Leach 2R-II User manual

2RII PACKMASTER
OPERATORS MANUAL
Over Serial Number 16000
BUILDING THE BEST

WARRANTY
Refuse bodies manufactured by Leach Company, (“Company”) are supplied and sold under a
Limited Warranty that they are and will remain free of defects in workmanship or material for a
period of six (6) months from the date of original sale under reasonable conditions of use and
operation, providing required planned maintenance services are performed. Extended war-
ranty packages are available for purchase. If a failure occurs during said period because of
such defect in the opinion of the Company, the component or part shall be repaired or replaced
by an authorized Leach Distributor at no cost to the customer provided the unit is brought to the
distributor’s service facility. After three (3) months, performance of adjustments or the replace-
ment of wear/expendable components is not covered under warranty. This limited warranty is
the sole and exclusive warranty of the Leach Company.
THE COMPANY MAKES NO WARRANTY AS TO MERCHANTABILITY, FITNESS FOR USE,
LEGALITY OF OPERATION IN ANY JURISDICTION OR ANY IMPLIED WARRANTY OF ANY
KIND OR NATURE. THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL OR CON-
SEQUENTIAL DAMAGES OF ANY KIND OR NATURE, OTHER THAN ITS LIMITED WAR-
RANTY OF REPLACEMENT HEREIN. NO OTHER PERSON, FIRM, OR CORPORATION
CAN BIND THE COMPANY TO ANY WARRANTY OTHER THAN HEREIN ABOVE STATED.
To validate the new unit warranty, an authorized Leach Distributor must have completed a pre-
delivery inspection before the unit is placed into service, and the delivery report form signed by
both the customer and the distributor must be submitted to the Leach Service Department.
Because Company products are engineered to work only with genuine Company parts, this
limited warranty will be void and of no effect if: (a) Company products are modified other than
as done at its factory or as authorized to be done by the factory in writing; or (b) Parts or assem-
blies of any other manufacturer are used as substitutes for genuine Company parts.
Genuine Leach replacement parts, components and assemblies are also sold under a Limited
Warranty to be free from defects in workmanship or material for a period of six (6) months.
This is a replacement only warranty and the item must be returned to the Leach distributor for
exchange. The labor to replace or repair the part shall be the responsibility of the customer.
There is no warranty on expendable items, wear components or used parts.
Leach Company reserves the right to redesign and/or discontinue the manufacture of parts,
components and assemblies at any time.
II

Leach Company has been a leader in the refuse industry for over 110 years. Leach refuse
bodies are the industry standard for both quality and performance. Leach Company is justifi-
ably proud of the quality engineering, material and workmanship that goes into each and every
packer we produce. This commitment to quality extends to the best parts, service and distribu-
tor organization in the industry.
One area of great importance to us is your safety. This unit was built in accordance with the
American National Standards Institute (ANSI) standard for Mobile Refuse Collection and Com-
paction Equipment-Safety Requirements, ANSI Z245.1-1992. Before operating this unit please
read and understand the safety precautions found in Section 2 of this manual. They are
important and are provided to assist you in the safe operation of the unit.
This manual was produced with the intention of providing clear, concise instructions for the
proper operation, maintenance and service of your 2RII refuse packer. It was produced with
the latest information available at the time of publication. We do, however, reserve the right to
redesign and/or discontinue the manufacture of parts, components or assemblies at any time.
Leach Company has an aggressive manual and product improvement program. In any conver-
sation or correspondence dealing with the information provided in any Leach manual please
refer to the part number of that manual.
The manuals provided with the unit are considered a permanent part of the unit and should be
included in the event of a re-sale. Additional manuals are available, free of charge, from your
local authorized Leach distributor. These manuals should be kept readily available for easy
reference. We ask that if you have comments or suggestions concerning this manual, please
contact us at [phone]. We are here to be of service to you, our valued customer.
FOREWARD
III

