RosRoca Dennis Eagle Olympus, Service Manual

Page 1: ...er when blade is in motion Stand clear when blade is in motion Do not reach into the hopper when blade is in motion 855371B Refer to workshop manual before any maintenance or repair operations 1002780 HYDRAULIC OIL ONLY RIDE ON REAR ENTER BODY WITH ENGINE RUNNING DO NOT WALK UNDER RAISED HOPPER DRIVE WITH BINS RAISED REACH INTO BINS REACH INTO HOPPER WALK UNDER RAISED BINS HOLD OBJECTS BEING PACKE...

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Page 3: ...onents described in the manual but can also be used as a reference workbook for training purposes RIDE ON REAR ENTER BODY WITH ENGINE RUNNING DO NOT WALK UNDER RAISED HOPPER DRIVE WITH BINS RAISED REACH INTO BINS REACH INTO HOPPER WALK UNDER RAISED BINS HOLD OBJECTS BEING PACKED 1002780 HYDRAULIC OIL ONLY PUSH TO STOP PUSH TO STOP Dennis Eagle Olympus Refuse Collection Vehicle Caution IMPORTANT It...

Page 4: ...nt described herein without prior notice at any time in the future in accordance with the Company s constant product improvement policy Dennis Eagle Ltd has made every reasonable effort to ensure the accuracy of the Company publications but nothing shown described or referred to in the publications should be regarded as an infallible guide to the procedures materials specification design of availa...

Page 5: ...NTENTS PAGE 1 Introduction 1 1 2 Health and safety 2 1 3 Daily checks 3 1 4 Hydraulic system oil level 4 1 5 Cleaning 5 1 6 Scheduled maintenance 6 1 7 Operational maintenance 7 1 8 General specification data 8 1 9 Supplementary information 9 1 I index I 1 ...

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Page 7: ...1 INTRODUCTION Olympus Service Manual 1 1 1 OL1D SM GB02D CONTENTS PAGE 1 Introduction 1 3 1 1 Safety precautions 1 3 1 2 Immobilising the vehicle prior to service procedures 1 3 ...

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Page 9: ... OR OPERATE VEHICLE to the steering wheel 10 Lock all cab doors Remove and retain the keys 11 If necessary isolate or disconnect the battery Refer to chassis cab manufacturer s service information for procedures 1 Introduction This manual identifies all the recommended preventative maintenance service procedures and inspections to be carried out on Olympus refuse collection bodies 1 1 Safety preca...

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Page 11: ... cleanliness 2 8 2 8 6 Moving or rotating parts 2 9 2 8 7 Hot components 2 9 2 8 8 Live work 2 9 2 8 9 Fasteners 2 9 2 8 10 Protecting vehicle components during grinding drilling and welding 2 9 2 8 11 Welding on or near the vehicle 2 9 2 8 12 Manual handling and movement of loads 2 10 2 8 13 Access and lifting equipment 2 10 2 8 14 Cleaning of equipment 2 10 2 8 15 Environmental protection precau...

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Page 13: ... air conditioning refrigeration systems fitted to modern commercial vehicle chassis cabs 2 2 Safety symbol warnings cautions and notes The following Safety Symbol is used throughout this Manual to indicate information that is essential to Health and Safety The symbol applies to ALL information contained in this chapter All Safety Information MUST be strictly adhered to WARNINGS WARNING A WARNING I...

Page 14: ...er 10 Apply barrier creams before each work period Note Preparations containing lanolin replace the natural skin oils which can be removed when washing 11 Do not wash skin with fuels thinners or solvents 12 Obtain medical advice if skin disorders develop 2 5 2 Protective clothing 1 Use and take care of all personal protective clothing and equipment supplied by your employer for your safety 2 While...

Page 15: ...actice Where components cannot be accessed from the side or rear of the vehicle and it becomes necessary to work on top of the body roof or tailgate always wear an approved safety harness connected to a Safety Harness Attachment Lug see Fig 2 1 2 in accordance with all prevailing safe systems of work Health and Safety Regulations Workshop Regulations and Workshop Codes of Practice Safety Harness A...

Page 16: ... First aid and emergency treatment 2 7 1 Workshop first aid equipment 1 The workshop must be equipped with First Aid equipment complying with local legislation 2 Familiarise yourself with the equipment procedures and practices 3 If the first aid kit requires replenishing report it to your supervisor 2 7 2 Cuts and wounds 1 Treat open cuts and wounds immediately 2 Wash every scratch graze or cut of...

