCH OR CONTAINER LIFT CYLINDER ATTACH CONTAINER 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.
Page 41: Using A Container Push Bar
SECTION 3 OPERATION USING A CONTAINER PUSH BAR (CPB) Once the container is secured within the latch assem- bly the container is ready to be dumped. After assuring that all persons are standing clear, the operator moves the CPB control lever in the direction shown on the in- struction decal to raise the container.
Page 42: Pushout Panel Operation During Packing
SECTION 3 OPERATION PUSHOUT PANEL OPERATION DURING PACKING TELESCOPIC PUSH OUT PUSHOUT LEVER The 2R-III telescopic pushout cylinder will normally move toward the front of the body automatically. When the resistance circuit is adjusted to produce maximum load density, it may become necessary to manually retract the telescopic pushout cylinder in order to allow the com- pacted refuse to move forward in the body.
Page 43: Unloading At Dumpsite
SECTION 3 OPERATION UNLOADING AT DUMPSITE Do not unload uphill or against a pile of refuse. 1. Apply the brakes, engage the PTO and ensure the transmission is in neutral. Relieve the pressure on the tailgate by moving the packer panel to the “interrupted cycle position”.
Page 44: Ejecting The Load
SECTION 3 OPERATION EJECTING THE LOAD 1. Depress and hold engine speed-up button, push the pushout lever rearward and hold until the pushout panel stops. PUSHOUT LEVER 2. Slowly pull the unit ahead to clear the refuse pile when the tailgate is lowered. Clear debris from the edges with a pole while stand- ing clear off to one side.
Page 45: Shut Down
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.
Page 46 SECTION 3 3-20...
Page 47: Section 4 - General Repair Practices
Of growing concern to the Leach Company is the use of counterfeit, will-fit or substitute parts. FS Depot re- placement parts are designed and manufactured to A Subsidiary of Federal Signal Corporation exacting standards. The use of counterfeit, will-fit or sub- stitute parts may effect the operation and performance of the unit and will void the warranty.
Page 48: Safety During Service And Repair
SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR Set the parking brake. When working on the unit always use the service tools listed in Section 10, SERVICE TOOLS if so Put the vehical in park, or if equipped with a manual directed by the instructions in Section 9, SERVICE transmission, put the unit in gear and remove the AND REPAIR.
Page 49: Oxy-Acetylene Torches
SECTION 4 GENERAL REPAIR PRACTICES OXY-ACETYLENE TORCHES Acetylene is a highly explosive gas which should If you suspect a leak in the system, perform a leak be treated with the greatest care. At pressures test using an approved leak detection system. DO above 15 psi, acetylene will explode by decompo- NOT USE HOUSEHOLD OR LAUNDRY SOAP sition without the presence of air.
Page 50: Welding
SECTION 4 GENERAL REPAIR PRACTICES SAFETY PRECAUTIONS PRIOR TO PERFORMING ANY SERVICE OR REPAIR Set the parking brake. When working on the unit always use the service tools listed in Section 10, SERVICE TOOLS if so Put the vehical in park, or if equipped with a manual directed by the instructions in Section 9, SERVICE transmission, put the unit in gear and remove the AND REPAIR.
Page 51: Lifting Instructions
SECTION 4 GENERAL REPAIR PRACTICES LIFTING INSTRUCTIONS Because of the size and weight of the major components found on the unit, it is necessary to use suitable lifting devices for removal. The following components require lifting devices for removal: cylinders, carrier panel, packer panel, pushout panel and tailgate.
Page 52: Capscrew Marking And Torque Values
SECTION 4 GENERAL REPAIR PRACTICES 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.
Page 53: Hydraulic Fitting Torque Values
SECTION 4 GENERAL REPAIR PRACTICES HYDRAULIC FITTING TORQUE VALUES JIC 37 DEGREE FLARED TUBE FITTINGS TUBE SIDE TORQUE TORQUE 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 54 SECTION 4...
