McNeilus Contender Operator's Manual

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OPERATOR’S MANUAL

Contender Front Loader

Publication No. 1474268

Rev. 0918

Disclaimer:

This manual must not be used to repair your vehicle. Repair information is available by calling McNeilus Customer Service at (888) 686-7278.

The information in this Operator

’s Manual will be your guide to operation and operator maintenance for this equipment.

A published. product improvement policy service, or maintenance improvement. www

No part of this publication may be reproduced by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems for any use or purpose - without the written permission of McN Tr

For assistance in ordering the Waste Collection V National W 1550 Crystal Drive A T

For assistance in ordering OSHA Publications, contact:

ll information, illustrations, and specifications in this manual are based on the information available at the time this manual was

The illustrations used in this manual are intended as representative reference views only. Because of our continuous

, we may modify information, illustrations, and/or specifications to explain and/or exemplify a product,

We reserve the right to make any change at any time without notice. Go to

.streetsmartparts.com for current information.

uck and Manufacturing, Inc.

ehicle Safety Guide, contact:

aste and Recycling Association

• Suite 804

rlington, VA 22202

elephone: 800-424-2869 • Fax: 202-966-4824

Contender Front Loader

U.S. Department of Labor/OSHA OSHA Publications P.O. Box 37535 Washington, D.C. 20210 Telephone: 202-693-1888 • Fax: 202-693-2498

eilus

1.0 Identication Plate

A McNeilus Truck and Manufacturing, Inc. Identication plate

(Figure 1) is located on the left front side of the body. The

identication plate contains the Model Number and Serial Number of your refuse system.

To serve you better, please ll out the following information and have it ready when calling McNeilus Truck and Manufacturing, Inc. for parts or product information:

Date of Purchase:

McNeilus Branch:

Model Number of Refuse Vehicle:

Serial Number of Refuse Vehicle:

VIN*

*Refer to chassis manufacturer literature for location.

Foreword

Figure 1

Contender Front Loader

Foreword

2.0 Complete Vehicle Document Decal

The Complete Vehicle Document Decal (Figure 2) documents the axle load and tire ratings as the vehicle left the McNeilus

production line. This decal is located inside the cab and may be placed on the driver’s door, doorjamb, or the seat riser.

This decal includes information such as the Maximum rated weight per axle (Item 2), Gross Vehicle Weight (Item 3), Chassis manufacturer (Item 4), Chassis build date (Item 5), Vehicle (chassis) ID number (Item 6), Tire and rim size and tire pressure specications (Item 7), and the Refuse vehicle system build date (Item 8).

S/O #: nnnnnn Body Mount Date: MM/D/YYYY Data Plate ID: nnnnn

MFD. BY McNEILUS TRUCK & MFG. INC

GVWR

FR. GAWR

1ST GAWR

2ND GAWR

3RD GAWR

4TH GAWR

REAR GAWR

CONFORMITY OF THE CHASSIS-CAB TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS WHICH HAVE BEEN PREVIOUSLY FULLY CERTIFIED BY THE INCOMPLETE VEHICLE MANUFACTURER OR BY THE INTERMEDIATE VEHICLE MANUFACTURER, HAS NOT BEEN AFFECTED BY FINAL-STAGE MANUFACTURER, THE VEHICLE HAS BEEN COMPLETED IN ACCORDANCE WITH THE PRIOR MANUFACTURER’S INSTRUCTIONS WHERE APPLICABLE. THIS VEHICLE CONFORMS TO ALL OTHER SAFETY STANDARDS IN EFFECT IN:

INCOMPLETE VEHICLE MFD. BY DATE

34,75576,620

LB KG

VEHICLE TYPE CLASSIFICATION

20,000

22,800

20,000

22,800

11,020

9,072

10,342

LB W/ TIRES ON RIMS @PSI COLD KPA

10,342

4,999

MFGR NAME

TRUCK

445/65R22.5

TIRES ON

445/65R22.5

TIRES ON

445/65R22.5

TIRES ON

255/70R22.5

TIRES ON

Figure 2

VEHICLE ID #

22.5 X 13.0

22.5 X 8.25

nnnnnnnnnnnnnnnnn

RIMS @

MM/D/YYYY

120

PSI COLD KPA

120

PSI COLD KPA

120

PSI COLD KPA

115

PSI COLD KPA

830

790

MMM

YYYY

Contender Front Loader

3.0 Purpose of Manual

NOTE

This Operator Manual provides operation and operator maintenance instructions for the Contender Front Loader refuse collection system manufactured by McNeilus Truck and

Manufacturing, Inc.

The information in this operator manual will be your guide to operation and operator maintenance for this equipment.

Keep this manual with the vehicle at all times.

WARNING

The operator of this vehicle must be properly licensed and trained to operate this vehicle.

If you do not have the proper training and licensing to operate this vehicle, you are putting yourself and others at risk of serious injury or death.

If you are uncertain how to operate this Packer, inform your supervisor or contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278.

Foreword

This manual is limited to the operation and light maintenance of the refuse collection system only.

This manual does not include the operation or maintenance of the chassis vehicle upon which the refuse collection system is mounted.

4.0 Scope

This manual provides information for use by the equipment operator under the following headings:

1. Safety. Includes important safety information.

2. General. Includes equipment identication.

3. Operation. Includes control functionality and normal

equipment operation.

4. Preventive Maintenance. Includes basic preventive maintenance information for the operator.

5. Troubleshooting. Includes basic troubleshooting information for the operator.

To order a replacement manual or safety signs, call McNeilus Parts and Service at 888-686-7278.

Contender Front Loader

Foreword

Phone Number

888-686-7278

State City

CA CT FL GA IL IN MN NY

Canada

Ontario and W Quebec and Maritime Provinces 800-996-4937

5.0 Parts and Service

Contact your McNeilus Parts and Service branch locations to order parts, receive service information, or for other assistance. Contact by phone or visit www.streetsmartparts.com. We have factory owned parts and

service centers near you.

Colton East Granby

Tampa

Villa Rica

Sugar Grove

Bronx

State City

OH Cincinnati OH Columbus PA Morgantown TX Houston

TX Hutchins Fort Wayne Dodge Center

UT West Valley City

WI Oshkosh

estern Provinces 800-265-1089

6.0 Corporate Headquarters

Contact McNeilus Truck and Manufacturing, Inc. directly at

our corporate headquarters at the following address, phone number, and website.

McNeilus Truck and Manufacturing, Inc.

524 County Road 34 East

Dodge Center, MN 55927

Telephone: 507-374-6321

Corporate Website: www.mcneiluscompanies.com

Parts and Service Website: www.streetsmartparts.com

Contender Front Loader

Table of Contents

SAFETY

1.0 IMPORTANT SAFETY INFORMATION .................................................................................................................................1

1.1 Battery Disconnect Switch ..........................................................................................................................................2

1.1.1 Battery Cable Disconnect ................................................................................................................................2

1.2 Safety Equipment ........................................................................................................................................................3

1.3 Reporting Safety Defects.............................................................................................................................................3

2.0 SAFETY NOTICES ................................................................................................................................................................4

3.0 PRODUCT SAFETY INFORMATION ....................................................................................................................................5

3.1 Safety ...........................................................................................................................................................................5

3.2 Cab Operation ..............................................................................................................................................................6

3.3 Maintenance ...............................................................................................................................................................10

3.4 Outside Operation ......................................................................................................................................................13

3.5 Hydraulics ...................................................................................................................................................................18

3.6 Electrical .....................................................................................................................................................................21

4.0 SAFETY SIGNS ..................................................................................................................................................................22

4.1 Safety Sign Location...................................................................................................................................................24

GENERAL INFORMATION

1.0 EXTERIOR SYSTEMS ARRANGEMENT ...........................................................................................................................27

1.1 Street Side View .........................................................................................................................................................27

1.2 Curb Side View ...........................................................................................................................................................28

1.3 S-Type Container Specications ................................................................................................................................29

Contender Front Loader

Table of Contents

OPERATION

1.0 OPERATING PROCEDURES .............................................................................................................................................31

1.1 Start-Up Procedure.....................................................................................................................................................31

1.2 Warm-Up Procedure ...................................................................................................................................................32

1.3 Traveling Procedure - Standard..................................................................................................................................33

1.4 Traveling Procedure - Residential ..............................................................................................................................34

1.5 Preparation Before Starting Route .............................................................................................................................35

1.6 Neutral Interlock Test Procedure for Optional Neutral Interlock .................................................................................35

1.7 Refuse Loading Procedure .........................................................................................................................................36

1.8 Refuse Empty Procedure ...........................................................................................................................................38

1.9 End of Day Checks .....................................................................................................................................................39

2.0 CONTROL BOX AND INSTRUMENTS ...............................................................................................................................39

2.1 Cab Controls...............................................................................................................................................................40

2.2 Control Box .................................................................................................................................................................41