Page 17: ...formation pertinent to systems and components fitted to vehicles for which this Manual is applicable at the end of this chapter There may be additional ways to make sure that operative and maintenance organisations work safely and you must also follow any local rules and safe working practices that may apply 2 8 Workshop precautions procedures and practices 2 8 1 Material safety data sheets The Eu...

Page 18: ...und 4 Do not allow hoses or cables to cross the workplace 2 8 2 Responsible technician the Key Holder 1 One person the Key Holder must be responsible for the safety of all personnel involved when a vehicle is undergoing any form of maintenance work Normally the Key Holder will be the person who is working on the vehicle 2 The Key Holder is responsible for immobilising the vehicle 3 Any other perso...

Page 19: ...repairs 2 Ensure that the vehicle is not leaking diesel oil or hydraulic fluids as these may ignite whilst welding 3 Always have a serviceable fire extinguisher close at hand 4 Wear eye protection to protect eyes from welding flash 5 Erect protective screens to protect other personnel from the dangers of the area 2 8 6 Moving or rotating parts There are risks of serious injury due to entanglement ...

Page 20: ...ms 5 Dispose of used oil through authorized waste disposal contractors 2 8 12 Manual handling and movement of loads All persons planning the lifting or movement of loads or involved in lifting or movement of loads must obey the requirements of National and Local legislation and regulations Many of the vehicle parts are either extremely heavy and or complicated in shape and size Attempting to move ...

Page 21: ...ealth To reduce risk to you other people and the environment work to the guidelines given below 1 Always obey local and national legislation about collection and disposal of waste diesel fuel lubricating oils hydraulic oil and lubricants 2 Take care to collect and dispose of diesel fuel lubricating oils hydraulic oil and lubricants carefully and properly Contact the supplier or your local authorit...

Page 22: ... or a vehicle with a 24 V electrical system Failure to do so will result in extensive damage to the equipment 2 9 Cleaning a vehicle 1 Wear protective clothing gloves and goggles when you clean the bodywork of an Olympus refuse collection body Loose debris may be ejected from the body and tailgate 2 Never enter the body or tailgate unless the Body main key operated switch is in the OFF position wi...

Page 23: ...connection of electrical components 1 Note the position of all the connectors before they are removed 2 When reconnecting components ensure connectors are refitted in the same positions as noted on removal If in doubt refer to the relevant circuit wiring diagram 3 If renewing halogen type bulbs do not touch the bulb glass with the fingers If necessary wipe the glass clean using a cloth moistened i...

Page 24: ...ipe nuts Cover the connection with a cloth while loosening the pipe nuts to prevent pressurised oil spraying from connection 3 When working on the hydraulic and pneumatic systems it is important to ensure maximum cleanliness 4 Always clean the area around a connection before dismantling a joint 5 Plug any open connections as soon as possible 6 Use only lint free cloths 7 Wherever possible avoid us...

Page 25: ...3 DAILY CHECKS Olympus Service Manual 3 3 1 OL1D SM GB02D CONTENTS PAGE 3 Daily checks 3 3 3 1 Daily safety checks 3 3 3 2 Daily safety check safety light curtain 3 22 3 3 Warning labels 3 23 ...

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Page 27: ...nnis Eagle Ltd Refuse Collection Vehicle to confirm the correct operation of the machine its controls safety circuits and interlocks in addition to checks specified in the chassis cab manufacturer s and waste container lifting device manufacturer s service information before it commences service The same checks should also be carried out by service personnel whenever scheduled maintenance service ...

Page 28: ...en should display the Body system run mode and System on pictogram 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors If any warning pictograms are displayed on the screen report to supervision immediately and do not proceed any further with the daily inspection 13 Switch the ignition on only do not start the engine The control screen should initiali...

Page 29: ...colour to green and a white number from 1 to 4 appears in the pictogram 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2 2748 DS046 OL1 D GB G1 WARNING MAK...

Page 30: ...OL1 D GB G3 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors WARNING COMPACTION MECHANISM MAY OPERATE MAKE SURE THAT THE TAILGATE AREA IS CLEAR OF PERSONNEL 23 Press and hold the Tailgate raise switch until the tailgate is just out of its locks and...

Page 31: ...ess in turn the 2842 OL1 D GB G1 Start pack cycle push button Rescue push button Compaction mechanism should not operate WARNING MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTAINER LIFTING DEVICE IF FITTED RAISED 27 On the compaction mechanism control panel where the Start pack cycle push button is energised press in turn the 2842 OL1 D GB G1 Start pack cycle p...