Page 55: Section 5 - Specifications
SECTION 5 SPECIFICATIONS 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 56: Lubricants
SECTION 5 SPECIFICATIONS LUBRICANTS Oil......SAE # 10 or equivalent Grease....Multiservice (quality grade) HYDRAULIC SYSTEM CAPACITY (approximately): Fluid tank............................50 gallons Total system System pressure settings.......................2350 PSI (162 BAR) Type of fittings..............Steel tubing with brazed ORFS fittings: reinforced rubber hose with crimped full-flow ORFS fittings, o-ring fittings Filtration........................Suction: Reusable wire mesh type Return line: Disposable filter element located on return line to the tank PUMP...
Page 57: Section 6 - Preventive Maintenance
SECTION 6 PREVENTIVE MAINTENANCE GENERAL The 2R-III has been designed for long periods of effi- cient uninterrupted operation. Careful attention to proper preventive maintenance, as described in this section, will ensure and extend trouble-free operation of the unit. Particular attention to correct lubrication of the unit and maintenance of the return filter, are probably the two most vital areas of preventive maintenance required.
Page 58: Lubrication Chart
SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART INSTRUCTIONS Grease weekly (every 40 hrs. of operation) with MOBILUX EPI-SERVICE grease or equivalent. In below freezing climates all grease and fluids Oil weekly (every 40 hrs. of operation) with SAE # 10 should have a cold test rating of at least -20 F. or equivalent.
Page 59 SECTION 6 PREVENTIVE MAINTENANCE LUBRICATION CHART NOTES: These parts require frequent inspection and lubri- cation as necessary to be in prime working condi- tion. Remove the top cover for access to lube points. Move roller track access covers to grease roller. Rollers need lubrication-roller tracks do not! Grease on the tracks will cause the rollers to slide, keep tracks clean and dry.
Page 60 SECTION 6 PREVENTIVE MAINTENANCE...
Page 61: Hydraulic System Service
SECTION 6 PREVENTIVE MAINTENANCE REPLACEMENT OF FILTER ELEMENT HYDRAULIC SYSTEM SERVICE (See Hydraulic System Illustration) (See accompanying Hydraulic System Illustration) Remove filter cover (4). Proper maintenance of the hydraulic components is of Remove o-ring (5). vital importance to the service life of the system and the operation of the unit as a whole.
Page 62 SECTION 6...
Page 63: Contamination
SECTION 6 PREVENTIVE MAINTENANCE of water contamination, the source of which must be HYDRAULIC SYSTEM SERVICE found and eliminated immediately. Common sources are inadequate outdoor storage, unsealed reservoir covers or condensation. CONTAMINATION It is estimated that as much as 90% of all hydraulic A “BLOTTER SPOT TEST”...
Page 64: Preventive Maintenance Requirements
SECTION 6 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE REQUIREMENTS DAILY PREVENTIVE MAINTENANCE Each day perform the following maintenance: CONTAINER HANDLING EQUIPMENT 1. INSPECTION In addition to performing the daily vehicle and packer Perform the PRE-OPERATIONAL INSPECTION de- body pre-operation inspection, also check the container scribed in Sec.
Page 65: Weekly Preventive Maintenance
SECTION 6 PREVENTIVE MAINTENANCE WEEKLY PREVENTIVE MAINTENANCE 1. CLEANING 5. CHECK-OUT PROCEDURES Clean and paint exposed metal surfaces to remove Each week perform the CHECK-OUT PROCE- and prevent the formation of rust. DURES listed in Sec. 7 of this manual. 6.
Page 66: Yearly Preventive Maintenance
SECTION 6 PREVENTIVE MAINTENANCE MAINTENANCE RECOMMENDATIONS CARRIER The packer/carrier assembly should be visually inspect- PANEL ed every forty (40) hours of operation for cracked or fatigued welds, loose or broken fasteners, worn bear- ings, pin hubs or pins. The four (4) torque tube bearing straps should be lubricated a minimum of every forty (40) hours of operation.
Page 67: Section 7 - Check-Out
SECTION 7 CHECK-OUT GENERAL The 2R-III has been designed to provide long periods of trouble-free operation. Performing the check-out pro- cedures below, at regular weekly intervals, will help to prevent unscheduled downtime. Make sure you know and observe all safety precau- tions listed in Sec.