2.2.1 Refuse Vehicle Button Functions....................................................................................................................42

2.2.2 LED Indicator Light Functions ........................................................................................................................45

2.2.3 Fuse Block ......................................................................................................................................................48

2.3 Arm and Fork Controls................................................................................................................................................50

2.3.1 Street Side/Curb Side Switch .........................................................................................................................50

2.3.2 Single Lever Joystick Control .........................................................................................................................51

2.3.3 Single Lever Joystick Control (Optional) ........................................................................................................52

Contender Front Loader

Table of Contents

2.3.4 Dual Lever Controls (Optional) .......................................................................................................................53

2.3.5 Auto Dump Single Lever .................................................................................................................................54

2.4 Outside Control Box (Optional)...................................................................................................................................55

3.0 CONTROL FUNCTIONS .....................................................................................................................................................56

3.1 E-STOP (Emergency Stop) Function .........................................................................................................................56

3.1.1 In-Cab Control Panel E-STOP Button ............................................................................................................56

3.1.2 Outside Control Box E-STOP Button ..............................................................................................................56

3.2 Pack/Eject Functions ..................................................................................................................................................58

3.2.1 Automatic Cycling of Pack/Eject .....................................................................................................................58

3.2.2 Manual Cycling of Pack/Eject .........................................................................................................................59

3.2.3 Manual Cycling with Tailgate Open ................................................................................................................60

3.3 Arm Functions.............................................................................................................................................................61

3.4 Fork Functions ............................................................................................................................................................62

3.5 Auto Dump Functions (Optional) ................................................................................................................................63

3.6 Tailgate Functions ....................................................................................................................................................... 64

3.6.1 Open Tailgate .................................................................................................................................................65

3.6.2 Close Tailgate ................................................................................................................................................. 65

3.7 Top Door Functions ....................................................................................................................................................66

3.7.1 Open Top Door ...............................................................................................................................................66

3.7.2 Close Top Door ............................................................................................................................................... 66

III

Contender Front Loader

Table of Contents

4.0 OPTIONAL EQUIPMENT ....................................................................................................................................................67

4.1 Residential Attachments .............................................................................................................................................67

4.1.1 Installing a Carry Can .....................................................................................................................................68

4.2 Pusher Axle or Tag Axle ..............................................................................................................................................69

4.2.1 Lowering the Pusher or Tag Axle ....................................................................................................................70

4.2.2 Raising the Pusher Axle or Tag Axle ...............................................................................................................70

4.3 Fall Protection Equipment ..........................................................................................................................................70

4.3.1 Fall Protection Roof Anchors ..........................................................................................................................70

4.3.2 Fall Protection Systems ..................................................................................................................................71

4.3.3 Working on the Roof .......................................................................................................................................71

4.4 Water Tank..................................................................................................................................................................72

4.4.1 Water Tank Safety ..........................................................................................................................................72

4.4.2 Introduction .....................................................................................................................................................72

4.4.3 Daily Inspection ..............................................................................................................................................73

4.4.3.1 Tank Integrity ................................................................................................................................... 73

4.4.3.2 Pressure Regulator Valve ...............................................................................................................73

4.4.3.3 Pressure Relief Valve ......................................................................................................................74

4.4.4 Daily Operation ...............................................................................................................................................74

4.4.5 Vehicle Handling Characteristics ....................................................................................................................74

4.4.6 Water Tank Decal Identication ......................................................................................................................75

4.4.7 Water Tank Operation .....................................................................................................................................75

Contender Front Loader

Table of Contents

4.4.7.1 Filling the Tank ................................................................................................................................ 76

4.4.7.2 Pressurizing the Water Tank ...........................................................................................................76

4.4.7.3 Depressurizing the Water Tank .......................................................................................................78

4.4.7.4 Draining the Water Tank..................................................................................................................79

PREVENTIVE MAINTENANCE

1.0 PREVENTIVE MAINTENANCE...........................................................................................................................................81

1.1 DOT Pre-Trip ..............................................................................................................................................................81

2.0 PREVENTIVE MAINTENANCE INTERVALS ......................................................................................................................81

3.0 DAILY PREVENTIVE MAINTENANCE CHECKS ...............................................................................................................87

3.1 Hydraulic System........................................................................................................................................................87

3.1.1 Hydraulic Oil Level..........................................................................................................................................87

3.1.1.1 Temperature / Level Sight Gauge ...................................................................................................87

3.2 Electrical System ........................................................................................................................................................89

3.2.1 Lighting System ..............................................................................................................................................89

3.3 Pneumatic System......................................................................................................................................................89

3.3.1 Coalescing Filter .............................................................................................................................................89

3.4 Mechanical System ....................................................................................................................................................90

3.4.1 Refuse Vehicle Body and Components ..........................................................................................................90

3.4.2 Tailgate Seal ................................................................................................................................................... 90

3.5 Operation ....................................................................................................................................................................90

3.5.1 Refuse Vehicle Controls .................................................................................................................................90

Contender Front Loader

Table of Contents

3.6 Trash Behind the Pack/Eject ......................................................................................................................................91

3.7 Safety Signs ...............................................................................................................................................................92

4.0 PROPPING THE TAILGATE ................................................................................................................................................92

4.7.1 Engaging the Standard Tailgate Prop ............................................................................................................. 93

4.7.2 Disengaging the Standard Tailgate Prop ........................................................................................................ 95

4.7.3 Engaging the Hinge Design Tailgate Prop ...................................................................................................... 96

4.7.4 Disengaging the Hinge Design Tailgate Prop ................................................................................................. 98

5.0 CANOPY LIFT/LOWER .......................................................................................................................................................99

5.1 Procedure for the Manual Canopy Lift Design............................................................................................................99

5.2 Procedure for the Pneumatic Canopy Lift Design ....................................................................................................100

6.0 LUBRICATION ...................................................................................................................................................................102

6.1 Daily Lubrication .......................................................................................................................................................102

6.2 Scheduled PM Lubrication........................................................................................................................................105

TROUBLESHOOTING

1.0 INTRODUCTION ...............................................................................................................................................................107

1.1 Onboard Diagnostics ................................................................................................................................................107

1.2 Troubleshooting Chart ..............................................................................................................................................109

INDEX

INDEX........................................................................................................................................................................................ 111

Contender Front Loader

Safety

1.0 Important Safety Information

READ AND UNDERSTAND THIS ENTIRE MANUAL

BEFORE OPERATING, REPAIRING, OR ADJUSTING YOUR

MCNEILUS EQUIPMENT.

THOSE WHO USE AND MAINTAIN THIS EQUIPMENT MUST BE THOROUGHLY TRAINED AND FAMILIAR WITH THE PRODUCT.

IF INCORRECTLY USED OR MAINTAINED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY.

Always keep this manual in a location where it is readily available for persons who operate or maintain the product. Additional copies of this manual are available from McNeilus

Truck and Manufacturing, Inc. Please contact McNeilus Truck

and Manufacturing, Inc. if you require additional manuals or if you have any questions about the information in this manual, this product, or safe operating procedures.

THESE SAFETY PROCEDURES ARE FOR YOUR OWN PROTECTION.

Do not operate this equipment until you have read its contents thoroughly. Read and understand the Waste Collection Vehicle Safety Guide that is placed in the vehicle’s cab. Please

contact McNeilus Truck and Manufacturing, Inc, if you require assistance.

Should operators of this equipment have a reading or learning disability, dyslexia, or other such condition, they must be assigned a mentor/trainer to read and explain to them the entire contents of this manual as well as the safety guidelines,

danger, caution, and warning safety signs on this unit. Such individuals should not be allowed to operate this equipment until they thoroughly understand all of these materials. Failure to do so can result in serious injury or death.

Refer to your company’s safety rules and procedures. Safety and safe working procedures must be followed at all times.

Perform your company’s Lockout/Tagout procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA 1910.147 and 1910.146 Conned Space as appropriate.

Contender Front Loader

Safety

1.1 Battery Disconnect Switch

If the vehicle is equipped with a battery disconnect switch, it

is located near the battery box. Use the battery disconnect

switch when performing any maintenance so the vehicle

1.1.1 Battery Cable Disconnect

If the vehicle is not equipped with a battery disconnect switch, disconnect the negative (black) battery cable rst, then disconnect the positive (red) cable.

cannot accidentally be started.

1. Turn the battery disconnect switch (Figure 3, Item 1)

counterclockwise so the hole on the switch aligns with the

hole in the bracket (Figure 3, Item 2).

2. Install the safety lockout device ring (Figure 4, Item 1)

through the holes on the battery disconnect switch and

the bracket.

3. Install a padlock (Figure 4, Item 2) onto the safety lockout

device ring, lock it, and put the key in your pocket. If more than one person is working on the vehicle, each person must install his or her own padlock.

For trucks without a battery disconnect switch, to prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding.

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting

WARNING

sparks can cause a battery explosion, which could result in death or serious injury.

