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RosRoca DENNIS EAGLE Olympus Twin Pack Service Manual

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Download this manual
manual before any
Refer to workshop
maintenance or repair
operations
855371B
Bin Lift remains
CAUTION
operational when
access door is open
PT No. 1018697
before entering
Stop engine
855370B4
www.dennis-eagle.co.uk
Olympus Twin Pack
Service Manual
855376
860745
860746
855376
RIDE ON REAR
WALK UNDER RAISED BINS
HOLD OBJECTS BEING PACKED
DO NOT
ENTER BODY WITH ENGINE RUNNING
WALK UNDER RAISED HOPPER
REACH INTO BINS
DRIVE WITH BINS RAISED
the hopper when
Do not reach into
Do not reach into
the hopper when
the hopper when
Do not reach into
blade is in motion
blade is in motion
blade is in motion
when blade is
Stand clear
when blade is
Stand clear
Stand clear
when blade is
in motion
in motion
in motion
  
 
  
  

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  • Page 1 Olympus Twin Pack Service Manual Refer to workshop manual before any maintenance or repair operations 855371B CAUTION Bin Lift remains 855376 operational when 860745 860746 access door is open PT No. 1018697 Stop engine before entering 855370B4 Do not reach into the hopper when Do not reach into the hopper when...
  • Page 3 This Service Manual provides all the relevant service information and data necessary to carry out designated scheduled maintenance inspections and procedures on systems and components fitted to the Dennis Eagle Olympus Twin Pack Refuse Collection Vehicle. This Service Manual is primarily designed to assist skilled technicians in the efficient servicing and repair of the systems and components described in the manual, but can also be used as a reference workbook for training purposes.
  • Page 4 Foreword Dennis Eagle Ltd. (the Company) reserves the right to description change the specification, design, material, procedures The Olympus Twin Pack refuse collection bodywork and dimensions of the vehicles described within this is a rear loaded, fixed refuse collection bodywork publication without prior notice at any time in the manufactured to EN 1501-1.
  • Page 5 CoNTeNTS Olympus Twin Pack Service Manual CoNTeNTS PAGe Introduction ...........................1-1 Health and safety ........................2-1 daily checks ...........................3-1 Hydraulic system oil level ....................4-1 Cleaning ..........................5-1 Scheduled maintenance ......................6-1 operational maintenance ....................7-1 General specification data ....................8-1 Supplementary information ....................9-1 Index ............................I-1 OT1D-SM-GB03D...
  • Page 6 CoNTeNTS This page intentionally left blank OT1D-SM-GB03D...
  • Page 7 INTrodUCTIoN Olympus Twin Pack Service Manual CoNTeNTS PAGe Introduction ...........................1-3 Safety precautions ........................... 1-3 Immobilising the vehicle prior to service procedures ..............1-3 OT1D-SM-GB03D...
  • Page 8 INTrodUCTIoN This page intentionally left blank OT1D-SM-GB03D...

  • Page 9: Safety Precautions

    INTrodUCTIoN Introduction Immobilising the vehicle prior to service procedures This manual identifies all the recommended preventative maintenance service procedures and Before commencing any service procedure, the refuse inspections to be carried out on Olympus Twin Pack collection vehicle must be immobilised as follows: refuse collection bodywork.
  • Page 10 INTrodUCTIoN This page intentionally left blank OT1D-SM-GB03D...

  • Page 11: Table Of Contents

    HeALTH ANd SAFeTY Olympus Twin Pack Service Manual CoNTeNTS PAGe Health and safety ........................2-3 Introduction ..............................2-3 Safety symbol, warnings, cautions and notes ................2-3 Trained personnel ............................. 2-3 Use of these instructions ........................2-3 Precautions and protection for personnel ..................2-4 2.5.1 Personal hygiene ............................
  • Page 12 HeALTH ANd SAFeTY 2.10 Vehicle electrical systems ........................2-12 2.10.1 General electrical precautions......................2-12 2.10.2 Disconnection and reconnection of electrical components ............ 2-12 2.11 Welding on or near the vehicle ......................2-12 2.12 Hydraulic and pneumatic systems ..................... 2-13 2.13 Returning the vehicle to service ......................

  • Page 13: Health And Safety

    HeALTH ANd SAFeTY Health and safety Safety symbol, warnings, cautions and notes Introduction The following Safety Symbol is used throughout this Manual to indicate information that is essential This chapter states the precautions to be observed by to Health and Safety. The symbol applies to ALL personnel carrying out maintenance operations on an information contained in this chapter.