Page 68: Check Engine Speed-Up Switch (Cab)
SECTION 7 CHECK-OUT CHECK ENGINE SPEED UP SWITCH ENGINE OPERATIONAL STATUS SPEED-UP SYSTEM Truck Running PTO Engaged Speed Up On IF ENGINE SPEEDS UP: OPERATIONAL STATUS Truck Running PTO Disengaged The system is grounded. Locate the short and repair as described under ELECTRICAL SYSTEM in Sec.
Page 69: Check Pack Cycle Time
SECTION 7 CHECK-OUT CHECK PACK CYCLE TIME OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Activate both the packer panel lever and carrier panel lever. Using a stopwatch, time a complete cycle. A complete cycle should take 23 to 26 sec- onds.
Page 70: Check Main Line Pressure
SECTION 7 CHECK-OUT CHECK MAIN LINE PRESSURE OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Make sure the area above the tailgate is clear be- fore raising the tailgate. Release the tailgate clamps. SPEED UP BUTTON TAILGATE LIFT Depress speed-up button. LEVER Move tailgate control lever to fully raise the tailgate.
Page 71: Check Packer And Carrier Panel Shift Pressures
SECTION 7 CHECK-OUT CHECK PACKER AND CARRIER PANEL SHIFT (KNOCKOUT) PRES- SURES OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Install a 0-3000 PSI (0-207 BAR) pressure gauge PACKER at the quick disconnect coupler on the front control LEVER valve.
Page 72: Check Resistance Cartridge Pressure
SECTION 7 CHECK-OUT CHECK RESISTANCE CARTRIDGE PRESSURE OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture (part number 710475) and test as shown on illustration. ATTACH PORT-A-POWER WITH 0-3000 PSI WHEN THE ADJUSTED PRESSURE IS GAUGE TO PORT MARKED “P2” REACHED (1800 PSI), FLUID WILL DRAIN FROM PORT MARKED “T2”...
Page 73 SECTION 7 CHECK-OUT CHECK PACKER HIGH PRESSURE (CIRCUIT) RELIEF CARTRIDGE OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture (part number 710475) and test as shown on illustration. ATTACH PORT-A-POWER WITH 0-6000 PSI WHEN THE ADJUSTED PRESSURE IS GAUGE TO PORT MARKED “P1” REACHED (3800 PSI), FLUID WILL DRAIN FROM PORT MARKED “T1”...
Page 74 SECTION 7 CHECK-OUT CHECK ACCESSORY (CIRCUIT) RE- LIEF CARTRIDGE OPERATIONAL STATUS Truck Off PTO Disengaged Use the test fixture (part number 710475) and test as shown on illustration. ATTACH PORT-A-POWER WITH 0-3000 PSI WHEN THE ADJUSTED PRESSURE IS GAUGE TO PORT MARKED “P1” REACHED (1700 PSI), FLUID WILL DRAIN FROM PORT MARKED “T1”...
Page 75: Check Pushout Panel Shoes
SECTION 7 CHECK-OUT CHECK PUSH OUT 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 Sec. 9, SERVICE AND REPAIR under PUSHOUT PANEL.
Page 76 SECTION 7 7-10...
Page 77: Section 8 - Troubleshooting
SECTION 8 TROUBLESHOOTING GENERAL Troubleshooting is a matter of quickly and logically iso- Hydraulic flow diagrams are provided in this section. lating the cause of a problem and taking corrective ac- These diagrams can be helpful in determining which tion. Factory trained mechanics, experienced operators, parts are associated with a particular function.
Page 78: Dieseling In Hydraulic System
SECTION 8 TROUBLESHOOTING DIESELING IN HYDRAULIC SYSTEMS Any hydraulic system should be a sealed environment A good example may be a front mounted pump dry valve free of foreign material including air. Unlike solid con- system. In the dry mode of operation, system hydraulic tamination, air is compressible and contains oxygen.