TABLE OF CONTENTS
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . III
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . IV
SECTION 1 – SAFETY PRECAUTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Danger, Warning and Caution Decals . . . . . . . . . 1-1
Prior To Start Up . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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
Container Attachment. . . . . . . . . . . . . . . . . . . . . 2-4
Container Handling Systems . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Terms You Need to Know . . . . . . . . . . . . . . . . . . 2-5
Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Container. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Container Attachment. . . . . . . . . . . . . . . . . . 2-5
Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Container Lifting Cylinder (CLC). . . . . . . . . . 2-6
Container Push Bar . . . . . . . . . . . . . . . . . . . 2-6
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION 3 – OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Description of Operating Controls . . . . . . . . . . . . 3-1
Location Of Operating Controls . . . . . . . . . . . . . 3-2
Compaction Cycle Operation . . . . . . . . . . . . . . . 3-5
Operating Procedures . . . . . . . . . . . . . . . . . . . . 3-6
Pre-operating Walk-around Inspection . . . . . . . . 3-6
Walk-around Inspection Checklist . . . . . . . . . . . 3-10
Start Up (Operating Instructions) . . . . . . . . . . . 3-11
Positioning Pushout Panel . . . . . . . . . . . . . . . . 3-12
SECTION 3 – OPERATION (continued)
Loading the Hopper . . . . . . . . . . . . . . . . . . . . . 3-13
Attaching a Container to the Packer . . . . . . . . . 3-13
Using a Winch or Container Lift Cylinder. . . . . . 3-14
Using a Container Push Bar . . . . . . . . . . . . . . . 3-15
Packing the Load . . . . . . . . . . . . . . . . . . . . . . . 3-15
Pushout Panel Operation During Packing
Telescopic . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disconnecting the Container. . . . . . . . . . . . . . . 3-16
Unloading at Dumpsite . . . . . . . . . . . . . . . . . . . 3-17
Lifting the Tailgate . . . . . . . . . . . . . . . . . . . . . . 3-17
Ejecting the Load . . . . . . . . . . . . . . . . . . . . . . . 3-18
Lowering the Tailgate . . . . . . . . . . . . . . . . . . . . 3-18
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
IV

SAFETY PRECAUTIONS
SECTION 1
Publication of these precautions does not imply or in
any way represent an all inclusive list. It is the opera-
tor’s responsibility to be familiar with and ensure that
operation is in accordance with safety requirements
and codes including all applicable Occupational Safety
& Health Act (OSHA) and American National Standards
Institute (ANSI) regulations.
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
hazards 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
unsafe practices which
could result in minor
personal injury or prop-
erty or product damage.
Strict compliance to these “safety alerts”combined with “common sense”operations are important accident pre-
vention measures.
The word NOTE is also used throughout the manual. It precedes information that provides special emphasis or clar-
ification on a specific operation or procedure.
GENERAL
The 2RII Packmaster has been designed with the oper-
ator in mind. However, as with any industrial machinery,
especially those that are large and apply forces through
hydraulic pressures, the ultimate responsibility for safe-
ty rests with you —the user. An alert, conscientious
attitude and observance of all known safe operating
practices are the best ways to prevent accidents.
Before operating the unit it is the operator’s responsibil-
ity to be thoroughly familiar with the instructions con-
tained in the Operator’s Manual.
DANGER, WARNING AND CAUTION
DECALS
See the accompanying illustration for the location and
label content of all safety decals.
1. These decals must be obeyed at all times.
2. These decals must be in place at all times. Report
any damaged or missing decals to the proper
authority at once.
3. Replacement decals can be ordered free of charge
from your local authorized Leach distributor.
1-1