  • Page 14: Precautions And Protection For Personnel

    HeALTH ANd SAFeTY Precautions and protection 2.5.2 Protective clothing for personnel Use and take care of all personal protective clothing and equipment supplied by your employer for your safety. 2.5.1 Personal hygiene 2. While operating or carrying out maintenance on a Personal hygiene is important at all times, particularly refuse collection vehicle, wear protective clothing for those working in the waste disposal environment...

  • Page 15: Working At High Level

    HeALTH ANd SAFeTY working at high level wArNINGS: FAILUre To oBSerVe THe FoLLowING PreCAUTIoNS MAY reSULT IN INJUrY or deATH. do NoT UNder ANY CIrCUMSTANCe wALK oN or LoAd THe PLASTIC TAILGATe rooF CoVerS (See FIG. 2-1, 1). THeSe Are NoT LoAd-BeArING STrUCTUreS.

  • Page 16: First Aid And Emergency Treatment

    HeALTH ANd SAFeTY First aid and emergency treatment 2.7.4 Burns In the event of a skin burn, immediately administer the 2.7.1 workshop first aid equipment following emergency treatment: Run cold, clean water over the affected area. The workshop must be equipped with First Aid equipment complying with local legislation.

  • Page 17: Workshop Precautions, Procedures And Practices

    HeALTH ANd SAFeTY • Manufacturers of Substances Hazardous to workshop precautions, Health are required by law to provide Safety procedures and practices Data Sheets for each product. It is the responsibility of all personnel who may come 2.8.1 Material safety data sheets into contact with such substances to familiarise themselves with the hazard and to take the necessary The European Commission’s Chemical Agents Directive...

  • Page 18: Immobilising The Vehicle

    HeALTH ANd SAFeTY 2.8.3 Immobilising the vehicle 2.8.4 General workshop precautions To immobilise the vehicle the Key Holder must: Chock the vehicle wheels at all times when maintenance work is in progress (Refer to Turn the ‘Body main’ key operated switch to off chassis-cab manufacturer’s Workshop Manual for and remove the key and any spare keys (see information and instructions).

  • Page 19: Hot Components

    HeALTH ANd SAFeTY 2.8.7 Hot components 2.8.10 Protecting vehicle components during grinding, drilling and welding Many vehicle components, i.e. the engine, gearbox, brakes etc. operate at temperatures high enough to When grinding, drilling and welding or similar, take cause skin burns to personnel coming into contact appropriate precautions to prevent damage to pipes, with a recently operated engine unit.

  • Page 20: Manual Handling And Movement Of Loads

    HeALTH ANd SAFeTY 2.8.12 Manual handling and 2.8.15 environmental protection precautions movement of loads Contact the Local Government Authority or Environmental Protection Agency for advice or All persons planning the lifting or movement of loads disposal facilities. or involved in lifting or movement of loads must obey the requirements of National and Local legislation and 2.

  • Page 21: Contact With Plastic Material Residues After Fires

    HeALTH ANd SAFeTY Cleaning a bodywork 2.8.18 Contact with plastic material residues after fires Wear protective clothing, gloves and goggles when you clean an Olympus Twin Pack refuse collection Most modern plastic materials release toxic gasses bodywork. Loose debris may be ejected from the when they burn.

  • Page 22: Vehicle Electrical Systems

    HeALTH ANd SAFeTY 2.10 Vehicle electrical systems 2.10.2 disconnection and reconnection of electrical components 2.10.1 General electrical precautions Note the position of all the connectors before they are removed. Always ensure correct polarity when making cable 2. When reconnecting components, ensure connections.

  • Page 23: Hydraulic And Pneumatic Systems

    HeALTH ANd SAFeTY 2.12 Hydraulic and pneumatic systems 2.13 returning the vehicle to service Vehicle hydraulic systems operate at high pressures, At the end of any maintenance work and before some parts of the system are under pressure even returning the vehicle to service, ensure that: whilst the vehicle is shut down.
  • Page 24 HeALTH ANd SAFeTY This page intentionally left blank 2-14 OT1D-SM-GB03D...
  • Page 25 dAILY CHeCKS Olympus Twin Pack Service Manual CoNTeNTS PAGe daily checks ...........................3-3 Daily safety checks ..........................3-3 Warning labels ............................3-28 OT1D-SM-GB03D...

  • Page 26: Daily Checks

    dAILY CHeCKS This page intentionally left blank OT1D-SM-GB03D...