Page 79: Operation Is Erratic
SECTION 8 TROUBLESHOOTING OPERATION IS ERRATIC REMEDY POSSIBLE CAUSE Speed up system operating erratically. Check electrical system. See Sec. 9, Service and Repair. Hydraulic fluid too hot. Check for proper grade of fluid. See Sec. 5, Speci- fications. Hydraulic fluid level too low. Check fluid level.
Page 80: Engine Will Not Speed Up When Carrier Panel Lever Or Speed Up Button Is Engaged
SECTION 8 TROUBLESHOOTING ENGINE WILL NOT SPEED UP WHEN CARRIER PANEL LEVER OR SPEED-UP BUTTON IS ENGAGED REMEDY POSSIBLE CAUSE Short in electrical wiring. Repair broken wire. See Sec. 9, Electrical System, Service and Repair. Blown fuse on speed-up relay. Replace fuse and check electrical system for shorts.
Page 81: Carrier Panel Valve Section Shifts To Neutral Too Soon
SECTION 8 TROUBLESHOOTING CARRIER PANEL VALVE SECTION SHIFTS TO NEUTRAL TOO SOON POSSIBLE CAUSE REMEDY Carrier panel valve section pressure too low. Perform pressure check as described in Sec. 7, Check-Out. PACKER PANEL VALVE SECTION WILL NOT SHIFT POSSIBLE CAUSE REMEDY Packer panel cylinder leaking.
Page 82: Loud Squealing Noise When Manually Retracting Tele- Scopic Cylinder
SECTION 8 TROUBLESHOOTING - TELESCOPIC PUSHOUT SYSTEM LOUD SQUEALING NOISE WHEN MANUALLY RETRACTING TELE- SCOPIC CYLINDER POSSIBLE CAUSE REMEDY Release speed-up button. Excessive fluid flow being forced through the main Only partially pull (feather) the Front Control Valve relief in the Front Control Valve. control handle.
Page 83: Packer Panel Drifts Open While Packing Load Into Body
SECTION 8 TROUBLESHOOTING PACKER PANEL DRIFTS OPEN WHILE PACKING LOAD INTO BODY REMEDY POSSIBLE CAUSE Packer panel cylinder seal leaking. Perform test for leaking cylinder. See Sec. 9, Ser- vice and Repair. Perform pressure test as described in Sec. 7, Packer panel valve section pressure too low.
Page 84: Container Won't Lift
SECTION 8 TROUBLESHOOTING CONTAINER WON’T LIFT REMEDY POSSIBLE CAUSE Check pressures as described in Sec. 7, Check- Insufficient hydraulic pressure. Out. Cable broken. Replace cable. Secure cable to lifting device. Cable loose from the lifting device (drum/cylinder). Container overload. Reduce weight of material in container. Container frozen to the ground.
Page 85: Description Of Hydraulic System
SECTION 8 TROUBLESHOOTING - TELESCOPIC SYSTEM DESCRIPTION OF HYDRAULIC SYS- The following is a description with flow diagrams of what happens in the hydraulic system of the telescopic sys- tem during the loading, packing and unloading opera- tions of the unit. Operator action is presented and then a description of the hydraulic flow and the interaction of system compo- nents (i.e., valves and cylinders) follows.
Page 86: Neutral
SECTION 8 TROUBLESHOOTING - TELESCOPIC SYSTEM 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. ENGINE SPEED-UP SYSTEM HYDRAULIC SEQUENCE Hydraulic fluid flows from the tank, by gravity, to the pump;...
Page 87: Packer Panel Sweeps Back Over Load
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM PACKER PANEL SWEEPS BACK OVER LOAD OPERATOR ACTION The operator moves the control levers inward to start the compaction cycle. HYDRAULIC SEQUENCE Operator action causes the MCV (Main Control Valve) to shift, diverting flow to the rod end of the packer panel cylinders.
Page 88: Carrier And Packer Panels Move Down To Interrupted Cycle Position
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM 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 car- rier cylinders.
Page 89: Packer Panel Sweeps Hopper
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM PACKER PANEL SWEEPS HOPPER OPERATOR ACTION Operator shifts the control levers outward to start com- paction. HYDRAULIC SEQUENCE Fluid flow ti through the MCV (Main Control Valve) packer section to the case end of the packer panel cyl- inders.