SAFETY PRECAUTIONS
SECTION 1
PRIOR TO START UP
1. Never operate machinery while wearing jewelry or
loose clothing. These items may become caught by
or entangled in the machinery causing serious
injury. Wear proper safety equipment as required by
your employer.
2. Never operate machinery while under the influence
of alcohol, narcotics or other mood altering sub-
stances. Workers who operate machinery while
under the influence are a hazard to themselves and
others.
3. 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
the checks listed in Section 3 - Operation of the
Operators/Service manual. Never start or operate
any equipment found to have malfunctions.
a. Report any malfunctions immediately to the
proper authorities.
b. Prior to leaving any malfunctioning unit the
parking brakes must be set, the PTO system
disengaged, the engine turned off, the ignition
key removed, and using a non-reusable fasten-
ing device, place a sign on the steering wheel
indicating the unit is inoperative.
4. Proper servicing requires specialized tools and pro-
cedures. Service must be performed by authorized
personnel only following procedures in the 2RII
Service manual.
5. Walk completely around the vehicle to make sure
all persons and obstructions are clear before start-
ing the unit.
6. The container handling system is a critical compo-
nent of the unit, use only the proper replacement
parts.
7. Inspect all hooks, chains and cables daily to
ensure serviceable condition. Replace damaged or
worn parts. (See Section 5, Preventive
Maintenance)
8. Before operating the vehicle the driver must be
thoroughly familiar with the employer’s safety pro-
gram concerning traffic rules, warning devices and
hand signals.
9. Be sure to know where to get assistance in the
event of an emergency.
10. Know your machine. Know the location and func-
tion of all controls, gauges, instruments and pro-
tective devices.
11. Should the height of a refuse collection vehicle be
altered by installing a container handling system,
be sure the overall height is rechecked and overall
height plus 3 inches is noted on the decals.
1-2

SAFETY PRECAUTIONS
SECTION 1
OPERATION
GENERAL
1. It is the operator’s responsibility to ensure that
operation of the unit is in accordance with the
guidelines contained in the Operator’s manual and
in accordance with all applicable codes including
Occupational Safety and Health Act (OSHA) and
American National Standards Institute (ANSI) reg-
ulations.
2. Do not attempt to operate this equipment without
proper training.
3. Move the vehicle as slowly as possible without
stalling when traveling in reverse.
4. Always make sure the area behind the unit is clear
before traveling in reverse.
5. Do not travel in reverse for distances greater than
those dictated by local ordinances. If reverse trav-
el exceeds 10 feet, use a “spotter”or move the
vehicle in 10 foot increments only, and then check
to make sure the area behind the unit is clear
between increments.
6. Do not attempt to dislodge any material above
waist level unless wearing eye protection such as
“approved”side shielded safety glasses or a full
face shield.
7. Never use the unit to push or tow another vehicle.
8. Never unload uphill or against a pile of refuse or
into the bank of a hill.
9. Never place head, body, fingers or any limbs into a
scissors point or pinch point on the equipment.
10. Before operating the vehicle the driver must be
thoroughly familiar with the employer’s safety pro-
gram concerning traffic rules, warning devices and
hand signals.
11. Know where to get assistance in the event of an
emergency.
12. Know your machine. Know the location and func-
tion of all controls, gauges, instruments and pro-
tective devices.
13. Wear your seat belt.
14. Start the engine following the manufacturer’s rec-
ommended procedure.
15. Always set the parking brake before leaving the
cab.
16. Turn on appropriate warning lights, put on a safety
vest, protective glasses and protective shoes.
17. All service opening covers and access doors must
be maintained and latched in place while operating
equipment.
18. Ensure all co-workers are in view before operating
or moving any controls or the unit.
19. Ensure that there is sufficient overhead clearance
before operating the unit.
20. Ride only in the cab or on riding platforms
designed for that purpose. Riding steps shall not
be used when speeds are expected to exceed 10
mph or when distance traveled without stopping
will exceed 2⁄10 of one mile. Do not mount or dis-
mount riding step when vehicle is in motion.
21. Never allow anyone to ride on the steps when the
vehicle is backing up.
22. Stop the vehicle immediately if warning lights for
the TAILGATE AJAR system come on.
23. Never use controls or hoses for hand holds when
mounting or dismounting. Controls and hoses are
movable. They do not provide proper support and
may cause accidental equipment movement.
24. Make sure the backup alarm is working properly.
25. Always ensure that all persons are clear before
raising or lowering the tailgate. It is the operator's
responsibility to warn all persons not to stand or
cross under a raised tailgate.
26. Do not move the vehicle with the tailgate raised
except during unloading and then only as neces-
sary to clear the load before lowering.
27. Stand clear when the tailgate is being raised or
lowered and during the unloading cycle. If it is nec-
essary to manually clear debris from the hopper,
use a long metal probe and DO NOT stand under
the tailgate.
28. Never load the hopper above the loading sill.
29. Never allow material to extend outside of the hop-
per when packing.
30. Allow the packer panel control lever and carrier
panel control lever to shift automatically.
31. To avoid possible bodily injury or equipment dam-
age, lower the tailgate slowly.
32. Never enter the body unless the pushout panel
clamp or the telescopic ejection system cylinder is
released, PTO disengaged and ignition key
removed and placed in your pocket.
33. Do not attempt to load refuse into the hopper after
1-3