  • Page 27: Daily Safety Checks

    dAILY CHeCKS daily checks daily safety checks Stand the vehicle on clean, level and stable ground It is important that your machine is kept in good with sufficient clearance to allow for the tailgate working order. and waste container lifting device, if fitted, to be The following Daily Safety Checks must be carried fully raised.
  • Page 28 dAILY CHeCKS • Visually check level of oil in hydraulic oil tank. • Visually check for obvious damage to lamps, The float in the bottom sight glass should warning beacons, reflectors and lenses and be at the top of the sight glass. If the level is bodywork.
  • Page 29 dAILY CHeCKS 13. Switch the ignition on only, do not start the engine. 16. Switch on the warning beacons. • The control screen should initialise and then • Check that the warning beacons and their display the ‘Body system off’ mode. associated warning lamps operate correctly when switched on and extinguish when switched off.
  • Page 30 dAILY CHeCKS 17. Make sure that the parking brake is applied and Neutral ‘N’ is selected. 18. Start the engine, check the warning panels and instrumentation for any indications of system malfunctions. • The ‘Low air pressure’ warning buzzers should not be sounding.
  • Page 31 dAILY CHeCKS 20. Press and release the ‘Work lamp’ switch. • Check that the tailgate loading lamps and all the work lamps fitted to the vehicle illuminate. 2253-OT1-D-GB-G3 2251-OT1-D-GB-G2 2384-OT1-D-GB-G2 OT1D-SM-GB03D...
  • Page 32 dAILY CHeCKS For each body in turn, carry out operations 21 - 50. 23. Check that ‘Tailgate clear’ pictogram at the bottom left hand corner is green. 21. Turn the ‘Body selector’ switch to select the If it is white: required body, left-hand or right-hand.
  • Page 33 dAILY CHeCKS 24. Press and hold the ‘Tailgate raise’ switch until the • ‘Tailgate out-of-locks’ pictogram should display tailgate is just out of its locks and then release the on the control panel screen when ‘Tailgate switch. raise’ switch is released. •...
  • Page 34 dAILY CHeCKS 27. Press and release the ‘Body system run controls’ 29. On each de-energised ‘Start pack cycle’ push- switch. button, press and release the ‘Start pack cycle’ push-button to activate it. • The screen should display the ‘Body system run’...
  • Page 35 dAILY CHeCKS 31. Press and release the ‘Internal discharge controls’ wArNING: switch. MAKe SUre THAT YoU KNow THe HeIGHT oF YoUr VeHICLe wITH THe TAILGATe • The screen should display the ‘Body discharge ANd wASTe CoNTAINer LIFTING deVICe, internal controls’ mode and ‘Tailgate-out-of- IF FITTed, rAISed.
  • Page 36 dAILY CHeCKS 34. While tailgate is rising, release the ‘Tailgate raise’ • When the tailgate is raised, the ‘Tailgate fully switch before it reaches its fully raised position. raised’ pictogram should display on the control panel screen. • Tailgate should stop rising immediately the switch is released.
  • Page 37 dAILY CHeCKS 36. Firmly apply the footbrake. Then select Drive ‘D’. 39. Press the ‘Retract’ switch. Release the switch when the ejection plate has reached the end of its travel. • ‘Tailgate out-of-locks’ warning buzzer in the cab should sound immediately Drive ‘D’ is selected.
  • Page 38 dAILY CHeCKS 40. Press the ‘Eject’ switch. Release the switch when 42. Press the two push-buttons on the ‘Tailgate the ejection plate has reached the end of its travel. lowering’ control panel simultaneously. • Tailgate should lower smoothly without judder. 2447-OT1-D-GB-G3 2451-OT1-D-GB-G2 •...
  • Page 39 dAILY CHeCKS 43. While tailgate is lowering, release one of the push- 45. Press the two push-buttons on the ‘Tailgate buttons but keep the other push-button depressed. lowering’ control panel simultaneously until the tailgate engages locks and then release the push- buttons.
  • Page 40 dAILY CHeCKS 48. Press and hold the ‘Tailgate raise’ switch until the 49. Press and hold ‘Lower tailgate to 1 metre’ switch tailgate is fully raised and then release the switch. until the tailgate stops lowering and then release the button. 2455-OT1-D-GB-G3 2456-OT1-D-GB-G3 •...
  • Page 41 dAILY CHeCKS 50. Press the two push-buttons on the ‘Tailgate 51. Press and release the ‘Body system run controls’ lowering’ control panel simultaneously until the switch. tailgate engages locks and then release the push- buttons. 2458-OT1-D-GB-G2 • Tailgate should rotate smoothly downwards about the hinge pins until it engages face of 2459-OT1-D-GB-G3 body, then lower into locks.
  • Page 42 dAILY CHeCKS 53. Assistant to press ‘Start pack cycle’ push-button • Compaction mechanism packer plate should on each compaction mechanism control panel. open (1), carriage plate and packer plate should move downwards (2), packer plate should close (3), carriage plate and packer plate should move upwards (4) and automatically stop in the packed position.
  • Page 43 dAILY CHeCKS open System vehicles (no waste container lifting Release the push-button while the carriage plate device fitted). and packer plate are moving downwards. Vehicles fitted with an open waste container lifting • Carriage plate and packer plate should stop device and guide plate in lowered position.
  • Page 44 dAILY CHeCKS 60. Press and release the ‘Signal’ push-button. For each ‘emergency stop’ push-button: • ‘Tailgate signal’ buzzer in the cab should • Cab control panel (x 1) sound immediately the push-button is pressed • Compaction mechanism control panel (x 2) and silence immediately the push-button is released.
  • Page 45 dAILY CHeCKS 62. On each compaction mechanism control panel, • Packer plate should open and carriage plate press in turn the: move upwards simultaneously until it is fully open and fully unpacked. ‘Start pack cycle’ push-button. 2280-OT1-D-GB-G1 2287-OT1-D-GB-G1 • Compaction mechanism should not operate. •...
  • Page 46 dAILY CHeCKS 65. Press the ‘Start pack cycle’ push-button. 70. Insert the key into the ‘Body main’ switch and turn it to run. • ‘Body access door open’ warning pictogram should display in the control panel screen. 2280-OT1-D-GB-G1 • Compaction mechanism should not operate. 66.
  • Page 47 dAILY CHeCKS 72. Press and release the ‘Internal discharge controls’ 73. Press and hold in turn the ‘Tailgate raise’, ‘Ejection switch. plate eject’ and ‘Ejection plate retract’ switches. • The screen should display the ‘Body discharge • Tailgate raise, ejection plate eject and ejection internal controls’...
  • Page 48 dAILY CHeCKS 74. Turn the ‘Body main’ switch to off position. on vehicles fitted with an external discharge control Remove and retain the key. panel carry out the following operations (79-89): 79. Turn the ‘Body selector’ switch to select the required body, left-hand or right-hand.
  • Page 49 dAILY CHeCKS 81. Press and release the ‘External discharge controls’ 82. Press the ‘Tailgate raise’ push-button. switch. • Tailgate should raise smoothly until out-of- • The screen should display the ‘Body discharge locks and then rotate smoothly upwards about external controls’ mode. the hinge pins.
  • Page 50 dAILY CHeCKS 83. While tailgate is rising, release push-button before 85. When the tailgate is raised, the ‘Tailgate fully it reaches its fully raised position. raised’ pictogram should display on the control panel screen. • Tailgate should stop rising immediately the switch is released.
  • Page 51 dAILY CHeCKS 87. Press the ‘Ejection plate retract’ push-button. 89. Press the two push-buttons on the ‘Tailgate Release the push-button when the ejection plate lowering’ control panel simultaneously until the has reached the end of its travel. tailgate engages locks and then release the push- buttons.