Remarks: in immediate

discharge.

this lock/tag may result Unauthor

ized remo

val of

been

LOCKED OUT!

This ene

rgy source

has

DANGER

Figure 3

Contender Front Loader

Figure 4

Safety

1.2 Safety Equipment

Some McNeilus Refuse Trucks come equipped with a ve pound Fire Extinguisher, which has a rating of B:C, and a Reective Warning Triangle Kit containing three triangles.

The re extinguisher may already be mounted to the refuse vehicle, otherwise it is temporarily placed into the cab of your truck along with the reective triangle kit.

If you are supplying your own re extinguisher, it must comply with DOT FMCSA regulation 173.309 and 393.95 for rating and placement on the vehicle.

You are responsible for permanent mounting of this equipment. The re extinguisher is required to be securely mounted to prevent sliding, rolling, or vertical movement. The placement and mounting location of the reective triangles are

at your discretion.

1.3 Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafc Safety Administration (NHTSA) in addition to notifying

McNeilus Truck and Manufacturing, Inc., and the

chassis manufacturer.

If NHTSA receives similar complaints, it may open an investigation, and if it nds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer,

McNeilus Truck and Manufacturing, Inc., or the chassis

manufacturer.

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153); go to http://www.safercar.gov; or write to: Administrator, NHTSA, 400 Seventh Street, SW., Washington, DC 20590. You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

Contender Front Loader

Safety

SAFETY NOTICE

OPERATOR’S INSTRUCTION

2.0 Safety Notices

Safety notices are one of the primary ways to call your attention to potential hazards.

Safety Alert Symbol

THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY

MESSAGES IN THIS MANUAL.

WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE

MESSAGE THAT FOLLOWS.

BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

The following safety notices are used throughout this manual.

DANGER

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Danger is used in the most extreme situations.

WARNING

Warning indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.

CAUTION

Caution indicates a situation that might result in property damage.

The “signal words” of DANGER, WARNING, and CAUTION have specic meanings to alert you to the relative level of hazard.

Take the safety notices seriously. If you do not understand

them or have questions about them, call McNeilus Truck and Manufacturing, Inc at 888-686-7278.

Contender Front Loader

Safety

3.0 Product Safety Information

Read, understand, and follow the safety guidelines and heed dangers and warnings listed below and contained in this manual as well as on the refuse vehicle itself to promote reliable operation and prevent serious personal injury.

Contact McNeilus Truck and Manufacturing, Inc. at 888-6867278 if you require assistance or have questions.

3.1 Safety

WARNING

Safety decals must be replaced anytime they are damaged, missing, or cannot be read clearly. Failure to have proper decals in place can result in serious injury or death. If you require safety decals, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278.

WARNING

The Packer must not be modiﬁed in any way without authorization from McNeilus Truck and Manufacturing, Inc. Modifications may not comply with safety standards, including ANSI safety standards, and may result in serious personal injury. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance.

WARNING

Wear Personal Protective Equipment (PPE) such as hard hats, safety glasses or goggles, sturdy gloves, hearing protection, steel toed boots, and snug fitting sturdy long-sleeve shirt and long pants when operating or maintaining the Packer. Reflective clothing is recommended for drivers and employees while packing during hours of darkness. Serious injury can result without proper PPE.

Contender Front Loader

Safety

WARNING

Operating, servicing, and maintaining this vehicle or equipment can expose you to chemicals including exhaust, carbon monoxide, phthalates, and lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well ventilated area and wear gloves or wash hands frequently when servicing. For more information, go to www.p65warnings.ca.gov.

WARNING

Read, understand, and follow all aspects of OSHA 1910.146 Confined Space and PermitRequired Confined Space. Check your local and state regulations.

Information is found in the Safety section of this manual.

Failure to follow regulations may cause serious personal injury or death.

3.2 Cab Operation

DANGER

If the Packer comes into contact or close proximity with a power line or there is any arcing, stay in the truck cab and keep away from the metal parts of the unit. Do not let anyone come close to the truck. Do not attempt to jump clear of the truck. Stay in the cab. The power company must disconnect the power before you can safely leave the cab.

Minimum clearance from power lines: 50,000 Volts or Less 4 Feet

50,000 + Volts 10 Feet 345,000 - 750,000 Volts 16 Feet

Know the clearance of overhead obstructions. Never drive the Packer under any overhead obstruction. Failure to do so may result in damage to the Packer body or truck, and may result in serious personal injury or death.

Contender Front Loader

Safety

DANGER

If chassis is equipped with a stand-up drive position, use stand-up position only during refuse pick-up or collection activities for distances of less than 2/10 mile (0.32 km). Failure to heed this warning may result in serious personal injury or death.

DANGER

DO NOT operate vehicle in excess of 20 MPH from stand-up position. Failure to do so can result in serious personal injury or death.

DANGER

Always drive defensively. Never exceed posted speeds. Use lower speeds when going around curves, corners, or freeway on/off ramps. You are carrying a high center of gravity load. Failure to comply can lead to a roll over or other loss of control of the vehicle resulting in serious personal injury or death.

WARNING

Operators must comply with Employee Responsibilities as outlined in ANSI Z245 and state, federal, and other safety and transportation regulations (e.g. OSHA, DOT, Motor Carrier, and FMVSS) when operating this refuse vehicle. Failure to comply may result in serious personal injury or death.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

Contender Front Loader

Safety

DANGER

Never attempt to clear a jammed Packer or container lift, enter a body or open an access door unless power is shut down, LOCKOUT/TAGOUT procedures have been complied with, and the employee is authorized, trained, and competent to perform such activities. Failure to comply may result in serious personal injury or death.

WARNING

Keep access door closed when in operation. Do not open access door unless:

1. Engine is stopped.

2. Key is removed from ignition

3. Hydraulic pressures are relieved.

4. OSHA LOCKOUT/TAGOUT Regulations are complied with.

Failure to heed these instructions/warnings may result in serious personal injury or death.

WARNING

Never walk or stand behind vehicle while it is backing up. Failure to heed these instructions/warnings may result in serious personal injury or death.

WARNING

Never climb on windshield guard (if equipped). This is not a ladder. If equipped, use the ladder provided on the body to access the top of the vehicle. Failure to comply may result in serious personal injury or death.

Contender Front Loader

Safety

WARNING

Be sure all non-operator personnel are clear of the area around the Packer before operating the Packer. Remain attentive at all times when operating the controls. Watch the mirrors for activity. Never back up the Packer unless and until you are completely sure it is safe. Use a spotter/observer and/or get out and check yourself, if necessary, to ensure it is safe to do so. Thoroughly understand the controls before operating the Packer. Failure to heed this warning may result in serious personal injury or death.

WARNING

Before opening the tailgate, be sure you have adequate clearance above the tailgate to prevent contact with buildings, electrical lines, and any other overhead obstructions. Failure to comply can cause damage to the vehicle and serious personal injury.

WARNING

Always keep hands and feet and other parts of your body clear of revolving or moving parts. Failure to comply can cause serious injury.

WARNING

The Packer and chassis should never be overloaded. Do not exceed the manufacturer’s recommended gross vehicle weight. Do not overload the Packer and chassis. Gross weights must meet federal, state, and local laws. Failure to comply can cause serious injury.

WARNING

If refuse is spilled on the cab shield, only use a extendable handled rake or broom to remove the refuse. Never climb on the cab shield.

A fall from the cab shield may cause serious personal injury or death.

Contender Front Loader

Safety

SAFETY NOTICE

CAUTION

Be sure to drain the water tank, hoses, and pipes when operating in temperatures below freezing.

Failure to drain the system may cause damage to equipment.

CAUTION

If chassis is equipped with a battery disconnect switch, it must be turned off anytime the equipment is parked overnight, in a shop, or out of service for any extended period of time. Failure to do so may result in a fire and personal injury or property damage.

CAUTION

The installation procedure must be followed when installing a carry can.

Failure to follow all these steps may cause serious personal injury or equipment damage.

3.3 Maintenance

Perform your company’s Lockout/Tagout procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA

1910.147 and 1910.146 Confined Space as appropriate.

DANGER

LOCKOUT/TAGOUT procedures must be followed when working on this equipment including, but not limited to, cylinders being changed or maintained. Failure to heed these instructions/warnings can result in serious personal injury or death.

Contender Front Loader

Safety

DANGER

If the hydraulic or electrical system on the Packer fails to operate for any reason, call a competent technician to repair the problem. Never let any untrained or incompetent personnel attempt to fix any problems or malfunctions that may occur. If you are not trained or do not have the competence, never attempt to fix any problems or malfunctions that may occur. Never alter the original equipment manufacturer’s design.

WARNING

If equipped with optional camera or object detection system, do not rely exclusively on the camera or object detection system. Follow all other safe driving procedures. Failure to heed this warning may result in serious personal injury or death.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

WARNING

No passenger is allowed in the cab unless a manufacturer’s approved passenger seat and seat belt are provided. Serious injury or death can result.