SAFETY PRECAUTIONS
SECTION 1
the packing cycle has begun. The packer panel
must be in the “home”position and stopped before
loading the hopper.
34. The dashboard solenoid switch must be “OFF”
between pickups or when parked. This prevents
inadvertent engine speed-up if the tailgate carrier
panel control lever is shifted.
35. The tailgate clamps must be tightened securely
before starting to load.
36. Do not step on the throttle pedal while the speed
up system is engaged.
37. Vehicles with automatic transmissions require the
shift lever to be in gear to engage the PTO and
then shifted to neutral to activate the PTO/pump.
38. Never use a rear loader to transport a container.
39. Follow all safety directions listed in the refuse body
Operator and Service manual under SAFETY PRE-
CAUTIONS.
.
40. Never use container handling chains or cable for
towing or pulling.
41. When not handling containers, keep the container
attachment closed and latched.
42. Do not operate the rear loader’s packing mecha-
nism with a container off the ground.
43. If it is necessary to manually free debris from the
container, use a long metal probe while the con-
tainer is on the ground, and DO NOT place yourself
between the container and the packer body.
44. Attach hook to the tailgate and take up the excess
slack when not in use.
54. Never hold the hook on an attachment point while
taking up slack.
46. Take up excess cable slack before moving the vehi-
cle.
47. Check overhead clearance before dumping a con-
tainer.
48. Do not move the vehicle with a container attached.
49. Always set the vehicle parking brake before attach-
ing or lifting a container.
50. Never lift a container which is non-compatible with
the Leach container attachment.
51. Never lift a container without first latching both con-
tainer latch arms.
52. Raise the container with a smooth even movement.
Do not bounce the container.
53. Do not slam the container against the packer tail-
gate or bump bar.
54. Do not attach the hook to any lift point which will not
be completely encircled by the hook with the safe-
ty latch closed. Do not remove the hook safety
latch.
55. Read and obey all container decals issued by the
container manufacturer.
56. Read and follow container manufacturers informa-
tion on accepted use practices.
57. Do not attempt to lift overloaded containers.
58. Center the container on the attachment.
59. All containers should be inspected for serviceabili-
ty and repaired if not in a safe, usable condition.
60. Do not use a non-standard or damaged trunnion
bar.
61. Never cross under a raised container.
62. Stand clear when dumping containers.
63. Before attempting to lift a container, below 32°F
(0°C) make sure it is not frozen to the ground.
64. When using an eye type container attachment
point, the base of the hook must be positioned to lift
on the inside of the eye.
65. Place the container on a flat, level surface.
1-4

1-5
SAFETY PRECAUTIONS
SECTION 1
HYDRAULICS
1. Hydraulic fluid operates under high temperatures.
Avoid contact with piping, hoses or cylinders to
prevent burns.
2. Never use hands to check for leaks. Hydraulic fluid
escaping under pressure may cause injury.
FIRE PROTECTION
1. Keep a fire extinguisher accessible at all times, as
recommended by the Bureau of Motor Carrier
Safety.
2. Never use lighted smoking materials, open flame or
sparks around when working with flammable mate-
rials such as fuel tanks or storage batteries.
3. Never have an open flame as a light source.
4. Never load ashes or other materials which might be
smoldering. These materials could ignite refuse in
the packer body.
HOUSEKEEPING
Good housekeeping habits are a major factor in acci-
dent prevention.
1. Keep handrails and steps clean and free of grease
or debris.
2. Do not store brooms or other equipment where
they could inadvertently activate the packer con-
trols.
SHUTDOWN
1. Put all controls in neutral.
2. Set parking brake.
3. Disengage PTO.
4. Shut off engine.
5. Shut off solenoid dashboard s witch.
6. Remove key.
7. Lock vehicle.
3. In case of injury seek proper medical treatment
immediately.
3. Rubbish, scrap paper and litter are highly com-
bustible. Such material should be stored in metal
containers entirely clear of sparks and flames.
1-5