Page 32: ...should display on the control panel screen 2846 OL1 D GB G1 32 Press and hold the Tailgate raise switch 2844 OL1 D GB G3 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 210 Bar 2 Tailgate should rotate smoothly upwards about the hinge pins Vehicle reversing alarm should sound 33 While tailgate is rising release the switch before ...

Page 33: ...n the cab control panel screen Immediately the tailgate reaches full height the compaction mechanism should complete the number of full cycles shown by the white number in the tip clear pictogram i e packer plate open carriage plate down packer plate close and then carriage plate up in one continuous sequence until fully packed when it should stop WARNINGS MAKE SURE THAT YOU KNOW THE HEIGHT OF YOU...

Page 34: ...he control panel screen Vehicle reversing alarm should silence 43 While keeping the push button depressed press the released push button again Tailgate should remain stationary Tailgate out of locks pictogram should continue to display on the control panel screen Release both push buttons 39 Press the eject switch Release the switch when the ejection plate has reached the end of its travel 2847 OL...

Page 35: ...ttons on the Tailgate lowering control panel simultaneously until the tailgate engages locks and then release the push buttons 2387 OT1 D GB G1 Tailgate should rotate smoothly downwards about the hinge pins until it engages face of body then lower into locks Vehicle reversing alarm should sound until the tailgate engages locks when it should silence System on pictogram should display when the tail...

Page 36: ...DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 47 Press and hold the Lower tailgate to 1 metre switch until the tailgate stops lowering and then release the switch 2856 OL1 D GB G2 1M 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 10 Ba...

Page 37: ... 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 2871 OL1 D GB G1 1 3 2 4 49 Press and release the return switch 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil ...

Page 38: ...l buzzer in the cab should sound immediately the push button is pressed and silence immediately the push button is released 2774 OL1 D GB G1 2821 OL1 D GB G1 The Signal warning pictogram should display on the control panel screen while the button is pressed Open System vehicles no waste container lifting device fitted Vehicles fitted with an open waste container lifting device and guide plate in l...

Page 39: ...ush button Cab control panel x 1 Compaction mechanism control panel x 2 Rave rail or waste container lifting device x 2 2779 OL1 D GB G2 Carry out the following operations 59 67 59 Press a Start pack cycle push button to operate the compaction mechanism so that carriage plate is moving upwards 2774 OL1 D GB G1 While the carriage plate is moving upwards press the Emergency stop push button Compacti...

Page 40: ... and operates to specification 66 Turn the Body main switch to Off position Remove and retain the key 67 Open the body access door Packer plate should open and carriage plate move upwards simultaneously until it is fully open and fully unpacked 2855 OL1 D GB G1 The Rescue warning pictogram should display on the control panel screen 61 Turn the Body main switch off and then on again 0 0 OL1SMGB01 0...

Page 41: ...o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar WARNING COMPACTION MECHANISM MAY OPERATE MAKE SURE THAT THE TAILGATE AREA IS CLEAR OF PERSONNEL WARNING MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTAINER LIFTING DEVICE IF FITTED RAISED 68 Insert the key into the Body main switch and turn it to Run Body access door open warning pictogram should display in the con...

Page 42: ... controls mode 2748 DS003 OL1 D GB G2 Hyd Oil Temp 32 o C 01 06 2013 09 00 00 0 No errors 0 No errors 0 No errors 2748 DS004 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 Hyd_Oil_Pressure 2 Bar 2748 DS028 OL1 D GB G2 76 Press and release the External discharge controls switch The screen should display the Body discharge external con...

Page 43: ...RE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WASTE CONTAINER LIFTING DEVICE IF FITTED RAISED 77 Press the Tailgate raise push button Tailgate should raise smoothly until out of locks and then rotate smoothly upwards about the hinge pins Vehicle reversing alarm should sound immediately the tailgate is out of locks and while tailgate is rising 2867 OL1 D GB G1 Tailgate out of lo...

Page 44: ...jection plate retract push button Release the push button when the ejection plate has reached the end of its travel Ejection plate should retract smoothly without judder 2869 OL1 D GB G1 83 Press the Ejection plate eject push button Release the push button when the ejection plate has reached the end of its travel Ejection plate should eject smoothly without judder 2868 OL1 D GB G1 WARNING MAKE SUR...

