Federal Signal Corporation LEACH 2R-III User manual

2R-III
SERVICE MANUAL
Over Serial Number 30000
BUILDING THE BEST
A Subsidiary of Federal Signal Corporation

WARRANTY
RefusebodiesmanufacturedbyLeachCompany,(“Company”)aresuppliedandsoldundera
Limited Warranty that they are and will remain free of defects in workmanship or material for
aperiodofsix(6)monthsfrom the dateoforiginalsaleunderreasonableconditionsofuseand
operation, providing required planned maintenance services are performed. Extended war-
ranty packages are available for purchase. If a failure occurs during said period because of
suchdefectintheopinionoftheCompany, thecomponentorpartshall be repairedorreplaced
by an authorized Leach Distributor at no cost to the customer provided the unit is brought to
the distributor’s service facility. After three (3) months, performance of adjustments or the
replacement of wear/expendable components is not covered under warranty. This limited
warranty is the sole and exclusive warranty of the Leach Company.
THECOMPANYMAKES NO WARRANTYASTOMERCHANTABILITY,FITNESS FOR USE,
LEGALITY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF
ANY KIND OR NATURE. THE COMPANY SHALLNOT BE LIABLE FORANYSPECIALOR
CONSEQUENTIAL DAMAGES OF ANY KIND OR NATURE, OTHER THAN ITS LIMITED
WARRANTY OF REPLACEMENTHEREIN. NO OTHER PERSON, FIRM, OR CORPORA-
TION CAN BIND THE COMPANY TO ANY WARRANTY OTHER THAN HEREIN ABOVE
STATED.
Tovalidate the new unitwarranty,an authorized Leach Distributormusthavecompletedapre-
delivery inspection before the unit is placed into service, and the warranty registration form
signed by both the customer and the distributor must be submitted to the Leach Service De-
partment.
Because Company products are engineered to work only with genuine Company parts, this
limitedwarrantywill be void andof no effect if:(a) Company productsare modified other than
as done at its factory or as authorized to be done by the factory in writing; or (b) Parts or
assemblies of any other manufacturer are used as substitutes for genuine Company parts.
GenuineLeach replacement parts, components andassembliesarealsosoldunder a Limited
Warrantytobe freefromdefectsinworkmanshipor materialfora period ofsix(6) months. This
is a replacement only warranty and the item must be returned to the Leach distributor for
exchange. The labor to replace or repair the part shall be the responsibility of the customer.
There is no warranty on expendable items, wear components or used parts.
Leach Company reserves the right to redesign and/or discontinue the manufacture of parts,
components and assemblies at any time.
A Subsidiary of Federal Signal Corporation
I

FOREWARD
LeachCompanyhas been a leader in the refuse industry for over 115years.Leachrefusebod-
ies are the industry standard for both quality and performance. Leach Company is justifiably
proudofthequalityengineering,materialandworkmanshipthatgoesintoeach andeverypacker
weproduce. Thiscommitmentto qualityextendstothe bestparts,service anddistributororgani-
zationintheindustry.
One area of great importance to us at Leach Company is your safety. This unit was built in
accordancewiththeAmericanNational StandardsInstitute(ANSI)standardforMobile Refuse
CollectionandCompactionEquipment-SafetyRequirements,ANSIZ245.1 - 1999. Before op-
erating this unit please read and understand the safety precautions found in Section 1 of the
Service and Operators manual. They are important and are provided to assist you in the safe
operationof the unit.
This manual was produced with the intention of providing clear, concise instructions for the
proper operation and servicing of your refuse packer. It was produced with the latest informa-
tion available at the time of publication. We do, however, reserve the right to redesign and/or
discontinuethemanufactureofparts, components or assemblies at any time.Leach Company
hasanaggressivemanualandproductimprovementprogram.Inanyconversationorcorrespon-
dencedealing with information provided inanyLeachmanualpleasereferto the part number of
thatmanual.
The manuals provided with the unit are considered a permanent part of the unit and should be
included in the event of a re-sale.Additional manuals are available, free of charge, from your
local authorized Leach distributor. These manuals should be kept readily available for easy
reference. We ask that if you have comments or suggestions concerning this manual please
contactus at [phone].Weare here to beof service toyou, our valuedcustomers.
II