  • Page 52: Warning Labels

    dAILY CHeCKS warning labels Note: Label not fitted when footboards are fitted. HEALTH & SAFETY It is an offence IMPORTANT for any person to ride on the rear of PIPES TO BE LINKED IN THE EVENT a moving vehicle OF THE BINLIFT BEING REMOVED 852194B 855377 855376...
  • Page 53 dAILY CHeCKS CAUTION Refer to workshop manual before any Bin Lift remains maintenance or repair operational when operations access door is open 855371B PT No. 1018697 Hydraulic Oil Max. O il li c IF IC G ES E CL IL LA Y US T SP A LL...
  • Page 54 dAILY CHeCKS 855373B 855373B 855375B 855375B 46789B 46789B 855377 855377 Note: Label not fitted when riding steps are fitted. Note: Label not fitted when riding steps are fitted. 46789B 3844-OT1-D-GB-G2 Fig. 3-5 warning labels; rear of collection bodywork 3.75m (12'-4") 1018698 PACK ON THE MOVE CAUTION...
  • Page 55 HYdrAULIC SYSTeM oIL LeVeL Olympus Twin Pack Service Manual CoNTeNTS PAGe Hydraulic system oil level ....................4-3 To check hydraulic system oil level ....................4-3 4.1.1 Topping up hydraulic oil - bulk oil supply ..................4-8 4.1.2 Topping up hydraulic oil - using hand pump ................. 4-9 OT1D-SM-GB03D...
  • Page 56 HYdrAULIC SYSTeM oIL LeVeL This page intentionally left blank OT1D-SM-GB03D...