Page 45: ...ould sound until the tailgate engages locks when it should silence The engine speed should lower to tick over System on pictogram should display when the tailgate engages locks 2748 DS005 OL1 D GB G2 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 09 00 00 Hyd_Oil_Pressure 0 No errors 0 No errors 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 09 00 00 H...

Page 46: ...cle push button 2774 OL1 D GB G1 1677 01 EU1 GB 1 1 Fig 3 1 Safety light curtain status indicator lamps 7 While the packer plate is closing and the carriage plate is moving upwards place a suitable soft object into the light curtain The mechanism should continue to operate and complete the packing cycle 8 Remove the soft object from the light curtain 9 Press and release the Start pack cycle push b...

Page 47: ... labels right hand rear of refuse collection bodywork 860261 855370B4 855370B PT No 863993 2749 OL1 D GB G2 Note Label fitted only when access steps are fitted ORDER No Telephone 01926 316000 Warwick CV34 6TE ENGLAND Heathcote Way Heathcote Industrial Estate 13 OLYMPUS CAT TYPE SERIAL No 855378B YEAR 201 CAUTION Bin Lift remains operational when access door is open PT No 1018697 Fig 3 3 Warning la...

Page 48: ...Y Hy draulic Oil Ma x CLE AN UP ALL SPI LLA GE S PT No 100199 6 6 ON LY USE CLE AN OIL OF THE CO RRE CT SPE CIF ICA TIO N MAX OL 25 2 7 ONL Y Fig 3 4 Warning labels left hand front of refuse collection bodywork 2750 OL1 D GB G2 RIDE ON REAR ENTER BODY WITH ENGINE RUNNING DO NOT WALK UNDER RAISED HOPPER DRIVE WITH BINS RAISED REACH INTO BINS REACH INTO HOPPER WALK UNDER RAISED BINS HOLD OBJECTS BEI...

Page 49: ...ted when footboards are fitted Fig 3 6 Warning labels rear of collection bodywork PACK ON THE MOVE CAUTION Ensure cab control panel has the operating system selected OFF when undertaking normal road use Do not allow the packing mechanism to labour at maximum stalling pressure for prolonged periods of time eg Body full The packing mechanism can be stopped from within the cab by selecting OFF on the...

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Page 51: ...ympus Service Manual 4 4 1 OL1D SM GB02D CONTENTS PAGE 4 Hydraulic system oil level 4 3 4 1 To check hydraulic system oil level 4 3 4 1 1 Topping up hydraulic oil bulk oil supply 4 7 4 1 2 Topping up hydraulic oil using hand pump 4 8 ...

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Page 53: ... allow for the tailgates to be fully raised 2 Engage the parking brakes 3 Select Neutral N 4 Check that the tailgate is in the normal position locked to the body 5 Make sure that all personnel are clear of the body tailgate and rear of the vehicle 4 Hydraulic system oil level It is most important that the level of fluid in the hydraulic reservoir is maintained within the specified limits Topping u...

Page 54: ... THE MESSAGE AREA OF THE SCREEN INVESTIGATE AND RECTIFY THE CAUSE OF THE WARNING BEFORE OPERATING THE SYSTEM 8 Press the Start pack cycle push button on the energised compaction mechanism control panel 2774 OL1 D GB G1 6 Switch the ignition on then start and run the engine The cab control panel will initialise and then display the Body system off mode I 0 II III 2748 DS002 OL1 D GB G2 01 06 2013 H...

Page 55: ...e compaction mechanism reaches the point where the carriage plate is in fully lowered position and the packer plate is open press an Emergency stop push button 2907 OL1 D GB G1 10 Release the Emergency stop push button 11 Turn the Body main switch off and then on again 0 0 OL1SMGB01 002 12 Press and release the Internal discharge switch on the cab control panel The screen will display the Body dis...

Page 56: ...in switch to Off position Remove and retain the key 17 Switch ignition off Remove and retain the key 18 Lock all cab doors Remove and retain the keys When the tailgate is out of its locks the Tailgate out of locks pictogram will display on the control panel screen 2810 OL1 D GB G2 14 Press and hold the Eject switch to move the ejection plate to the rear of the body Release the switch when the ejec...

Page 57: ...Disconnect the filling equipment from the quick release coupling 4 Replace the quick release coupling cap 5 If the hydraulic level is very low inspect all the hydraulic systems including bin lifts if fitted for hydraulic oil leaks Rectify any leaks before operating the vehicle 19 Check the oil level The reservoir is fitted with two oil sight glasses The upper glass is marked with black and red lin...