Contender Front Loader

Safety

WARNING

At the landﬁll or when operating off-road, use the lowest transmission gear and proceed at low speed (3 mph maximum). Failure to comply can cause serious injury.

WARNING

It is important that the pump ON indicator light is working. No damage will be done to the hydraulic system if the Packer is driven with the pump in the ON position. However, the controls will function if accidentally bumped. This can cause serious injury or death.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

CAUTION

Always check indicator lights in the chassis cab or on the control panel at the front of the Packer. Replace bulbs or lights when required. (Note: All models may not have indicator lights.) Failure to inspect indicator lights may lead to more serious conditions.

CAUTION

Stow arms, forks, and container in hopper at the lowest height during transit. Be sure containers are stored at their lowest level in the hopper.

Failure to do so may result in a collision with bridges, overhead power lines, etc.

CAUTION

Use caution when raising the arm assembly with a container.

Contender Front Loader

Safety

CAUTION

The tailgate must be completely open before raising the body or damage to the rear bumper may occur.

CAUTION

If you detect a problem with any control function, it must be repaired immediately.

DO NOT operate the Packer with malfunctioning controls.

Damage to property or equipment may occur.

3.4 Outside Operation

DANGER

WARNING

If a container is dropped in the hopper, call maintenance for assistance in removing the container from the hopper.

Failure to do so may result in serious personal injury or death.

DANGER

Auxiliary pusher or tag axles must be supported with jack stands, blocks, or similar devices while being serviced or maintained to prevent serious personal injury or death if auxiliary axle drops unexpectedly. Failure to do so may result in serious personal injury or death.

DANGER

Use the three-point rule when climbing the ladder. Failure to heed may cause serious personal injury.

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Safety

DANGER

Do not climb on ladder while body is tilted or truck is in motion. Serious personal injury can occur due to a fall.

WARNING

Inspect ladder bolts every 30 days for wear and replace if necessary.

Failure to do so may result in serious personal injury or death.

DANGER

Verify that the body props are fully seated in the pockets on the frame.

Serious personal injury or death may occur.

DANGER

Crush hazard. Verify that the body props are properly positioned around the rods of the cylinders.

Serious personal injury or death may occur.

DANGER

PACKER BODY MUST BE EMPTY and body props employed when servicing Packer body in the raised position. Body props are meant to support only the empty body. Never overload.

Failure to empty body or employ body props may cause serious personal injury or death.

DANGER

Stand clear when the tailgate is in motion and during the unloading cycle. Do not stand under or cross under the raised tailgate.

Serious personal injury or death may occur.

DANGER

Whenever the tailgate is in a raised position, it must be securely propped or blocked so it cannot fall on anyone.

Serious personal injury or death may occur.

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Safety

DANGER

Never attempt to use extraneous sources of power or extraneous machines to overcome a malfunctioning system.

Never override with overhead cranes, forklifts, jacks, etc. or alter or modify systems or equipment that may be malfunctioning.

Failure to heed these instructions/warnings can result in serious personal injury or death.

WARNING

Daily inspections should be performed on the Packer. This includes proper operation of the controls, hydraulic systems, electrical systems, optional cameras are clean and working, camera lens is clean, lighting system including turn signals, back up alarm, brake lights, clearance lights, head lamps, tail lamps, safety equipment, and work lights are all operational. The Packer’s air system must operate properly and have no leaks. Water and moisture should be drained from the Packer’s air system daily. Failure to ensure all systems are operating properly can result in serious personal injury or death.

WARNING

Do not wear watches, rings, and jewelry while working with electrical and mechanical equipment. These items can be hazardous and can cause serious and painful injuries if they come into contact with electrical wires, moving parts, or hydraulic equipment.

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Safety

WARNING

Use only the access door for entry to the Packer. Remember to follow the LOCKOUT/TAGOUT procedures when entering the Packer body. Only exit the Packer body through the access door.

WARNING

If equipped with optional camera, camera lens must be kept clean at all times to help achieve good monitor pictures. Failure to heed this warning may result in serious personal injury or death.

CAUTION

Correct all identified deficiencies BEFORE operating the Packer. Failure to correct deficiencies may cause damage to equipment.

WARNING

Electrical wiring, battery wiring, and electrical cable must be inspected on a daily basis for cuts, abrasions, damage, aging, improper clearance and along the frame for hidden damage. If you find electrical wiring or electrical cable with any such adverse conditions or damage, they must be replaced with electrical wiring or electrical cable of equivalent specifications before the Packer is returned to service. Failure to properly inspect and maintain your Packer may result in serious personal injury or death.

WARNING

When working on the Packer, the wheels must be blocked, the parking brake on, LOCKOUT/TAGOUT procedures in effect, and the keys out of the truck’s ignition. Failure to do so may result in serious personal injury or death.

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Safety

WARNING

Anytime a tailgate is raised in the shop or for maintenance, the tailgate must be supported to prevent the tailgate from coming down unexpectedly. Never allow anyone to work around or enter the tailgate area unless the tailgate is raised and supported! Failure to follow this procedure can result in serious injury or death.

WARNING

Do not repair or weld steel or aluminum water tanks. Inspect the water tank for rust or corrosion every 30 days. Inspect the water tank under the straps, on the exterior, and on the interior by removing the flopper. If any rust or corrosion is found, replace the water tank with an OEM water tank from McNeilus. Failure to maintain water tanks may result in serious personal injury or death.

WARNING

Never place yourself between the tailgate and the body. Always engage both tailgate props when performing maintenance or inspections in or around the open tailgate area.

Failure to engage both tailgate props may result in serious personal injury or death.

WARNING

Packer must be disabled by the following steps before proceeding.

1. Place transmission in NEUTRAL.

2. Apply chassis parking brake.

3. Shut engine OFF.

4. Remove chassis ignition key and maintain in personal possession.

5. Turn chassis BATTERY switch OFF.

Failure to disable the Packer may result in serious personal injury or death.

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Safety

CAUTION

Disconnect battery before welding on body. Failure to do so might result in personal injury or damage to property or equipment.

CAUTION

Never attempt to prop a body or tailgate unless completely empty. Never walk or work under a raised body or tailgate unless props are in place. Failure to do so may result in serious personal injury or equipment damage.

3.5 Hydraulics

Call McNeilus Truck and Manufacturing, Inc. at 888-686-7278 anytime you have questions concerning hydraulic hoses, tubes, or pipes.

DANGER

Hydraulic systems operate under very high pressure. Hydraulic fluid escaping from a pressurized system can penetrate unprotected body tissue. Never inspect for hydraulic leaks with bare hands or other exposed body parts. As a minimum, wear leather gloves and use cardboard or wood to inspect for leaks. If leaks are present, relieve pressure and allow system to cool prior to servicing. If injured by escaping hydraulic oil, contact a physician immediately. Serious complications may arise if not treated immediately.

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Safety

WARNING

Hydraulic hoses and tubing must be inspected on a daily basis for leaks, cuts, abrasions, damage, aging, improper clearance, and along the frame for hidden damage. If you find hoses with any such adverse conditions or damage, they must be replaced before the vehicle is returned to service! Failure to properly inspect and maintain your vehicle may result in serious personal injury or death.

WARNING

Hydraulic systems are hot. DO NOT TOUCH! Serious personal injury or death may result from hot oil. When you have completed working on the hydraulic systems, thoroughly clean any spilled oil from the equipment. Do not spill any hydraulic fluid on the ground. Clean any hydraulic fluid from your skin as soon as you have completed your maintenance and repairs. Dispose of used oil and filters as required by law.

WARNING

The hydraulic cylinders can be holding a function in a certain position when the engine is OFF. An example of this would be a function being held in the lift or partial lift position by the cylinders. If a hydraulic line is removed or the hydraulic circuits or controls are being worked on, gravity may allow the function being held in position to drop. All workers and personnel must remain clear of these areas when working on or operating the McNeilus equipment. Block and secure all applicable devices and functions before beginning work or operation. Failure to comply with this can result in serious injury or death.

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Safety

WARNING

Hydraulic hoses have the SAE ratings marked on the hose to assist in selecting the correct hose. Replacement hydraulic hose and fitting components must be supplied by the same manufacturer to prevent serious injury or death. An as example: Brand “A” hose and brand “B” fitting will not normally be compatible.

WARNING

Do not heat hydraulic tubing. The carbon content of this steel tube is such that if heated for bending, and either water or air is quenched, the tubing may lose its ductility and thereby be subject to failure under high pressure or hydraulic shock conditions. Serious injury can result. Damaged or leaking tubing must be replaced before the Packer is returned to service. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance or have questions.

WARNING

Hydraulic systems operate under high pressure. Only qualified, experienced people properly trained in hydraulic system maintenance should attempt repairs or troubleshoot hydraulic systems. Use the proper tools and equipment when servicing the hydraulic system. Failure to comply can cause serious injury. Please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you require assistance.