III
TABLE OF CONTENTS
WARRANTY..................................................................I
FORWARD....................................................................II
TABLE OF CONTENTS..............................................III
SECTION 1 - SAFETY PRECAUTIONS
General................................................................1-1
Danger, Warningand CautionDecals......................1-1
Prior To Start Up...................................................1-2
General Operation.................................................1-3
Hydraulics............................................................1-5
Fire Protection......................................................1-5
Housekeeping.......................................................1-5
Shutdown.............................................................1-5
Decal Locations....................................................1-6
SECTION 2 - INTRODUCTION
Terms You Will Need To Know................................2-1
Loading................................................................2-2
Compaction..........................................................2-2
Unloading.............................................................2-3
ContainerAttachment(Latchand Ears)...................2-4
Container Handling Systems.................................2-4
General................................................................2-5
Terms You Will Need To Know................................2-5
Hook........................................................2-5
Container..................................................2-5
Container Attachment................................2-5
Winch......................................................2-6
ContainerLiftingCylinder (CLC)..................2-6
Container Push Bar (CPB).........................2-6
Basic Operation....................................................2-7
Attach......................................................2-7
Dump.......................................................2-7
Dosconnect..............................................2-7
SECTION 3 - OPERATION
General................................................................3-1
Description of Operating Controls...........................3-1
Location of Operating Controls...............................3-2
Pump/PTO Control....................................3-3
Speed-Up Toggle Switch............................3-3
Tailgate Open Light...................................3-3
EngineSpeed-UpPush Button...................3-4
Front Control Valve...................................3-4
Push Out Lever.........................................3-4
Tailgate Lift Lever......................................3-4
Tailgate Clamps........................................3-4
Driver Signal Buttons................................3-5
PackerandCarrierPanelControlLevers......3-5
Compaction Cycle Operation.....................3-5
ContainerHandlingControl Levers..............3-5
Operating Procedures............................................3-6
Pre-OperatingWalkAround Inspection....................3-6
WalkAround Inspection Check List.......................3-10
Start Up (Operating Instructions)............................3-11
Positioning the Pushout Panel..............................3-12
Loadingthe Hopper...............................................3-13
SECTION 3 - OPERATION (continued)
Attaching a Container to The Packer.....................3-13
Usinga Winchor ContainerLiftCylinder................3-14
Using a Container Push Bar..................................3-15
Packing The Load.................................................3-15
PushoutPanel OperationDuring Packing..............3-16
DisconnectingTheContainer.................................3-16
UnloadingAt Dumpsite..........................................3-17
Lifting The Tailgate................................................3-17
Ejecting The Load.................................................3-18
LoweringTheTailgate............................................3-18
Shut Down...........................................................3-19
SECTION 4 - GENERAL REPAIR PRACTICES
Preparation For Service.........................................4-1
Replacement Parts...............................................4-1
Technical Service Bulletins....................................4-1
SafetyPrecautions Prior to Service orRepair...........4-2
SafetyDuring ServiceAndRepair............................4-2
Welding Precautions.............................................4-2
Oxy-Acetylene Torches.........................................4-3
Reassembly And Installation..................................4-4
Electrical Testing..................................................4-4
Checking For Voltage................................4-4
Checking Continuity..................................4-4
Welding................................................................4-4
Lifting Instructions.................................................4-5
Capacity of Lifting Device.......................................4-5
Sling Strap Specifications......................................4-5
ChainAndHardware Specifications.........................4-5
CapscrewMarkingAndTorque Values.....................4-6
Hydraulic Fitting Torque Values..............................4-7
SECTION 5 - SPECIFICATIONS
Body Specification Chart.......................................5-1
Lubricants.............................................................5-2
Hydraulic System.................................................5-2
Pump...................................................................5-2
Hydraulic Fluid Recommendation...........................5-2
SECTION 6 - PREVENTIVE MAINTENANCE
General................................................................6-1
Operatingand Maintenance Records......................6-1
Lubrication Chart...................................................6-2
Hydraulic System Service.....................................6-5
Checking Fluid Level.................................6-5
Clean Tank Breather..................................6-5
Check/ReplaceReturn Line Filter...............6-5
Flushing Hydraulic System........................6-5
Contamination.......................................................6-7
Commercial Hydraulic Fluid Testing........................6-7
In House Hydraulic Fluid Testing.............................6-7
PreventiveMaintenanceRequirements....................6-8
Daily Preventive Maintenance................................6-8
WeeklyPreventive Maintenance.............................6-9
MonthlyPreventiveMaintenance............................6-10
Yearly Preventive Maintenance...............................6-10