Page 90: Packing Refuse
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM PACKING REFUSE OPERATOR ACTION None-MCV (Main Control Valve) shifts automatically. HYDRAULIC SEQUENCE Fluid flows from the MCV (Main Control Valve) to the packer cylinders will increase. Should this pressure case end of the carrier panel cylinders. The cylinders reach 3800 PSI (262 BAR), a relief valve will open re- extend, moving the carrier and packer panels up, pack- ducing the pressure by allowing some trapped fluid to...
Page 91 SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM PACKING REFUSE-CONTINUED HYDRAULIC SEQUENCE While the carrier and packer panels are moving up, compacting refuse against the pushout panel, pressure is building in the case end of the 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 92: Raising Tailgate
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM RAISING TAILGATE OPERATOR ACTION Operator opens the packer panel to release pressure. Operator loosens and swings away from the body the tailgate clamps. Operator depresses the speed-up but- ton. Operator moves the tailgate lift lever rearward. SPEED UP BUTTON TAILGATE LIFT LIFT LEVER...
Page 93: Ejecting Load
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM 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.
Page 94: Retracting Pushout Panel
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM RETRACTING PUSHOUT PANEL OPERATOR ACTION Operator releases speed-up button. NOTE: Speed-up may have to be used to retract pushout panel if engine RPM drops too far. Operator moves the pushout lever forward. SPEED UP BUTTON PUSHOUT LEVER HYDRAULIC SEQUENCE Moving the pushout lever forward shifts a spool in the...
Page 95: Lowering Tailgate
SECTION 8 TROUBLESHOOTING-TELESCOPIC SYSTEM 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 96: Section 9 - Service And Repair
SECTION 9 SERVICE AND REPAIR GENERAL This section contains the instructions necessary for the repair and replacement of the main components of the unit. Before attempting any repair of the unit, become thor- oughly familiar with the OPERATION instructions (Sec. 3) and GENERAL REPAIR PRACTICES (Sec.
Page 97: Test For Leaking Packer Panel Cylinders
SECTION 9 SERVICE AND REPAIR TEST FOR LEAKING PACKER PANEL CYLINDERS PACKER PANEL CYLINDERS NOTE: Before testing any cylinder, make sure the main sys- tem pressure is correct as described under MAIN LINE PRESSURE CHECK, Sec. 7, CHECK-OUT PROCE- DURES. OPERATIONAL STATUS Truck Off PTO Disengaged...
Page 98 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On PACKER Shift the packer panel lever outward to apply hy- PANEL draulic pressure to the case end of the packer panel LEVER cylinders. Hold the lever and observe the fluid flow from the open port on the rod end of the cylinder.
Page 99: Test For Leaking Carrier Panel Cylinders
SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On PACKER Shift the packer panel lever inward to apply hydraulic PANEL pressure to the rod end of the packer panel cylin- LEVER der. Hold the lever and observe the fluid flow from the port on the case end of the cylinder.
Page 100 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On CARRIER Shift the carrier panel lever outward to fully extend PANEL the carrier panel cylinders (“home position”). LEVER OPERATIONAL STATUS Truck Off PTO Disengaged Disconnect and plug the lines that connect to the rod end of one cylinder.
Page 101 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On CARRIER Shift the carrier panel lever inward to retract the car- PANEL rier panel cylinder. LEVER Loosen the hydraulic fittings slowly to release any trapped pressure. Watch for inadvertent movement of components.
Page 102: Removal Of Packer Panel Cylinders
SECTION 9 SERVICE AND REPAIR PACKER REMOVAL OF PACKER PANEL PANEL CYLINDERS CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged Remove the top sheet to provide better accessibility to the packer panel. NOTE: See Sec. 4, GENERAL REPAIR PRACTICES, for more detailed information about the correct use of slings and lifting chains.
Page 103 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged PIVOT PIN 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 On Shift the packer panel lever inward to completely retract the cylinder.