1-6
SAFETY PRECAUTIONS
SECTION 1
1
4
2
5
6
3
7
89
10
7
7
9
1
8452610
1
3
1-6

SAFETY PRECAUTIONS
SECTION 1
2
1
3
45
12
3
4
5
1-7

SAFETY PRECAUTIONS
SECTION 1
1
1
23
11
14 23
17 512
6
479 10
13 15 16 18 19
820 21 22
234
5
67
8910
1-8

SAFETY PRECAUTIONS
SECTION 1
11 12
13
14
15
16
17
18
19
20
21 22
23
1-9

44 612 44 20 30 43
7
28
5815
416 39 21 34
4
56
7
16
8
12
15
20
21
28
43
30
44
39
SECTION 1
SAFETY PRECAUTIONS
1-10

SAFETY PRECAUTIONS
SECTION 1
1-11

INTRODUCTION
SECTION 2
TERMS YOU WILL NEED TO KNOW
TAILGATE
ASSEMBLY
HOPPER
LOADING
EDGE
HYDRAULIC
TANK
PUSHOUT
PANEL
CARRIER
PANEL
PACKER
PANEL
2-1

INTRODUCTION
SECTION 2
The main purpose of the 2RII Packmaster is to safely and effi-
ciently: load, compact, transport and unload refuse. The following
describes how the unit performs those tasks in the most basic
terms. For a more detailed description of the unit and its com-
ponents, read the complete 2RII PACKMASTER SERVICE
MANUAL. Before going further, look at the accompanying
full page illustration of the 2RII Packmaster and become
familiar with the terms you will need to know.
LOADING
Refuse is first loaded into the hopper of the tailgate
assembly. The carrier and packer panels, which
sweep up and pack the refuse from the hopper, will
be in the “home” position.
COMPACTION
When the operator starts the packing cycle the carrier
and packer panels move rearward, over the load.
Next, the carrier and packer panel automatically
stop at the “interrupted cycle” position.
CARRIER & PACKER PANELS MOVE OVER LOAD
“INTERRUPTED CYCLE”
"HOME" POSITION
CARRIER
PANEL
PACKER
PANEL
PACKER
PANEL
CARRIER
PANEL
2-2

INTRODUCTION
SECTION 2
COMPACTION POSITION
PUSHOUT PANEL MOVES FORWARD
TAILGATE RAISED
PUSHOUT PANEL MOVES REARWARD
EJECTING THE LOAD
The operator again activates the packing cycle. The
carrier and packer panels move forward and sweep the
refuse from the hopper up into the body and pack it
against the pushout panel. Having completed a cycle,
the carrier and packer panels are back into the “home”
position and the hopper is cleared for more refuse.
Also, during the compaction cycle, considerable
hydraulic pressure is applied to the cylinders which
control movement of the carrier and packer panels.This
causes the refuse to be compacted tightly allowing for
a large carrying capacity.
On units with the standard clamp pushout system, the
operator must manually release the pushout panel
clamping system to allow movement of the pushout
panel.
Once the body is full the 2RII Packmaster can be
moved to the dumpsite for unloading.
UNLOADING
At the dumpsite the unit is unloaded in two easy steps:
First, the tailgate is raised by the operator.
Second, the pushout panel is moved to the rear of the
body, pushing out the load.
After unloading, on telescopic units the tailgate is low-
ered and “latched” to the body.
On clamp style units, the the pushout cylinder is retract-
ed and then the clamp is set by extending the cylinder
a couple of inches. The tailgate is then lowered and
“latched” to the body.
2-3
PACKER
PANEL
CARRIER
PANEL
PUSHOUT
PANEL
PACKER
PANEL
CARRIER
PANEL PUSHOUT
PANEL
TAILGATE
TAILGATE PUSHOUT
PANEL