WARNING

Increasing hydraulic pressure beyond the recommendations may result in serious damage to the Packer or serious personal injury or death and may void the Packer Warranty.

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Safety

WARNING

All hydraulic pressures must be relieved from the hydraulic system prior to removing any components from the system to prevent oil from spraying or functions or systems from falling. Failure to follow this procedure can result in serious personal injury or death.

WARNING

Do not steam clean or pressure wash the pump or hydraulic hose. Cleaning the pump with a high pressure washer or steam cleaning may damage the pump’s seals and allow water to enter the hydraulic system. Cleaning the hydraulic hose with a high pressure washer or steam cleaning will damage the hose’s outer covering and steel braid and lead to premature failure. The pump and hydraulic hose should be wiped with a clean lint-free cloth rather than washed.

WARNING

Hydraulic components can be heavy. Use caution while lifting these components. Serious personal injury can be avoided with proper handling of the components.

3.6 Electrical

WARNING

Proximity switches must remain functional for safe operation of the Packer. If a switch does not work, it must be replaced immediately with an OEM switch before the Packer returns to service. Failure to comply can result in serious injury or death. Contact McNeilusTruck and Manufacturing, Inc. at 888-686-7278 for assistance if required.

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Safety

4.0 Safety Signs

The following safety signs are found on your refuse collection system and warn of hazards related to the use of this equipment. Read and understand all safety signs before operating this equipment.

NOTE

Depending on the Packer configuration and optional equipment, the actual location of decals and/or placards may vary slightly from the examples shown.

If any safety signs on the equipment are not clearly readable, call McNeilus Parts and Service at 888-686-7278 or visit www.streetsmartparts.com to order replacements. Use only McNeilus replacement safety signs.

The table below contains part numbers for the individual safety signs. See the Figures in this section for safety sign

locations.

NOTE

Specifications, appearance, and part numbers for safety decals are subject to change without notice.

No. Part Number Qty. Comments

1 9590.614298 2

2 1107479 1

3 9090.614542 2

4 9190.614301 2

5 9090.614430 2

6 9190.614299 3

7 9190.614302 1

8 9090.614548 1

9 780.214618 1

10 9190.614305 1

11 1140908 1

12 9790.614269 1

13 9090.614412 1

14 780.214500 1

15 9090.614541 1

16 1318804 1

17 9790.614306 1

18 9090.614526 1

19 9790.614308 1

20 9790.601933 1

21 9790.614277 1

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Safety

No. Part Number Qty. Comments

22 9790.614286 1

23 9790.614296 1

24 9190.614263 3

25 9790.614261 1

26 9190.614271 4

27 9790.614274 1

28 9190.614292 3

29 9090.614583 1 If equipped.

30 1108358 2

31 9090.614392 2

32 1172954 1

33 9090.614559 1

34 9190.614285 1

35 9090.614547 1 If equipped.

36 9790.660903 1

37 9090.612453 1

38 9190.614270 1

39 9090.614448 2

40 9790.614338 1

41 1107478 3

42 1108425 1

No. Part Number Qty. Comments

43 1109764 1

44 1225787 2

45 1326487 1 If equipped. Not shown.

46 1327929 1

47 1327934 1

48 1324145 1

1329260

1329261

50 1449162 1 If equipped.

51 1104395 1 If equipped with water tank.

52 1327939 1 If equipped with water tank.

53 1397069 1

1404116

55 1

56 1265704 Varies

57 1260913 Varies

58 1260914 Varies

59 1133532 1 If equipped. Location varies.

60 1140666 1 If equipped. Location varies.

61 1490253 1 If equipped. Location varies.

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Safety

4.1 Safety Sign Location

26 41

50 52

5 3

2642630312432

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Safety

26 27

30 31 41 26

Contender Front Loader

Safety

40 42 2

12 13 14 15 16 17 18 19

21 22 23 29 36 37

Contender Front Loader

1.0 Exterior Systems Arrangement

1.1 Street Side View

General Information

Ref. No System Description

1 Cab Control Box and Joystick

2 Fork Assembly

3 Arm Assembly

4 Pack/Eject

5 Top Door

6 Tailgate

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General Information

1.2 Curb Side View

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Ref. No System Description

7 Body

8 Hopper

9 Side Access Door

10 Hydraulic Oil Reservoir

11 Service Lift Cylinders (Optional)

General Information

1.3 S-Type Container Specications

Only lift containers that are compatible with ANSI Z245.62008, type S containers. Check to make sure the container meets the dimensional requirements before lifting (Figure 3).

No. Description Specication

Width of the fork receiver area at

the inside surface of the outboard

pocket walls.

Width at the top of the container,

including all lids, hinges and hinge rods.

Width of the fork receiver area at

the inside surface inboard pocket wall, including bump plates.

Height of the pocket between the

inside surfaces of the top and bottom wall.

Extension of the bump plates below

the inside surface of the bottom pocket wall.

Height of the pocket above ground

at the inside surface of the top wall.

Height from inside top pocket wall

to the top leading edge of the

container, over all lids and hinges.

Min: 79 in. Max: 80 in.

Max: 78 in.

Max: 73-1/2 in.

Min. 4 in.

Min: 25 in.

Max: 48 in.

Figure 3

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General Information

NOTES

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Operation

1.0 Operating Procedures

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

NOTE

Turn the pump ON and idle the truck for a minimum of five minutes before operating the hydraulic functions when the air temperature is 50° F (10° C) or below.

WARNING

Do not leave the truck unattended until the parking brake has been securely set and all reasonable precautions have been taken to prevent the movement of the truck. The operator must chock the truck wheels anytime he is away from the vehicle for an extended period of time. Wheel chocks are available for purchase from McNeilus Truck and Manufacturing, Inc. by calling 888-686-7278.

Failure to comply may result in serious personal injury or death or damage to equipment.

1.1 Start-Up Procedure

Before starting the vehicle, make certain that:

1. Battery switch is ON.

2. Daily checks have been completed and veried.

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Operation

1.2 Warm-Up Procedure

At start-up of the equipment each morning, it is important to cycle through each of the main hydraulic circuits to be certain each circuit is functioning properly. Cycling through each operation also helps ensure that the hydraulic uid is up to operating temperature and is present throughout the system.

CAUTION

If you detect a problem with any control function, it must be repaired immediately.

DO NOT operate the Packer with malfunctioning controls.

Damage to property or equipment may occur.

1. Cycle through each of the following operations:

Pack/Eject Functions - Cycle three (3) times.

Tailgate Functions - Cycle one (1) time.

Top Door Functions - Cycle three (3) times.

Fork and Arm Functions - Cycle ten (10) times.

2. After completing the cycle tests, inspect the refuse vehicle for any hydraulic leaks. If the leaks are detected, correct them BEFORE the refuse vehicle is placed into actual operation.

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Operation

1.3 Traveling Procedure - Standard

Before beginning travel to the next site, be sure that all

hydraulic functions are in their HOME positions. This means that the:

1. Tailgate is fully closed.

2. The arms and forks must be positioned properly for travel.

3. The arms and forks can either be positioned with the forks

raised and arms raised above the windshield (Figure 5, Item 1), or with the forks tucked and the arms fully raised

(Figure 6, Item 2).

4. Turn PUMP rocker switch OFF to disable hydraulic functions.

5. Turn all warning and strobe lights ON.

Figure 5

Figure 6

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Operation

1.4 Traveling Procedure - Residential

Before beginning travel to the next site, be sure that all

hydraulic functions are in their HOME positions. This means that the:

1. Tailgate is fully closed.

2. The arms and forks must be positioned properly for travel.

3. For a residential application equipped with a carry can,

the arms must be fully raised with the carry can inserted into the hopper (Figure 7, Item 1). Never travel to the

next site with the can positioned low (Figure 8, Item 2). This position is for work only.

4. Turn PUMP rocker switch OFF to disable hydraulic functions.

5. Turn all warning and strobe lights ON.

Figure 7

WARNING

Depending on what size carry can you use, verify the overall height of the truck with the carry can inserted into the hopper does not exceed the specified overall truck height listed on the height decal on the truck.

Failure to comply may cause serious injury or death or damage to equipment.

Contender Front Loader

Figure 8

Operation

1.5 Preparation Before Starting Route

1. Turn battery disconnect ON.

2. If necessary, turn rear and side lights ON to enhance

vision.

3. Turn pump rocker switch ON.

4. Activate all E-STOP buttons.

1.6 Neutral Interlock Test Procedure for Optional Neutral Interlock

WARNING

Never disable neutral safety or interlocks. Failure

to comply may result in serious injury or death or damage to equipment.

If equipped with the optional throttle momentary switch, follow this procedure weekly to ensure the proper operation of the neutral interlock. Before performing this procedure, the packer should be located outside and away from people, other vehicles, and buildings. Two people are required for this procedure.