Page 104: Removal Of Carrier Panel Cylinders
SECTION 9 SERVICE AND REPAIR REMOVAL OF CARRIER PANEL CYLINDERS OPERATIONAL STATUS Truck Off PTO Disengaged Remove the top sheet to provide better accessibil- ity. Remove two capscrews (1), lockwashers (2) and spacer (3) securing the upper track hole cover (4) and remove the upper covers from each side of the tailgate.
Page 105 SECTION 9 SERVICE AND REPAIR Once the carrier panel has been securely supported, remove the roller assemblies (1) from each side of the tailgate through the open upper track holes. Remove the split pin that retains the roller pivot (2) and remove the roller shaft bushings.
Page 106: Disassembly Of Operating Cylinders
SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF OPERATING CYL- INDERS Remove all grease fittings, clean parts, drain fluid and follow all other applicable guidelines for disas- sembly provided in Sec. 4, GENERAL REPAIR PRACTICES before proceeding to disassemble the cylinder. Secure the case end of the cylinder to the floor or workbench.
Page 107: Reassembly And Installation Of Operating Cylinders
SECTION 9 SERVICE AND REPAIR 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 PACKER PANEL panel and four operating cylinders to make up the com- paction mechanism.
Page 108: Roller Replacement/Shimming
SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged Remove the nuts (2) and through-bolts (1). Remove the bearing assembly (3). Inspect the bearing surface for excessive or un- even wear, scoring or other damage. Replace a worn bearing assembly. Install the bearing housing over the packer panel tube and secure to the carrier panel channel with new through-bolts, shims and nuts.
Page 109 SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Shift the control levers and cycle the panels as nec- essary to align the upper and lower rollers with the track holes. NOTE: If the top roller is removed, first place a wedge between the carrier panel and the partition sheet to take the weight off the roller assemblies.
Page 110: Description Of Tailgate Lift Cylinders
SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Off PTO Disengaged Remove the appropriate rollers and add shims as required to obtain smooth operation of the packer and carrier panel. (This may require adding or re- moving shims and operating the packing lever sev- eral times until the correct alignment is achieved).
Page 111: Removal Of Tailgate Lift Cylinders
SECTION 9 SERVICE AND REPAIR OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Depress the speed-up button and move the tail- gate lift lever to raise the tailgate and hold. Visual inspection of the tailgate cylinders is the only leakage test necessary.
Page 112: Disassembly Of Tailgate Lift Cylinder
SECTION 9 SERVICE AND REPAIR DISASSEMBLY OF TAILGATE LIFT CYLINDER Wash the outside of the cylinder assembly com- surface of the exposed section of the cylinder rod, about 1/2 way up the cylinder rod. The tape should pletely to prevent contamination and/or damage to the cylinder components.
Page 113: Description Of Tailgate Assembly
SECTION 9 SERVICE AND REPAIR DESCRIPTION OF THE TAILGATE ASSEMBLY The tailgate assembly consists of the operating cylin- ders, carrier and packer panels and the “hopper” where refuse is first loaded into the unit. The tailgate is lifted (for unloading) and lowered by the tailgate lift cylinders which are actuated by the tailgate lift lever, located at the front of the body.
Page 114: Inspection Of Tailgate
SECTION 9 SERVICE AND REPAIR Remove capscrew and locknut (not shown) to re- move retainer (1) and hinge pin (2). Operate the lifting device and/or move the truck for- ward to free the tailgate from the body. Position the tailgate on supports as needed to fa- cilitate repairs.
Page 115: Front Control Valve
SECTION 9 SERVICE AND REPAIR FRONT CONTROL VALVE The Front Control Valve (FVC) is located behind the access door in the front left hand side of the body. It is FRONT CONTROL manually activated and controls the raising and lower- VALVE ing of the tailgate and the operation of the pushout panel.
Page 116: Reassembly Of Front Control Valve
SECTION 9 SERVICE AND REPAIR Remove boot, retainer plate, retainer plate washer, o-ring seal and back-up washer. RETAINER PLATE Thoroughly clean counterbore. BONNET To remove the bonnet, remove two (2) capscrews securing the bonnet to the work section. The spool positioner is now exposed for inspection RESISTANCE and repair.