Page 58: ...6 Insert the filler hose into the oil drum so that the filter is submerged in the oil 7 Insert the handle into the pump 8 Operate the pump until the oil level in the tank is correct 9 Withdraw the filler hose from the drum and wipe clean Refit the protective cap over the filter and stow the hose securely in its mounting clips 10 Refit the filler plug in the drum and remove the oil drum 4 1 2 Toppi...

Page 59: ...lympus Service Manual 5 5 1 OL1D SM GB02D CONTENTS PAGE 5 Cleaning 5 3 5 1 Drain 5 4 5 1 1 Body drain 5 4 5 1 2 Tailgate drains 5 4 5 2 Daily cleaning 5 5 5 3 Pressure washing 5 6 5 4 Cleaning the leachate tank 5 6 ...

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Page 61: ...ons for cleaning commercial vehicles and steam cleaning according to the following guidelines Caution Caustic or acidic cleaning solutions must not be used as they may damage components and assemblies Use of such solutions may invalidate the warranty granted with this product WARNINGS NEVER ENTER THE TAILGATE OR BODY TO CLEAN DEBRIS UNLESS YOU KNOW AND CAN WORK TO THE SAFE WORKING PROCEDURES DETAI...

Page 62: ... Type PH2OHGB05 040 D C C To open Unscrew drain plug off drain D To close Screw drain plug onto drain 2 Valve Type PH2OHGB05 039 F E E To open Turn lever outwards F To close Turn lever inwards 5 1 Drain 5 1 1 Body drain The body drain is on the right hand side of the body at the front 2881 OL1 D GB G1 A B Fig 5 1 Body drain A To open Release hose B To close Stow hose in bracket ...

Page 63: ...s ladder if fitted on right hand side of vehicle OL1SMGB01 142 12 Open the body access door The door has a safety interlock to stop operation of the body mechanism when it is open 13 Clean out any refuse which has entered the body in front of the ejection plate 14 Clean debris from the body sump and wash out thoroughly Drain through the external hose to ensure thorough cleaning is achieved 15 Clos...

Page 64: ...ism and slide tracks by Pressure washing at least once a week as follows 1 Stand the vehicle on clean level and stable ground with sufficient clearance to allow for the tailgate to be fully raised 2 Engage the parking brakes 3 Select Neutral N 4 Open the tailgate drains see 5 1 2 Tailgate drains on page 5 4 5 Prop the tailgate see Operator s Handbook 6 Turn the Body main switch to the OFF position...

Page 65: ...mounting bolts 6 7 6 8 2 Clean the tailgate proximity switches 6 8 6 9 12 Week service checks 6 9 6 9 1 Body checks 6 9 6 9 2 Tailgate checks 6 9 6 9 3 Hydraulic system components checks 6 10 6 9 4 Electrical system checks 6 10 6 9 5 Power take off propeller shaft if fitted 6 11 6 9 6 Hand wash unit optional item 6 11 6 9 7 Operational check 6 11 6 9 8 Compaction mechanism cycle time check 6 11 6 ...

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Page 67: ...e mechanism especially in the pivoting and locking of the tailgate to the body Any problems must be reported to supervision immediately 6 3 Routine maintenance To maintain the mechanism at peak operational efficiency and good condition The refuse collection mechanism should be serviced according to the procedures and at the intervals specified in this chapter Only approved lubricants fluids and re...

Page 68: ...gate proximity switches Page 6 9 X X X X X Check condition integrity and security of body components Page 6 10 X X X X Check condition integrity and security of tailgate components Page 6 10 X X X X Check condition integrity and security of hydraulic system components Page 6 11 X X X X Check condition integrity and security of electrical system components Page 6 11 X X X X Check condition integrit...

Page 69: ...rgise the compaction mechanism control panels 5 Press and release the Start pack cycle push button 6 When the grease nipple is visible in the access hole press an Emergency stop push button 7 Reset the Emergency stop push button 8 Immobilise the vehicle see 1 2 Immobilising the vehicle prior to service procedures on page 1 3 9 Clean the following mechanisms and lubricate with clean oil Side door h...

Page 70: ...EN THE ENGINE IS RUNNING 2 Power Take Off with grease nipple see Fig 6 2 4 Use grease gun to apply Spline Lubricant Chelsea Part No 379688 or Castrol Optimol Paste White T through this grease nipple 3 Power Take Off without grease nipple It will be necessary to remove the hydraulic pump fixings and carefully manoeuvre the pump to expose the splines and apply Spline Lubricant Chelsea Part No 379688...