  • Page 57: Hydraulic System Oil Level

    HYdrAULIC SYSTeM oIL LeVeL Hydraulic system oil level To check hydraulic system oil level It is most important that the level of fluid in the wArNING: hydraulic reservoir is maintained within the specified THe BodY MUST Be eMPTY wHeN limits. CHeCKING THe HYdrAULIC SYSTeM oIL LeVeL.
  • Page 58 HYdrAULIC SYSTeM oIL LeVeL 6. Start and run the engine. • The screen will display the ‘Body system run’ mode. • The screen will initialise and then display the ‘Body system off’ mode. 2248-OT1-D-GB-G4 If LED below the left-hand bank of switches flashes amber, turn the ‘Body main’...
  • Page 59 HYdrAULIC SYSTeM oIL LeVeL 8. For each tailgate operate the ‘Start pack cycle’ 10. Press and release the internal discharge switch on push-button on the energised ‘Compaction the cab control panel. mechanism’ control panel so that the compaction mechanism completes a full cycle and the packer plate is closed and carriage plate fully raised.
  • Page 60 HYdrAULIC SYSTeM oIL LeVeL 11. Press and hold the tailgate raise switch until the 12. Press and hold the eject switch to move the tailgate is out of its locks and then release the ejection plate to the rear of the body. Release the switch.
  • Page 61 HYdrAULIC SYSTeM oIL LeVeL 15. Repeat operations 11 to 13 to move the left-hand ejection plate to the rear of the body. 16. Turn the ‘Body main’ switch to off position. Remove and retain the key. 17. Switch ignition off. Remove and retain the key. 18.

  • Page 62: Topping Up Hydraulic Oil - Bulk Oil Supply

    HYdrAULIC SYSTeM oIL LeVeL 2. Connect the filling equipment to the quick release 4.1.1 Topping up hydraulic oil coupling (see Fig. 4-2). Top up as necessary to the - bulk oil supply correct level using new hydraulic oil to the correct If topping up is necessary, thoroughly clean: specification.

  • Page 63: Topping Up Hydraulic Oil - Using Hand Pump

    HYdrAULIC SYSTeM oIL LeVeL 4.1.2 Topping up hydraulic oil - using hand pump 2570-OT1-D-GB-G3 Fig. 4-4 Hand pump connections Position a drum of new hydraulic oil close to the filler point. 2. Clean the top of the drum and unscrew the filler plug.
  • Page 64 HYdrAULIC SYSTeM oIL LeVeL This page intentionally left blank 4-10 OT1D-SM-GB03D...
  • Page 65 CLeANING Olympus Twin Pack Service Manual CoNTeNTS PAGe Cleaning ..........................5-3 Drain ................................5-4 5.1.1 Body drain ..............................5-4 5.1.2 Tailgate drains............................5-4 Daily cleaning ............................5-5 Pressure washing ............................5-6 Cleaning the leachate tank ........................5-6 OT1D-SM-GB03D...
  • Page 66 CLeANING This page intentionally left blank OT1D-SM-GB03D...

  • Page 67: Cleaning

    CLeANING Cleaning FIre HAZArd. reFUSe PUSH oVer AT FroNT oF BodY The refuse collection vehicle and its ancillary dUe To eXCeSS BUILd UP oF reFUSe CAN equipment must be kept as clean as possible to FALL oNTo HoT eNGINe ANd eXHAUST. prevent potential health hazards and promote trouble free operation.

  • Page 68: Drain

    CLeANING drain 5.1.2 Tailgate drains There is a drain point on the outer side of each tailgate 5.1.1 Body drain and leachate tank (if fitted). A body drain is at the front of each body. 2572-OT1-D-GB-G3 Fig. 5-2 Tailgate drains Plug type PH2OHGB05-040 C.

  • Page 69: Daily Cleaning

    CLeANING 12. Open each body access door. daily cleaning • Each door has a safety interlock to stop Stand the vehicle on clean, level and stable ground operation of the body mechanism when it is with sufficient clearance to allow for the tailgates open.