IV
TABLE OF CONTENTS
SECTION 7 - CHECK-OUT
General................................................................7-1
Check Hydraulic Tank Fluid Level...........................7-1
CheckEngine Speed-Up Switch (Cab)....................7-2
CheckEngine Speed-UpSwitches (Body)...............7-2
Check Pack Cycle Time........................................7-3
Check Pressures..................................................7-3
Check Main Line Pressure.....................................7-4
CheckPackerAndCarrierPanelShiftPressures......7-5
Check Resistance Cartridge Pressure....................7-6
CheckPackerPanel High Pressure(Circuit)Relief...7-7
CheckAccessory (Circuit) Relief Pressure..............7-8
Check Pushout Panel Shoes.................................7-9
Check Power Take Off (PTO)..................................7-9
SECTION 8 - TROUBLESHOOTING
General................................................................8-1
Compaction..........................................................8-1
Dieseling In Hydraulic System...............................8-2
Operation Is Erratic...............................................8-3
Pump Noise Is Excessive......................................8-3
EngineWill Not Speed Up When Carrier PanelLever or
Speed Up Button Is Engaged.................................8-4
EngineSpeedUpWillNotReturnToNormalWhenPack-
ing Cycle Is Complete or Speed Up Button Is Re-
leased..................................................................8-4
PackerPanel Valve SectionShiftsToo Slow.............8-4
Carrier Panel Valve Section Shifts To Neutral Too
Soon....................................................................8-5
PackerPanel Valve Section Will Not Shift................8-5
CarrierPanelValve Section WillNotShiftTo Neutral.8-5
Packer/CarrierPanelsDoNotDeliverFullForceToPack
Load Into Body.....................................................8-5
LoudSquealing NoiseWhen ManuallyRetractingTele-
scopic Cylinder.....................................................8-6
Load Will Not Push Out.........................................8-6
Pushout Panel Slides Forward Too Fast While Packing
Refuse..................................................................8-6
PushoutPanelWill Not SlideForwardAutomatically.8-6
CarrierAnd Packer PanelsStopShortOfHomePosition
After Each Cycle..................................................8-6
Packer Panel Drifts Open While Packing Load Into
Body....................................................................8-7
Cycle Time Too Slow.............................................8-7
Tailgate Will Not Raise..........................................8-7
Container Won’t Lift..............................................8-8
Winch Motor Leaking............................................8-8
Container Raises Very Slowly................................8-8
Description Of Hydraulic System............................8-9
System Component Nomenclature.........................8-9
Neutral.................................................................8-10
PackerPanel SweepsBackOver Load..................8-11
CarrierAnd Packer Panels Move Down To Interrupted
Cycle Position......................................................8-12
PackerPanel SweepsHopper...............................8-13
Packing Refuse....................................................8-14
Raising Tailgate....................................................8-15
SECTION 8 Continued
Ejecting Load.......................................................8-17
Retracting Pushout Panel.....................................8-18
LoweringTailgate..................................................8-19
SECTION 9 - SERVICE AND REPAIR
General................................................................9-1
Description Of Operating Cylinders.........................9-1
Test For Leaking Packer Panel Cylinders................9-2
Test For Leaking Carrier Panel Cylinders.................9-4
RemovalOf PackerPanel Cylinders........................9-7
RemovalOf CarrierPanel Cylinders........................9-9
DisassemblyOf Operating Cylinders......................9-11
Reassembly And Installation Of Operating Cylin-
ders.....................................................................9-12
Description Of Packer Panel.................................9-12
BearingReplacement............................................9-12
RollerReplacement/Shimming...............................9-13
Description Of Tailgate Lift Cylinders.....................9-15
TestFor LeakingTailgateLiftCylinders..................9-15
RemovalOfTailgate LiftCylinders.........................9-16
DisassemblyOfTailgate Lift Cylinder.....................9-17
Inspection,ReassemblyAndInstallationOfTailgateLift
Cylinders..............................................................9-17
DescriptionOfTailgateAssembly...........................9-18
RemovalOfTailgateAssembly...............................9-18
InspectionOfTailgate............................................9-19
ReassemblyAnd InstallationOfTailgate................9-19
Front Control Valve...............................................9-20
Removal Of Front Control Valve............................9-20
Disassembly And Inspection Of Front Control
Valve....................................................................9-20
ReassemblyOf FrontControl Valve.......................9-21
ReinstallationOf Front Control Valve......................9-22
Main Control Valve................................................9-23
RemovalOf MainControl Valve.............................9-24
DisassemblyAnd Inspection Of MainControlValve.9-25
ReassemblyOf Main Control Valve........................9-25
RemovalOfTelescopic Cylinder.............................9-26
Telescopic CylinderPacking Replacement.............9-27
Telescopic CylinderDisassembly...........................9-28
Description Of Pushout Panel...............................9-29
WearBlock Replacement......................................9-29
Removal Of Pushout Panel...................................9-30
Installation Of Pushout Panel................................9-31
DescriptionOf CarrierAnd Packer Panels..............9-32
Removal Of Packer Panel.....................................9-33
InspectionAndReplacement Of PackerPanel........9-34
ReplacementOf Packer Edge...............................9-35
Installation Of Packer Panel..................................9-35
Carrier Panel........................................................9-36
RemovalOf CarrierPanel......................................9-36
InspectionAnd ReplacementOfCarrier Panel........9-37
InstallationOf CarrierPanel...................................9-37
TrackBar Replacement.........................................9-37
DescriptionOf HydraulicPump..............................9-38
RemovalOf HydraulicPump..................................9-38