Page 117: Reinstallation Of Front Control Valve
SECTION 9 SERVICE AND REPAIR Torque tie bolts to 32 ft. lbs. (43 Nm.). RESISTANCE CARTRIDGE If tie bolts are not tightened to the proper torque, valve spools may bind or stick, or cause section seals to extrude. Torque value of the resistance, main relief cartridge will be 20 ft.
Page 118 SECTION 9 SERVICE AND REPAIR MAIN CONTROL VALVE (MCV) The Main Control Valve (MCV) is located on the tail- gate above the packer and carrier panels. It controls the operation of the packer and carrier panels through the entire packing cycle. It may have either 2, 3 or 4 individual valve sections, depending on the installation of options.
Page 119 SECTION 9 SERVICE AND REPAIR INTERRUPTED CYCLE POSITION REMOVAL OF THE MAIN CONTROL VALVE CARRIER PANEL Place the packer and carrier panels in the “inter- rupted cycle” position. PACKER PANEL Move the packer panel control lever outward to sweep the packer panel through the hopper toward the home position.
Page 120: Main Control Valve
SECTION 9 SERVICE AND REPAIR REASSEMBLY OF MAIN CONTROL DISASSEMBLY AND INSPECTION OF VALVE MAIN CONTROL VALVE Replace work sections and covers with the tie bolts Wash the valve body with solvent to prevent con- in the same order in which they were removed. tamination.
Page 121: Removal Of Telescopic Cylinder
SECTION 9 SERVICE AND REPAIR REMOVAL OF TELESCOPIC CYLIN- 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. PUSHOUT LEVER OPERATIONAL STATUS...
Page 122: Telescopic Cylinder Packing Replacement
SECTION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER PACKING REPLACEMENT R OD E ND 1. Drain the hydraulic fluid from the cylinder. Clean the outside of the cylinder prior to working on it to prevent contamination from entering the cylinder. Secure the cylinder to the floor or a workbench in a vertical position (rod end up).
Page 123: Telescopic Cylinder Disassembly
S E C T ION 9 SERVICE AND REPAIR TELESCOPIC CYLINDER DISASSEMBLY R OD E ND 1. Prior to disassembling the cylinder, first make four clips from thin steel. These clips should be approx- imately .020" thick,1/2 " wide and 4" long. Bend each clip, at a right angle, about 1"...
Page 124: Description Of Pushout Panel
SECTION 9 SERVICE AND REPAIR DESCRIPTION OF PUSHOUT PANEL PUSHOUT PANEL Refuse is compacted against and ejected from the body by the Pushout Panel. The telescopic system uses one multi-stage cylinder that is attached to the pushout panel approximately half-way up the pushout panel. During its movement through the body, the pushout panel rides in a trough.
Page 125: Removal Of Pushout Panel
SECTION 9 SERVICE AND REPAIR REMOVAL OF PUSHOUT PANEL OPERATIONAL STATUS Truck Running PTO Engaged Speed Up On Move the pushout lever rearward and position the pushout panel at the extreme rear of the body. Remove the tailgate lift cylinders as described ear- lier in this section.
Page 126: Installation Of Pushout Panel
SECTION 9 SERVICE AND REPAIR INSTALLATION OF PUSHOUT PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Install the pushout panel into the body of the unit. Install the tailgate and tailgate lift cylinders. Slowly extend the telescopic cylinder until the case end is beneath the crossmember of the pushout panel where the lifting eye is welded.
Page 127: Description Of Carrier And Packer Panels
SECTION 1 SERVICE AND REPAIR DESCRIPTION OF CARRIER AND PACKER PANELS The carrier and packer panels operate as a single unit This section focuses on some factors that need to be to sweep the refuse from the hopper and to pack it taken into consideration when performing packer/car- against the pushout panel.
Page 128: Removal Of Packer Panel
SECTION 9 SERVICE AND REPAIR REMOVAL OF PACKER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged IF THE CARRIER PANEL IS ALSO TO BE RE- MOVED; remove all four operating cylinders as described earlier in this section and proceed to step OPERATIONAL STATUS Truck Off PTO Disengaged...