  • Page 70: Pressure Washing

    CLeANING Pressure washing Cleaning the leachate tank Caution: when pressure washing the refuse Collection Vehicle, its chassis-cab, body, refuse compaction mechanism and any ancillary equipment, such as waste container lifting devices, do not allow the jet nozzle to approach closer than 1 metre. Clean the compaction mechanism and slide tracks by pressure washing at least once a week as follows: Stand the vehicle on clean, level and stable ground...
  • Page 71 SCHedULed MAINTeNANCe Olympus Twin Pack Service Manual CoNTeNTS PAGe Scheduled maintenance ......................6-3 Introduction ..............................6-3 Operational maintenance ........................6-3 Routine maintenance ..........................6-3 Warnings ..............................6-3 Maintenance summary ........................... 6-4 Lubrication ..............................6-5 Weekly service checks ........................... 6-7 6.7.1 Clean the body and tailgate ......................... 6-7 6.7.2 Lubricate hinges and linkages ......................

  • Page 72: Scheduled Maintenance

    SCHedULed MAINTeNANCe This page intentionally left blank OT1D-SM-GB03D...

  • Page 73: Introduction

    SCHedULed MAINTeNANCe Scheduled maintenance routine maintenance To maintain the mechanism at peak operational Introduction efficiency and good condition: • The refuse collection mechanism should be The refuse collection mechanism should be serviced serviced according to the procedures and at only by skilled engineers who have received the the intervals specified in this chapter.

  • Page 74: Maintenance Summary

    SCHedULed MAINTeNANCe Maintenance summary Interval every every every every operation reference every every every week Year weeks weeks Years Years Clean body and tailgate. Page 5-5 Daily safety check. Page 3-3 Check warning labels. Page 3-28 Check hydraulic system oil level. Page 4-3 Pressure wash compaction mechanism and slide Page 5-6...

  • Page 75: Lubrication

    SCHedULed MAINTeNANCe Lubrication Immobilise the vehicle (see ‘1.2 Immobilising the vehicle prior to service procedures’ on page 1-3). 2. Clean the following mechanisms and lubricate with clean oil: • Access door hinges (see Fig. 6-1, 1 & Fig. 6-2, 1). •...
  • Page 76 SCHedULed MAINTeNANCe 2547-OT1-D-GB-G3 Fig. 6-2 Lubrication points OT1D-SM-GB03D...

  • Page 77: Weekly Service Checks

    SCHedULed MAINTeNANCe weekly service checks The following service checks should be carried out once a week or more frequently when the Refuse Collection Vehicle is operating in severe conditions. The following service checks should be carried out in addition to the Daily Service Checks. 6.7.1 Clean the body and tailgate (See Fig.

  • Page 78: 6-Week Service Checks

    SCHedULed MAINTeNANCe 6-week service checks The following service checks should be carried out once every 6 weeks or more frequently when the Refuse Collection Vehicle is operating in severe conditions. The following service checks should be carried out in addition to the Daily Service Checks and Weekly Service Checks.
  • Page 79 SCHedULed MAINTeNANCe 2559-OT1-D-GB-G1 Fig. 6-4 Body mounting bolts OT1D-SM-GB03D...

  • Page 80: Clean The Tailgate Proximity Switches

    SCHedULed MAINTeNANCe 6.8.2 Clean the tailgate proximity switches Remove the tailgate side covers (1) and clean the tailgate proximity switches (2). • Carefully wipe any dirt away from the face of each proximity switch and its operating plate (3). 2574-OT1-D-GB-G3 Fig.

  • Page 81: 12-Week Service Checks

    SCHedULed MAINTeNANCe 12-week service checks 6.9.2 Tailgate checks The following service checks should be carried out For each tailgate: every 12 weeks or more frequently when the Refuse Check that the tailgate is sitting square on the Collection Vehicle is operating in severe conditions. body.

  • Page 82: Hydraulic System Components Checks

    SCHedULed MAINTeNANCe 6.9.3 Hydraulic system components checks 6.9.4 electrical system checks Examine the following hydraulic system Examine all the electrical wiring looms, their components and their mountings for, security, connectors, wires and mountings for, condition, fractures, displacement, wear, distortion, cracks, security, fractures, displacement, wear, distortion, damage, leaks or corrosion.

  • Page 83: Hand Wash Unit (Optional Item)

    SCHedULed MAINTeNANCe 6.9.6 Hand wash unit (optional item) 6.9.9 Tailgate lower time check Check the hand wash unit for, security of mounting, Check the tailgate lower time for each tailgate as damage, corrosion and leaks. follows: 2. Check that it operates to specification. Start engine.