V
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

GENERAL
The2R-III hasbeendesigned with theoperatorinmind.
However, as with any industrial machinery, especially
those that are large and apply forces through hydraulic
pressures,theultimateresponsibilityforsafetyrestswith
you - the user. An alert, conscientious attitude and ob-
servance of all known safe operating practices are the
best ways to prevent accidents.
Before operating the unit, it is the operator’s responsi-
bilityto be thoroughly familiar with the instructions con-
tained in the Operator’s Manual.
SAFETY PRECAUTIONS
Publication of these precautions does not imply or in
any way represent an all inclusive list. It is the opera-
tors responsibility to be familiar with and ensure that
operationisinaccordance with safetyrequirementsand
codes including all applicable Occupational Safety &
Health Act (OSHA) and American National Standards
Institute (ANSI) regulations.
DANGER, WARNINGAND CAUTION
DECALS
See the accompanying illustration for the location and
label content of all safety decals.
1. These decals must be obeyed at all times.
2. These decals must be in place at all times. Report
any damaged or missing decals to the proper
authority at once.
3. Replacement decals can be ordered free of charge
from your local authorized Leach distributor.
DANGER, WARNING AND CAUTION
Throughout this manual “DANGER” “WARNING” and “CAUTION” notations accompanied by the International
Hazard Symbol are used to alert the operator and mechanics to special instructions concerning a particular
operation or service that may be hazardous if performed incorrectly or carelessly.
DANGER - Immediate haz-
ards which WILL result in
severe personal injury or
death
WARNING - Hazards or
unsafe practices which
COULD result in severe
personal injury or death.
CAUTION - Hazards or un-
safepracticeswhichcould
result in minor personal
injury or property or prod-
uct damage.
Strict compliance to these “safety alerts” combined with “common sence” operations are important accident
prevention measures.
The word NOTE is also used throughout the manual. It precedes information that provides special emphasis or
clarification on a specific operation or procedure.
SECTION 1
1-1

SECTION 1
SAFETY PRECAUTIONS
PRIOR TO START UP
Never operate machinery while wearing jewelry or
looseclothing.These items may become caught by
or entangled in the machinery causing serious in-
jury. Wear proper safety equipment as required by
youremployer.
Never operate machinery while under the influence
of alcohol, narcotics or other mood altering sub-
stances.Workerswhooperate machinery while un-
der the influence are a hazard to themselves and
others.
Perform a pre-operation “walk around” inspection
of the truck chassis in accordance with the chassis
manufacturer’s guidelines. Perform a “walk around”
inspection of the refuse packer in accordance with
thechecks listedin Section 3 - Operationof the Op-
erators/Service manual. Never start or operate any
equipment found to have malfunctions.
1.
2.
3.
Report any malfunctions immediately to the
properauthorities.
Priortoleavinganymalfunctioningunitthepark-
ing brakes must be set, the PTO system
disengaged, the engine turned off, the ignition
key removed, and using a non-reusable fas-
teningdevice,placeasignonthesteeringwheel
indicating the unit is inoperative.
a.
b.
Properservicing requires specialized tools andpro-
cedures. Service must be performed by authorized
personnel only following procedures in the 2RIII
Service manual.
4.
Walk completely around the vehicle to make sure
allpersons and obstructions are clearbefore start-
ing the unit.
Thecontainerhandling systemis a critical compo-
nent of the unit. Use only the proper replacement
parts.
Inspect all hooks, chains and cables daily to en-
sure serviceable condition. Replace damaged or
worn parts. (See Section 5, Preventive Mainte-
nance)
Before operating the vehicle the driver must be
thoroughly familiar with the employer’s safety pro-
gramconcerning trafficrules, warning devicesand
hand signals.
Be sure to know where to get assistance in the
event of an emergency.
Know your machine. Know the location and func-
tion of all controls, gauges, instruments and pro-
tective devices.
Should the height of a refuse collection vehicle be
altered by installing a container handling system,
besure theoverall height is rechecked and overall
height plus 3 inches is noted on the decals.
5.
6.
7.
8.
9.
10.
11.
1-2