Page 71: ...Clean the tailgate using a pressure washer see 5 3 Pressure washing on page 5 6 Make sure you remove foreign matter from The hopper 2a The slide ways in the tailgate 2b The gap between the carriage plate and retaining plate 2c The bottom end of the carriage plate carriage plate cylinder bearing block 2d The area where hydraulic cylinders close into the body or small spaces 2e 3 Clean the body in f...

Page 72: ...f body mounting bolts Check that body mounting bolts are tightened to the specified torques and spring lengths and gaps are correct Ref Components Size Spring length gap mm Nm lbf ft 1 Front body mounting bolts M24 x 80 1000 740 2 Front body mounting bolts M20 x 190 65 3 Intermediate body mounting bolts M24 x 170 5 4 Intermediate body mounting bolts M24 x 170 70 5 Intermediate body mounting bolts ...

Page 73: ...n the tailgate proximity switches 1 Remove the tailgate side covers and clean the tailgate proximity switches Carefully wipe any dirt away from the face of each proximity switch and its operating plate 2886 OL1 D GB G1 Fig 6 5 Tailgate proximity switches ...

Page 74: ... Tailgate lock pins Cylinder mountings and pivots Body access door and its hinges locks and switch Ejection plate Ejection plate guides Ejection plate slide blocks 3 Check that structural stressed panels are not damaged or worn to less than 75 of their original thickness 6 9 2 Tailgate checks 1 Check that the tailgate is sitting square on the body 2 Check that the carriage plate assembly is sittin...

Page 75: ...of exposure to excessive heat Leaks particularly when the system is in operation Check for signs of weakness or bulging particularly when under maximum pressure Check for signs of perishing on the outer cover 6 9 4 Electrical system checks 1 Examine all the electrical wiring looms their connectors wires and mountings for condition security fractures displacement wear distortion cracks damage or co...

Page 76: ...ff propeller shaft if fitted 1 Examine the power take off propeller shaft universal joints for security worn bearings damage to grease seals and cracks 2 Examine the power take off propeller shaft flange nuts for security and condition 3 Examine the power take off propeller shaft slider joint and grease seal for wear and damage 6 9 6 Hand wash unit optional item 1 Check the hand wash unit for secu...

Page 77: ...AX OL 25 27 ONLY 1 2 3 Fig 6 6 Hydraulic oil filter and breather filter 1 Return line oil filter 2 Breather filter 3 High pressure oil filter 6 9 9 Tailgate lower time check Check the tailgate lower time as follows 1 Start engine WARNINGS MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE BODY TAILGATE AND REAR OF THE VEHICLE MAKE SURE THAT YOU KNOW THE HEIGHT OF YOUR VEHICLE WITH THE TAILGATE AND WAST...

Page 78: ...nt that may have settled in the bottom of the bowl and the O ring locations 10 Fit new O rings and a new filter element 11 Install the filter bowl assembly and tighten to 20 4 Nm 15 lbf ft Return line oil filter 12 Remove the 4 screws securing the filter head cover plate 13 Remove the square section sealing ring from the cover plate and fit a new one 14 Remove the filter element and insert a new f...

Page 79: ... Service Manual 7 7 1 OL1D SM GB02D CONTENTS PAGE 7 Operational maintenance 7 2 7 1 Body lamp bulb replacement 7 2 7 2 Fuses and relays 7 4 7 3 Maintenance screen 7 6 7 3 1 Entering a password 7 7 7 3 2 Adjusting the clock calendar 7 8 ...

Page 80: ... lamps 24 Volt 3 Watt 2 Rear marker lamps 24 Volt 5 Watt 3 Tailgate high level lamp Tail Stop lamp 24 Volt 6 24 Watt Turn indicator lamp 24 Volt 21 Watt Rear fog lamp 24 Volt 21 Watt 4 Tailgate rear lamp Tail Stop lamp 24 Volt 6 24 Watt Turn indicator lamp 24 Volt 21 Watt Reverse lamp 24 Volt 5 Watt Rear fog lamp 24 Volt 21 Watt 5 Number plate lamp 24 Volt 5 Watt 6 Warning beacon rotating Halogen ...