  • Page 84: 12-Month Service Checks

    SCHedULed MAINTeNANCe 6.10 12-Month service checks The following service checks should be carried out every 12 months or more frequently when the Refuse Collection Vehicle is operating in severe conditions. The following service checks should be carried out in addition to the Daily Service Checks, Weekly Service Checks, 6-Week Service Checks and 12-Week Service Checks.
  • Page 85 SCHedULed MAINTeNANCe Thoroughly clean the area around the filters. 2. Immobilise the vehicle - (see ‘1.2 Immobilising the vehicle prior to service procedures’ on page 1-3). 3. Tilt the cab (refer to chassis-cab manufacturer’s instructions). 4. Place drip trays under the body functions control valve block and the hydraulic tank to collect any spilt oil.

  • Page 86: 24-Month Hydraulic System Oil Quality Check/ 36-Month Hydraulic System Oil Change

    SCHedULed MAINTeNANCe 6.11 24-Month hydraulic system oil quality check/ 36-month hydraulic system oil change The strainer filters and hydraulic system oil should be changed at every 36 months. • It is recommended that at 24 months from delivery of the vehicle or from changing the hydraulic system oil, a sample of the hydraulic oil should be taken from the hydraulic tank and analysed by a qualified laboratory.
  • Page 87 oPerATIoNAL MAINTeNANCe Olympus Twin Pack Service Manual CoNTeNTS PAGe operational maintenance ....................7-2 Bodywork lamp bulb replacement ....................7-2 Fuses and relays ............................7-2 7.2.1 Left-hand body box ..........................7-2 7.2.2 Right-hand body box ..........................7-4 Setting the clock/calendar ........................7-6 OT1D-SM-GB03D...

  • Page 88: Operational Maintenance

    oPerATIoNAL MAINTeNANCe operational maintenance Bodywork lamp bulb replacement All bodywork lamps are LED lamps and do not feature replaceable bulbs. Fuses and relays 7.2.1 Left-hand body box PLC 1 PLC 2 LED 1 LED 2 SL 1 SL 2 F20L F19L RL1L F18L...
  • Page 89 oPerATIoNAL MAINTeNANCe Fuses Fuse Function Fuse rating Spare. Ignition supply work lamps relay RL3L. 7.5A Supply to PLC2-5 power for module. Supply to PLC1 outputs via PLC1-5. Supply to PLC1 outputs via PLC1-34. Supply to emergency stop circuits into PLC1. 24 volt supply to: •...

  • Page 90: Right-Hand Body Box

    oPerATIoNAL MAINTeNANCe 7.2.2 right-hand body box PLC 1 PLC 2 LED 1 LED 2 SL 1 SL 2 F20R F19R RL1R F18R RL4R RL2R RL3R F17R F16R F15R F14R RL8R RL6R RL7R F13R RL5R F12R F10R F11R 3879-OT1-D-GB-G2 OT1D-SM-GB03D...
  • Page 91 oPerATIoNAL MAINTeNANCe Fuses Fuse Function Fuse rating Ignition supply work lamps relay RL3R. 7.5A Supply to warning beacons Relay RL2R. Supply to PLC3 outputs via PLC3-5. Supply to PLC3 outputs via PLC3-34. Supply to Spare Relay SPP2. Supply to PLC3 outputs via PLC3-23. Supply to PLC4 outputs via PLC4-23.

  • Page 92: Setting The Clock/Calendar

    oPerATIoNAL MAINTeNANCe 4. After 6 seconds release the top and bottom Setting the clock/calendar buttons. To set any of the clock or calendar values: • The screen will continue to initialise and then Make sure the vehicle is stationary with the parking show the ‘SET UP’...
  • Page 93 oPerATIoNAL MAINTeNANCe 6. Press and release the switch labelled ‘ENTER’. Press and release the switch labelled ‘ENTER’. • ‘ETHERNET’ will be highlighted by a black • The clock calendar adjustment screen will border. show. SELECT ETHERNET SELECT ETHERNET BACKLIGHT BACKLIGHT ENTER ENTER BACKSEL...
  • Page 94 oPerATIoNAL MAINTeNANCe 10. If other parameters require changing, repeat 13. Turn the encoder control, or press the switches operations 8 & 9 until all the all the parameters are labelled ‘UP’ and ‘DOWN’, until ‘APPLICATION’ is correct. highlighted by the black border. 11.
  • Page 95 oPerATIoNAL MAINTeNANCe 16. Turn the ignition on. 17. After initialising, the clock calendar values shown on the screen will be changed to the new settings. 14:21 12:05 4May 2Apr 14:21 12:05 4May 2Apr 2534-OT1-D-GB-G3 OT1D-SM-GB03D...
  • Page 96 oPerATIoNAL MAINTeNANCe This page intentionally left blank 7-10 OT1D-SM-GB03D...
  • Page 97 GeNerAL SPeCIFICATIoN dATA Olympus Twin Pack Service Manual CoNTeNTS PAGe General specification data ....................8-2 Dimensions, Olympus Twin Pack series ................... 8-2 Vehicle data sheets, masses and dimensions ................8-4 Vehicle Stability calculations ....................... 8-4 Typical operation times ......................... 8-4 8.4.1 Cycle time ..............................