1. Move the truck to an outside area away from people,

other vehicles, and buildings. Clear a 50’ area in the front and behind the truck in case the truck moves backward or forward while performing the following test. If the truck

moves backward or forward during the test, person #1 in the cab should apply the brakes and immediately disarm the throttle. If the truck moves backward or forward while performing the test, person #2 (the outside operator) should immediately release the throttle momentary toggle switch to allow it to return to the “off” position.

2. Place approved blocks on the rear wheels to prevent the truck from moving.

3. Person #1 should enter the truck cab, apply the parking brake, and start the truck engine, and remain in the cab.

4. Person #1 should ready the cab throttle momentary toggle switch, place the automatic transmission in reverse, and remain in the cab.

5. Person #2 should go to the optional outside control box and engage the throttle momentary toggle switch. The

throttle should not engage unless the truck is in neutral.

6. Person #1 should place the automatic transmission in

drive and remain in the cab.

7. Repeat step #5.

8. If the throttle engages with the transmission in reverse or

drive, the truck may have a malfunctioning neutral switch or not have a neutral switch for the throttle system.

9. If the truck has a malfunctioning neutral switch, immediately remove the truck from service and call McNeilus Service Department immediately at 888-686-

7278.

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Operation

1.7 Refuse Loading Procedure

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

WARNING

If refuse is spilled on the cab shield, only use a extendable handled rake or broom to remove the refuse. Never climb on the cab shield.

A fall from the cab shield may cause serious personal injury or death.

1. Make certain the top door is OPEN and the pack/eject is in the HOME position.

2. Lower the fork and arm assemblies into position to lift the container.

3. Position the vehicle in line with the container, and drive

the vehicle forward until the forks are all the way through the container fork pockets (Figure 9).

4. Adjust the fork assembly so the container is level.

CAUTION

Use caution when raising the arm assembly with a container.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

5. Raise the arm assembly until the fork assembly is visible at the top of the windshield.

6. Lower fork assembly to level the container.

7. Continue to raise the arm assembly until arm assembly

reaches the arm stops.

8. Completely raise fork assembly to empty container.

9. Lower the fork assembly until the container has cleared

the hopper and the forks are vertical.

10. Lower the arm assembly to return the container to the ground.

11. Adjust the fork assembly as needed to allow the vehicle to

back away from the container.

12. Place the fork and arm assemblies in the travel position.

Contender Front Loader

CAUTION

Do not operate pack and sweep with container in hopper.

Serious damage may result to the Packer.

13. Execute an AutoPack Function.

14. Close the top door.

15. Travel to the next pickup site.

Operation

Figure 9

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Operation

1.8 Refuse Empty Procedure

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

Figure 10

1. Position the rear of the refuse vehicle as appropriate.

2. Verify the top door is open, the fork and arm assemblies

are in the travel position.

3. Open the tailgate fully (Figure 10, Item 1).

4. Extend the pack/eject to the rear (Figure 11, Item 1) of the

body to eject the load.

5. Retract the pack/eject to the HOME position.

6. Lower the tailgate and prop for maintenance. (In the Preventive Maintenance section, see 4.7.1 Engaging the Standard Tailgate Prop.)

WARNING

Never place yourself between the tailgate and the body. Always engage both tailgate props when performing maintenance or inspections in or around the open tailgate area.

Failure to engage both tailgate props may result in serious personal injury or death.

7. Inspect and clean the tailgate seal and sealing areas of the body, and then fully close the tailgate.

8. Remove the props from the tailgate. (In the Preventive Maintenance section, see 4.7.2 Disengaging the Standard Tailgate Prop.)

Contender Front Loader

Operation

Figure 11

1.9 End of Day Checks

At the end of the day, make certain that:

1. Pack/Eject is fully retracted.

2. Fork and arm assemblies are fully raised.

3. Tailgate is fully closed.

4. Body (OPTIONAL) is fully lowered.

5. All equipment is properly shut down (see the Chassis Manual for more information on proper shut-down procedures for the engine).

2.0 Control Box and Instruments

NOTE

Control configurations and locations may vary depending upon customer ordered options.

Your Packer may not have all the features or options covered in this manual. You should pay careful attention to the instructions that pertain to your vehicle. If your vehicle is equipped with special equipment or options not covered in this manual, please contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278.

The following gures and tables identify and describe the controls used on the equipment. Not all of the instruments and controls shown here are on your equipment. Items covering various models and options are illustrated.

To make sure you understand proper operating procedures, read this section and carefully practice with the controls and instruments to learn how to safely operate the equipment.

Contender Front Loader

Operation

2.1 Cab Controls

The in-cab controls consist of in-dash controls or a control box (Figure 12, Item 1) and a joystick(s) (Figure 12, Item 2). There are several types of joystick options available. The dual-lever joystick option is shown.

No. Position Normal Use or Reading

1 Control Box Controls refuse vehicle functions,

lights, and options.

2 Joystick Controls the arm and fork

movements.

Contender Front Loader

Figure 12

Operation

WARNING

2.2 Control Box

The in-cab control box contains the E-STOP (emergency stop) button (Figure 13, Item 1), buttons for the refuse vehicle functions, lights, pump, and options (Figure 13, Item 2), and a red LED warning light (Figure 13, Item 3).

No. Position Normal Use or Reading

1 E-STOP

Button

2 Switches and

LED Lights

Disables all hydraulic and electric refuse vehicle functions.

Controls refuse vehicle functions,

lights and options, and displays error codes and status of operations.

3 Red LED

Warning Light

If light is on or ashing, it indicates an unsafe condition. Look at the LED

Figure 13

lights on the control box to determine what the unsafe condition is. Under normal operating conditions, the light will be off.

Contender Front Loader

Operation

2.2.1 Refuse Vehicle Button Functions

Refuse vehicle functions, lights, some accessories, and options are operated by the buttons on the control box (Figure

14). Accessories and options vary depending on your model.

No. Position Normal Use or Reading

Press to activate hydraulic functions. The indicator light above the button

1 PUMP Button

TAILGATE

CLOSE Button

TAILGATE

OPEN Button

ACTIVATE

Button

will be green when the pump is on.

Press again to disable hydraulic functions.

Press and hold button to close the

tailgate. You must also press and hold the ACTIVATE button while holding the TAILGATE CLOSE

button. The indicator light above the

button will be green when the tailgate

is fully closed.

Press and hold button to open the tailgate. You must also press and hold the ACTIVATE button while holding the TAILGATE OPEN button.

Press and hold the button to enable the tailgate functions.

No. Position Normal Use or Reading

Press and hold the button to open

TOP DOOR

OPEN Button

the top door. The indicator light above the button will be green when the top door is fully open.

Press and hold the button to close

TOP DOOR

CLOSE Button

the top door. The indicator light above the button will be ashing red when the top door is fully closed.

AUTOPACK / EJECT Button

RETRACT

Button

EXTEND

Button

ARM OVER BODY OVERRIDE

Press this button to start the

autopack.

Press this button to retract the pack/ eject to the HOME position.

Press this button to extend the pack/ eject. Pressing the button will stop the auto pack mode if active.

Press and hold to override the

interlock to operate the pack/eject when arms are above the body.

Button

Press the button to enable the outside control box. The indicator

REMOTE

Button

light above the button will be green.

Press the button again to disable the outside control box. The indicator

light above the button will turn off.

Contender Front Loader

Operation

No. Position Normal Use or Reading

Press the button to enable the auto

RESIDENTIAL

MODE Button

dump and residential controls when using the Dual Lever Joysticks.

Press the button again to disable the

auto dump.

Press the button to turn on the rear

REAR WORK

LIGHT Button (OPTIONAL)

work lights. Press the button again to turn off the rear work lights. The truck must be moving less than 10 mph for the rear work lights to come

on.

TAG AXLE

RAISE Button

Press the button to raise the tag axle.

(OPTIONAL)

TAG AXLE LOWER

Button

Press the button to lower the tag

axle.

(OPTIONAL)

WORK LIGHT Button (OPTIONAL)

PUSHER AXLE RAISE

Button

Press the button to turn on the work

lights. Press the button again to turn

off the work lights.

Press the button to raise the pusher

axle.

(OPTIONAL)

No. Position Normal Use or Reading

PUSHER AXLE LOWER

Button

Press the button to lower the pusher

axle.

(OPTIONAL)

Press the button to turn on the strobe lights. Press the button again

to turn the strobe lights off. With the “strobes on with pump” option, the button will not turn the strobe lights

STROBE LIGHT Button (OPTIONAL)

off when the pump is on.

None functional button. Warning light only. See 2.2.2 LED Indicator Light

Functions for more information.

SIDE DOOR

Button

Contender Front Loader

Operation

WARNING

Figure 14

Contender Front Loader

Operation

2.2.2 LED Indicator Light Functions

The LED indicator lights are used to display the status of various functions and operations (Figure 15). When the ignition switch is rst turned on, the lights will perform a selftest which will light all the lights for a few seconds.