Page 129: Inspection And Replacement Of Packer Panel
SECTION 9 SERVICE AND REPAIR Attach a chain connected to a suitable lifting de- vice, 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 130: Replacement Of Packer Edge
SECTION 9 SERVICE AND REPAIR REPLACEMENT OF PACKER EDGE Remove the old edge with an air arc to obtain a clean cut. Grind smooth the packer panel where the new edge will be attached. Weld a new edge in place. NOTE: Pay particular attention to the torque tube.
Page 131: Carrier Panel
SECTION 9 SERVICE AND REPAIR CARRIER PANEL The correct method of operation is thoroughly described Short cycling is when the carrier panel is stopped be- in the 2R-III Operator’s Manual. Our policy is not to de- fore it completely lowers. The operator then attempts to penetrate down through the refuse that is in the hopper scribe the many different ways in which a unit might be incorrectly operated;...
Page 132: Inspection And Replacement Of Carrier Panel
SECTION 9 SERVICE AND REPAIR INSPECTION AND REPLACEMENT OF CARRIER PANEL OPERATIONAL STATUS Truck Off PTO Disengaged Carefully inspect all pivot, bearing and roller sur- faces for excessive or uneven wear, scoring or dam- age. Check the panel for broken welds, bent edges or warpage.
Page 133: Description Of Hydraulic Pump
SECTION 9 SERVICE AND REPAIR PUMP DESCRIPTION OF HYDRAULIC PUMP The pump which serves the complete hydraulic system is a gear type, coupled either to the PTO or chassis engine through a yoke arrangement. PTO driven hy- draulic pumps will be mounted near the chassis trans- mission.
Page 134: Installation Of Hydraulic Pump
SECTION 9 SERVICE AND REPAIR INSTALLATION OF HYDRAULIC PUMP OPERATIONAL STATUS Truck Off PTO Disengaged Install pump in the reverse order of removal. NOTE: PRESSURE The pump suction line (tube and hose) will also be filled with hydraulic fluid. The pump and line may be drained into an absolutely clean container and the fluid poured back into the tank.
Page 135: Schematics
SECTION 9 SERVICE AND REPAIR DESCRIPTION OF ELECTRICAL REPAIR SYSTEM Repair of the electrical system is limited to the replace- ment of burned out bulbs and other defective parts or The packer electrical system includes all of the body wiring. running and marker lights, operational speed up switches, the operator ready and back-up warning INSPECTION...
Page 136: Service Tools
SECTION 10 SERVICE TOOLS G E NE R A L The Service Tools shown in this section will be required for some service and repair procedures. These tools are available from your local authorized Leach Distributor. The actual use of each tool is described in Section 9, Service and Repair, of the appropriate service manual.
Page 137 SECTION 10 SERVICE TOOLS PART NO. DESCRIPTION EXPLANATION UNIT 603667 Pressure Gauge To measure system pressure All except FL104/Beta T-SK-793-100 Pin Puller Remove pivot pins 100368 Snap Connector Quick coupling for pressure gauges 103081 O-Ring Kit # 4 to # 24 Straight Thread o-rings All except FL104 972087...
Page 138 LEACH/WITTKE CUSTOMER SUPPORT MANUAL/LITERATURE ORDER FORM SHIP TO: INTERNAL USE ONLY ________________________ ORDERED BY: ________________________ DATE ORDERED: ________________________ DATE SHIPPED: ________________________ TITLE QTY. TITLE QTY. Current Procuction Units Other Publications 2R-III 105305 2” LEACH BINDER ____ 105339 2R-III OPERATORS, OVER 30000 ____ 105309 REARLOADER PRE-OP...
Page 139 REWARD! 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.
Page 140 A Subsidiary of Federal Signal Corporation 2737 Harrison Street Oshkosh, Wisconsin 54901 (877) 800-1111 Please visit our website: www.LeachUSA.com PRINTED IN U.S.A. October 1, 2003 Part Number 105341...

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