Page 81: ...1D SM GB02D 2895 OL1 D GB G1 8 3 2 8 2 3 8 4 4 7 6 8 5 6 7 8 1 1 1 Side marker lamp 2 Rear marker lamp 3 Tailgate high level lamp 4 Tailgate rear lamp 5 Number plate lamp 6 Warning beacon rotating 7 Warning beacon flashing 8 Work lamp ...

Page 82: ...OL1D SM GB02D 7 2 Fuses and relays 3131 OL1 D GB G2 BC9 CR10 CR8 CR1 SW1 SPR1 BC8 BC10 SPR2 CS BR RW HL SW2 SIDE 1 SIDE 2 CR4 F10 F9 F8 F7 F6 F5 F4 F3 F2 CR5 CR6 CR2 CR3 BC7 10 F11 6 10 5 15 7 5 2 10 5 15 F1 15 Fig 7 1 Main body box ...

Page 83: ...A F8 Rear view camera 5A F7 Controller outputs 15A F6 Waste container lifting device 7 5A F5 Controller inputs 2A F4 Options 10A F3 Option work lamps 5A F2 Rear work lamps 15A F1 Warning beacons 15A Relays Relay Function SPR1 Spare relay SPR2 Spare relay CS Control panel selection relay BR Beacon relay RW Work lamp relay HL Hopper lamp relay ...

Page 84: ... screen display dependant on position of Body main switch Hyd Oil Temp 09 00 00 0 No errors 0 No errors 0 No errors Hyd Oil Temp 01 06 2013 09 00 00 F2 F3 F4 F5 F6 F7 F8 0 No errors 0 No errors 0 No errors Password Level 32 o C Hyd Oil Temp 09 00 00 0 No errors 0 No errors 0 No errors Hyd Oil Temp 01 06 2013 09 00 00 F2 F3 F4 F5 F6 F7 F8 0 No errors 0 No errors 0 No errors Password Level 32 o C 27...

Page 85: ...ered 2748 DS069 OL1 D GB G3 0 No errors 0 No errors 0 No errors 01 06 2013 Maintenance 09 00 00 Config Date Time Data Logger Inform Monitoring Inform Config Inform Monitoring In Out Config RCV RIDE ON REAR ENTER BODY WITH ENGINE RUNNING DO NOT WALK UNDER RAISED HOPPER DRIVE WITH BINS RAISED REACH INTO BINS REACH INTO HOPPER WALK UNDER RAISED BINS HOLD OBJECTS BEING PACKED PUSH TO STOP PUSH TO STOP...

Page 86: ...013 Hour 09 Day 01 Minute 00 Month 06 Second 00 7 3 2 Adjusting the clock calendar Adjustment of the clock and or calendar can only be made from a password protected Maintenance screen To demonstrate the procedure changing the time from 09 00 00 to 11 15 00 is shown 1 Press the switch under Config Date Time The Config Date Time screen will display 2748 DS070 OL1 D GB G3 0 No errors Hyd Oil Temp 0 ...

Page 87: ...9 Day 01 Minute 00 Month 06 Second 00 Hour 09 Minut Hour 11 Minut 7 Press Set to confirm the setting 2748 DS076 OL1 D GB G3 0 No errors Hyd Oil Temp Date 01 06 2013 Time 11 00 00 0 No errors 0 No errors 32 o C Hyd Oil Pressure 2 Bar 01 06 2013 Config Date Time 09 00 00 SET Date Set Scale 1 Year 2013 Hour 11 Day 01 Minute 00 Month 06 Second 00 8 Press either of the arrow switches to select the next...

Page 88: ...e 15 Month 06 Second 00 Date 01 06 2013 Time 11 15 00 Hour 11 Minute 15 Secon Hour 11 Minute 15 10 Press the return switch to return to the maintenance screen 2748 DS079 OL1 D GB G3 0 No errors Hyd Oil Temp 0 No errors 0 No errors 32 o C 01 06 2013 Maintenance 11 15 00 Config Date Time Data Logger Inform Monitoring Inform Config Inform Monitoring In Out Config RCV RIDE ON REAR ENTER BODY WITH ENGI...

Page 89: ...l operation times 8 3 8 1 1 Cycle time 8 3 8 1 2 Ejection plate 8 3 8 1 3 Tailgate raise lower 8 3 8 2 Noise level 8 3 8 3 Hydraulic pressures 8 3 8 4 Hydraulic oils and greases 8 4 8 5 Dimensions 8 5 8 5 1 Olympus series smooth body narrow RCV 8 5 8 5 2 Olympus series smooth body wide RCV 8 6 8 5 3 Body identification label 8 7 ...