No. Position Normal Use or Reading

1 Pump On LED

Error Code

LED

Tailgate Closed

LED

Tailgate Open

LED

The LED will be green when the pump is on.

There are six LEDs that will be on or off depending on the error code. If any of these LEDs are lighted,

refer to the error code decal located

on the cab center console. Note: To enter the diagnostic mode, press and hold both buttons with the exclamation icon for ve seconds.

The LED will be green when the tailgate is fully closed. The LED will ash red when the tailgate is in the process of being closed.

The LED will ash red if the tailgate

is not fully closed.

No. Position Normal Use or Reading

If a button is pressed that requires the ACTIVATE button to be pressed,

5 Activate LED

but the ACTIVATE button was not pressed, the amber LED will ash, indicating the ACTIVATE button must also be pressed.

Top Door Open

LED

Top Door Close

LED

The LED will be green when the top door is fully open.

The LED will ash red when the top door is in the fully closed position.

When the side door is fully closed, the LED will be off. When the side door is opened, it

8 Side Door LED

activates the E-STOP, shuts off the hydraulic pump, and the red LED will ash. The hydraulic pump icon and the amber LED above it will also ash.

The two red LEDs will ash when

9 AutoPack LEDs

the pack/eject is in the autopack mode.

The LED will be green when the pack/eject is retracted into the HOME position.

Pack/Eject Retract LED

Contender Front Loader

Operation

No. Position Normal Use or Reading

The red LED will light when the pack/eject is extended. The pack/ eject will not extend to the full eject mode unless the tailgate is fully

Pack/Eject Extend LED

open.

Arm Over Body

Override LED

The LED will be green when the arm is in the over body override mode.

The LED will be green when the

Remote Button

LED

REMOTE button is activated. The outside control box is now operational.

Residential

Controls Mode

The LED will be green when the arm

is in the Residential Controls Mode.

LED

Rear Work

Light LED

Tag Axle Up

LED

Tag Axle Down

LED

18 Work Light LED

Pusher Axle Up

LED

The LED will be green when the rear work lights are on.

The LED will be green when the tag axle is in the fully RAISED position.

The LED will be green when the tag axle is in the fully DOWN position.

The LED will be green when the work lights are on.

The LED will be green when the pusher axle is in the fully RAISED position.

No. Position Normal Use or Reading

The LED will be green when the pusher axle is in the fully DOWN position.

The LED will be green when the

strobe lights are on.

Pusher Axle

Down LED

Strobe Light LED

Contender Front Loader

Operation

WARNING

Figure 15

Contender Front Loader

Operation

2.2.3 Fuse Block

The fuse block protects the in-dash controls from an

overloaded condition. The fuse block is located on the refuse vehicle behind the cab. Open the cover (Figure 16, Item 1) to gain access to the fuses (Figure 17).

No. Amp Description

3 5 Control Power

4 10 Tag Axle/Reverse Alarm Fuse

5 5 Pusher Axle Fuse

6 10 3G Power Auxiliary Power Fuse

7 5 Module Power Fuse

8 15 Strobe Light Fuse

9 15 Rear Lights Fuse

10 Spare

11 10 Hydraulic Controls Fuse

12 E-STOP Power Relay

13 10 Hydraulic 1 Fuse

14 5 Top Door Fuse

15 5 Hydraulic 2 Fuse

16 Spare

17 Front Work Lights Relay

18 Rear Work Lights Relay

Figure 16

19 Strobe Lights Relay

20 Spare Relay

1 5 Proximity Switch Power Fuse

2 15 Front Lights Fuse

No. Amp Description

21 Ignition Relay 1

22 3 Module Memory Fuse

23 Ignition Relay 2

Contender Front Loader

Operation

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17181920212223

101252

Figure 17

Contender Front Loader

Operation

2.3 Arm and Fork Controls

There are three types of controls for the Arm and Fork Functions. There are two types of single lever joysticks available that enable the single joystick to operate both the Arm and Fork Functions. The second type of control is the dual lever in which one lever controls the Arm Functions and

the other lever controls the Fork Functions.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

CAUTION

Use caution when raising the arm assembly with a container.

2.3.1 Street Side/Curb Side Switch

When you have more than one joystick which can be operated from the Street Side or the Curb Side of the cab, the switch must be moved to the correct position.

When the toggle switch (Figure 18, Item 1) is in the middle, it is in the OFF position (Figure 18, Item 2). The joysticks will not function in the OFF position.

Move the toggle switch (Figure 18, Item 1) to the Street Side Joystick position (Figure 10, Item 3) for Street Side Joystick operation.

Move the toggle switch (Figure 18, Item 1) to the Curb Side Joystick position (Figure 18, Item 4) for Curb Side Joystick operation.

Streetside Joystick

Figure 18

OFF

Curbside

Joystick

1226671

Contender Front Loader

Operation

2.3.2 Single Lever Joystick Control

The single lever joystick (Figure 19) controls the movement of both the arm and fork assemblies.

The joystick is spring loaded and will automatically return to the middle (neutral) position when released.

Move the STREET SIDE/CURB SIDE switch to the position the controls will be operated from. (See Street Side/Curb Side Switch.)

Pull the joystick BACK (Figure 19, Item 1) to raise the arm assembly.

Push the joystick FORWARD (Figure 19, Item 2) to lower the arm assembly.

Push the joystick AWAY from the operator (Figure 19, Item 3) to lower the fork assembly.

Pull the joystick TOWARD the operator (Figure 19, Item 4) to raise the fork assembly.

Figure 19

Figure represents view from street side in chassis cab.

Contender Front Loader

Operation

2.3.3 Single Lever Joystick Control (Optional)

The joystick is spring loaded and will automatically return to the middle (neutral) position when released.

The single lever joystick (Figure 20) controls the movement of both the arm and fork assemblies.

Move the Street Side/Curb Side switch to the position the controls will be operated from and activate the Residential Controls switch.

Press in and hold the CENTER (Operator Presence) switch (Figure 20, Item 5) to activate the joystick.

Pull the joystick BACK (Figure 20, Item 2) to raise the arm assembly.

Push the joystick FORWARD (Figure 20, Item 1) to lower the arm assembly.

Push the forks LOWER button (Figure 20, Item 4) to lower the fork assembly.

Push the forks RAISE button (Figure 20, Item 3) to raise the fork assembly.

Figure 20

CENTER BUTTON

ACTIVATE

FORKS

RAISE

LOWER

Contender Front Loader

2.3.4 Dual Lever Controls (Optional)

NOTE

The INSIDE lever of the dual controls always controls the arm function. It does not matter whether it is mounted on the curbside or the streetside.

The INSIDE lever is always closest to the operator.

The Dual Lever controls consist of two separate levers. One lever controls the movement of the arm assembly. The other lever controls the movement of the fork assembly.

The control levers are spring loaded and will automatically return to the middle (neutral) position when released.

Move the Street Side/Curb Side switch to the position the controls will be operated from.

Pull the corresponding control lever BACK (Figure 21, Item 1) to raise the arm assembly.

Push the corresponding control lever FORWARD (Figure 21, Item 2) to lower the arm assembly.

Push the corresponding control lever FORWARD (Figure 21, Item 3) to lower the fork assembly.

Pull the corresponding control lever BACK (Figure 21, Item 4) to raise the fork assembly.

Operation

Figure 21

Figure represents view from street Side in chassis cab.

Contender Front Loader

Operation

2.3.5 Auto Dump Single Lever

Press in and hold the CENTER (Operator Presence) switch (Figure 22, Item 3) to activate the joystick.

Pull the joystick back (Figure 22, Item 2) and hold to begin the auto dump function.

To return the container to the ground, push the joystick forward (Figure 22, Item 1) and hold.

CENTER BUTTON

ACTIVATE

FORKS

RAISE

LOWER

Contender Front Loader

Figure 22

2.4 Outside Control Box (Optional)

The Arm, Fork, Pack/Eject, Throttle Advance, and E-STOP Functions can be operated from the outside control box (Figure 23). The REMOTE button on the in-dash control panel must be ON to enable the outside controls.

No. Description Normal Use or Reading

AUTO PACK/EJECT

Switch

THROTTLE

ADVANCE Switch

FORK Control

Switch

4 ARM Control Switch

5 E-STOP Button

Operator Presence

Button

Press and hold the switch up to activate automatic cycling of Pack/Eject Function.

Press and hold the switch up to

increase chassis engine RPM.

Press and hold the switch to the left to raise fork assembly. Press and hold the switch to the right to lower fork assembly.

Press and hold the switch to the left to raise arm assembly. Press and hold the switch to the right to lower arm assembly.

Disables all hydraulic,

pneumatic, electric functions.

Press and hold the button when

using any of the outside control

switches.