  • Page 98: General Specification Data

    GeNerAL SPeCIFICATIoN dATA General specification data dimensions, olympus Twin Pack series Dennis Eagle Elite 6 municipal chassis-cab fitted with ‘Smooth sided’ twin pack full width (2.53 m) refuse collection bodywork. Refer to workshop manual before any maintenance or repair operations 855371B CAUTION Bin Lift remains...
  • Page 99 GeNerAL SPeCIFICATIoN dATA Dennis Eagle Elite 6 municipal chassis-cab fitted with ‘Smooth sided’ twin pack narrow width (2.30 m) refuse collection bodywork. Refer to workshop manual before any maintenance or repair operations 855371B CAUTION operational when Bin Lift remains 855376 860745 860746 access door is open...

  • Page 100: Vehicle Data Sheets, Masses And Dimensions

    GeNerAL SPeCIFICATIoN dATA Vehicle data sheets, masses Noise level and dimensions The maximum A-weighted sound pressure level at operator’s work-stations is less than or equal to Data sheets, incorporating information conforming to 85 dB(A). the requirements of EN1501-1, specific to the individual chassis/bodywork and lifting device are supplied to the original owner of the vehicle as part of the vehicle Vibration levels...

  • Page 101: Hydraulic Oils And Greases

    GeNerAL SPeCIFICATIoN dATA Hydraulic oils and greases recommended hydraulic oil Temperature BS 4231 Viscosity Manufacturer’s ISo oil type Note range grade specification -30° to +80° Q8 Foil 32 Biodegradeable viscosity 46 oil is used where specified by customers. recommended greases Application Manufacturer’s specification General lubrication...

  • Page 102: Body Identification Label

    GeNerAL SPeCIFICATIoN dATA Body identification label The body identification label is now affixed to right- hand drain box. The information on the label is shown below: Machine category / Body type. Serial number. Order number. Year of manufacture. 1018404 Heathcote Way, Heathcote Industrial Estate, Warwick.
  • Page 103 SUPPLeMeNTArY INForMATIoN Olympus Twin Pack Service Manual CoNTeNTS PAGe Supplementary information ....................9-2 OT1D-SM-GB03D...

  • Page 104: Supplementary Information

    SUPPLeMeNTArY INForMATIoN Supplementary information Supplementary information/owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes. OT1D-SM-GB03D...
  • Page 105 SUPPLeMeNTArY INForMATIoN Supplementary information/owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes. OT1D-SM-GB03D...
  • Page 106 SUPPLeMeNTArY INForMATIoN Supplementary information/owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes. OT1D-SM-GB03D...
  • Page 107 SUPPLeMeNTArY INForMATIoN Supplementary information/owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes. OT1D-SM-GB03D...
  • Page 108 SUPPLeMeNTArY INForMATIoN Supplementary information/owners comments This page has been left blank to enable supplementary information to be incorporated in the handbook or for the owner to make notes. OT1D-SM-GB03D...
  • Page 109 INdeX Hydraulic and pneumatic systems — 2-13 Introduction — 2-3 Precautions and protection for personnel — 2-4 Cleaning — 5-3 Personal hygiene — 2-4 Cleaning the leachate tank — 5-6 Protective clothing — 2-4 Daily cleaning — 5-5 Returning the vehicle to service — 2-13 Drain —...
  • Page 110 INdeX Introduction — 1-3 Scheduled maintenance — 6-3 Immobilising the vehicle prior to service 6-Week service checks — 6-8 procedures — 1-3 Check the security of body mounting bolts — Safety precautions — 1-3 Clean the tailgate proximity switches — 6-10 12-Month service checks —...

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