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Page 91: ... NOT ATTEMPT TO MAKE ANY HYDRAULIC ADJUSTMENTS AS THIS WILL COMPROMISE SAFETY AND NULLIFY ANY WARRANTY AGREEMENTS WITH DENNIS EAGLE 8 General specification data 8 1 Typical operation times 8 1 1 Cycle time Cycle time with an empty tailgate 18 20 seconds 8 1 2 Ejection plate Eject stroke 25 35 seconds Note Ejection plate times are approximate because of friction on the tracks Times may vary dependi...

Page 92: ...r s specification Note 30 to 80 32 HM Q8 Foil 32 Biodegradeable viscosity 46 oil is used where specified by customers Recommended greases Application Manufacturer s specification General lubrication Shell Retinax A BP Energol LS2 or L2 Castrol LM Total EP2 Energol HLP32 Carriage plate Packer plate pivot pins Fuchs Renolit Aqua 2 or similar lubricant to DEF STAN 91 34 1 ...

Page 93: ...NDER RAISED BINS HOLD OBJECTS BEING PACKED 855376 CAUTION CHECK DAILY REPORT FAULTS CLEAN AS NECESSARY REFUSE BUILD UP SPILLAGE HYDRAULIC OIL LEAKS DIESEL FUEL OIL LEAKS ENGINE OIL LEAKS PT No 863993 Compaction body type OL 10N OL 11N with Combi KS2 2 0 3 5 4 2 NTD OL 14N OL 16N OL 19N OL 14N with Combi KS 2 0 3 5 NTD Elite chassis type 4x2 6x2RS 6x2ML a 6x2ML a 6x2MS b 6x2RS c 6x2RS b V1 Overall ...

Page 94: ...FAULTS CLEAN AS NECESSARY REFUSE BUILD UP SPILLAGE HYDRAULIC OIL LEAKS DIESEL FUEL OIL LEAKS ENGINE OIL LEAKS PT No 863993 Compaction body type OL 13W OL 16W OL 20W OL 21W OL 23W OL 27W OL 13W with Combi KS 2 5 4 0 5 0 TD OL 16W with Combi KS 2 5 4 0 5 0 TD Elite chassis type 4x2 a 6x2ML a 6x2MS a 6x2RS b 6x4 c 6x2ML a 6x2MS b 6x2RS c 6x4 d 8x4MS 6x2RS b 6x4 c 6x4 b V1 Overall wheelbase 3500 a 405...

Page 95: ...front of the body on the lower right hand corner The information on the label is shown below Machine category Body type Serial number Order number Year of manufacturer 2915 OL1 D GB G1 ORDER No Telephone 01926 316000 Warwick CV34 6TE ENGLAND Heathcote Way Heathcote Industrial Estate 13 OLYMPUS CAT TYPE SERIAL No 855378B YEAR 201 ...

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Page 97: ...9 SUPPLEMENTARY INFORMATION Olympus Service Manual 9 9 1 OL1D SM GB02D CONTENTS PAGE 9 Supplementary information 9 2 ...

Page 98: ...ORMATION OL1D SM GB02D 9 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 ...

Page 99: ...PLEMENTARY INFORMATION OL1D SM GB02D 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 ...

Page 100: ...PLEMENTARY INFORMATION OL1D SM GB02D 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 ...

Page 101: ...PLEMENTARY INFORMATION OL1D SM GB02D 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 ...

Page 102: ...PLEMENTARY INFORMATION OL1D SM GB02D 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 ...

Page 103: ...9 Protecting vehicle components during grinding drilling and welding 2 9 Responsible technician the Key Holder 2 8 Solvents 2 11 Welding on or near the vehicle 2 9 Work place cleanliness 2 8 Hydraulic system oil level 4 3 To check hydraulic system oil level 4 3 Topping up hydraulic oil bulk oil supply 4 7 Topping up hydraulic oil using hand pump 4 8 C Cleaning 5 3 Body drain 5 4 Cleaning the leach...

Page 104: ...ew hydraulic oil filter elements and breather filter 6 13 12 Week service checks 6 10 Body checks 6 10 Compaction mechanism cycle time check 6 12 Electrical system checks 6 11 Hand wash unit Optional item 6 12 Hydraulic system components checks 6 11 Power take off propeller shaft if fitted 6 12 Tailgate checks 6 10 Tailgate lower time check 6 13 24 Month hydraulic system oil quality check 36 Month...