Operation

Figure 23

Contender Front Loader

Operation

3.0 Control Functions

3.1 E-STOP (Emergency Stop) Function

Press any of the E-STOP buttons (Figure 24) to IMMEDIATELY DISABLE refuse vehicle and Hydraulic

functions.

The E-STOP button is a safety function. Pressing the E-STOP button disables all refuse vehicle Electrical, Pneumatic, and Hydraulic functions.

Figure 24

3.1.1 In-Cab Control Panel E-STOP Button

Pull up on the button to release the in-dash control panel E-STOP button (Figure 25, Item 1).

3.1.2 Outside Control Box E-STOP Button

Pull up on the button to release the outside control box E-STOP button (Figure 25, Item 2).

NOTE

All E-STOP buttons must be in the UP position before the refuse vehicle functions can be restored.

NOTE

If Packer functions are not operational, reset the controls by pulling up ALL of the E-STOP buttons and turning the pump back on.

Contender Front Loader

WARNING

Figure 25

Operation

Contender Front Loader

Operation

3.2 Pack/Eject Functions

The Pack/Eject Functions are controlled by two buttons located on the in-cab control panel. Automatic cycling of the Pack/Eject Functions is controlled by the AUTOPACK button. Manual cycling of the Pack/Eject Functions is controlled by the EXTEND button or the RETRACT button.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

3.2.1 Automatic Cycling of Pack/Eject

Conditions

• Tailgate CLOSED indicator light must be green

• Side door indicator light must be off

• Top Door OPEN indicator light must be green

• Engine speed must be below 1600 rpm

Press the AUTOPACK button to activate automatic cycling of the Pack/Eject Functions. When activated, the pack/eject extends from the HOME position (Figure 26, Item 1) into the hopper until it reaches the EXTEND position (Figure 26, Item

2). The pack/eject then reverses direction and retracts until it returns to the HOME position.

NOTE

The automatic packing cycle can be interrupted by pressing any of the E-STOP buttons.

Contender Front Loader

3.2.2 Manual Cycling of Pack/Eject

Conditions

(Applies to Extend Function Only)

• Tailgate CLOSED indicator light must be green

• Side door indicator light must be off

• Top Door OPEN indicator light must be green

• Arms must be lowered below cab

• Engine speed must be below 1600 rpm

Manual cycling of the Pack/Eject Functions is controlled by the EXTEND button or the RETRACT button located on the in-cab control panel. With the tailgate CLOSED, the pack/eject can only travel to the EXTEND position (Figure 26, Item 2).

Press and hold the EXTEND button to manually control the extend movement of the pack/eject. When the button is released, the pack/eject will stop at its current position.

Press and hold the RETRACT button located on the in-cab control panel to retract the pack/eject. The pack/eject will retract to the HOME position (Figure 26, Item 1). When the RETRACT button is released, the pack/eject will stop at its current position.

Operation

Figure 26

Contender Front Loader

Operation

3.2.3 Manual Cycling with Tailgate Open

Conditions

(Applies to Extend Function Only)

• Side door indicator light must be off

• Top Door OPEN indicator light must be green

• Tailgate must be fully open

• Engine speed must be below 1600 rpm

When the tailgate is OPEN, the EXTEND button or the RETRACT button controls the Pack/Eject Functions, however, the pack/eject can travel into the body.

With the tailgate fully OPEN, the pack/eject will extend past the EXTEND position. The distance that the pack/eject extends into the body is determined by holding the EXTEND

button.

While holding the EXTEND button, the pack/eject (Figure 27, Item 1) will extend to the rear of the body to eject the load.

Press and hold the RETRACT button to retract the pack/eject to the HOME position.

Figure 27

Contender Front Loader

Operation

3.3 Arm Functions

The Arm Functions are controlled from the chassis cab or

outside control box.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

CAUTION

Use caution when raising the arm assembly with a container.

Conditions

• Side door indicator light must be off

• Top Door OPEN indicator light must be green

• Pack/Eject RETRACT indicator light must be green

• Engine speed must be below 1600 rpm

Use the arm controls to raise the arm assembly (Figure 28, Item 1).

Use the arm controls to lower the arm assembly (Figure 28, Item 2).

Figure 28

Contender Front Loader

Operation

3.4 Fork Functions

The Fork Functions are controlled from the chassis cab or

outside control box.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

Conditions

• Side door indicator light must be off

• Engine speed must be below 1600 rpm

Use the fork controls to raise the fork assembly (Figure 29, Item 1).

Use the fork controls to lower the fork assembly (Figure 29, Item 2).

Figure 29

Contender Front Loader

Operation

3.5 Auto Dump Functions (Optional)

With the Auto Dump Function, the fork assembly is automatically rotated when the arm assembly is raised or lowered. The fork assembly is rotated to avoid interference with the body canopy.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

CAUTION

Use caution when raising the arm assembly with a container.

Conditions

• Side door indicator light must be off

• Top Door OPEN indicator light must be green

• Pack/Eject RETRACT indicator light must be green

• Engine speed must be below 1600 rpm

After the forks are positioned in the container, follow the procedure for Auto Dump controls on your refuse vehicle (see

2.3.5 Auto Dump Single Lever).

1. Turn on pump.

2. Turn on Residential Mode.

3. Pull and hold the joystick straight back.

4. The arm assembly will begin to raise with the container (Figure 30, Item 1).

5. As the arm assembly raises above the body (cab), the fork assembly will automatically lower to a level position

(Figure 30, Item 2).

6. The arm assembly will start to raise until the fork

assembly is fully raised and the container is in the DUMP position (Figure 30, Item 3).

7. Push and hold forward once load is dumped to lower can.

8. After the container is emptied, the fork assembly will

begin to lower until the container is out of the hopper.

9. After the fork assembly stops, the arm assembly will begin to lower and place the container on the ground.

Contender Front Loader

Operation

3.6 Tailgate Functions

The Tailgate Functions are controlled by the TAILGATE OPEN and CLOSE buttons and the ACTIVATE button located on the in-cab control box.

WARNING

Be sure all non-operator personnel are at

least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

DANGER

Make sure the area above the vehicle is clear of objects and power lines before raising the arm. Serious personal injury or death may occur.

Conditions

• Side door indicator light must be off

• Engine speed must be below 1600 rpm

Contender Front Loader

Figure 30

Operation

3.6.1 Open Tailgate

Press and hold the ACTIVATE and the OPEN TAILGATE buttons at the same time to open the tailgate (Figure 31, Item

1).

3.6.2 Close Tailgate

Press and hold the ACTIVATE and the CLOSE TAILGATE buttons at the same time to close the tailgate (Figure 31, Item

2).

NOTE

The warble alarm sounds when the tailgate is opening and remains on until the tailgate is closed. The alarm does not sound if the ignition switch is OFF or any of the E-STOP buttons are pressed down.

Figure 31

Contender Front Loader

Operation

3.7 Top Door Functions

The top door functions are used to close off the refuse hopper during travel to keep trash from blowing out of the hopper. The Top Door functions are controlled by the TOP DOOR OPEN and CLOSE buttons on the in-dash/cab control panel.

WARNING

Be sure all non-operator personnel are at least 20 feet (6 meters) away from all areas of the Packer. Serious personal injury or death may occur.

Conditions

• Side door indicator light must be off

• Engine speed must be below 1600 rpm

CAUTION

Use the top door only to seal off the hopper area when traveling. The top door should not be used as a pack assist panel when using the Pack and Sweep function. Damage to the top door may result.

3.7.1 Open Top Door

Press and hold the TOP DOOR OPEN button to open the top door (Figure 32, Item 1).

3.7.2 Close Top Door

Press and hold the TOP DOOR CLOSE button to close the top

door (Figure 32, Item 2).

Contender Front Loader

Figure 32

Operation

4.0 Optional Equipment

4.1 Residential Attachments

The residential application for a front loader requires the use of a carry can. The carry can is mounted and secured to the fork assembly. When the carry can is equipped with a cart tipper or automatic arm, the required hydraulic and electrical lines are routed down the curb side arm assembly with the connections (Figure 33) mounted on the fork assembly.

The routing of hydraulic and electrical lines from the connections to the carry can will vary with different models and manufacturers of carry cans.

Figure 33

Contender Front Loader

Operation

4.1.1 Installing a Carry Can

CAUTION

The installation procedure must be followed when installing a carry can.

Failure to follow all these steps may cause serious personal injury or equipment damage.

1. Always follow the mandated Lockout/Tagout procedures.

2. Always clear area around arm and fork area in front of the truck.

3. Fully raise arms to stow arms in hopper.

4. Remove truck key from ignition.

5. Install bumper arm rest pads and secure with pin and

lock.

6. Clear the area, start truck, and lower arms.

7. Insert forks into carry can pockets.

8. Tip forks up slightly to correctly position carry can on forks.

9. Install carry can spacer tubes and retaining bolts (if

applicable).

10. Remove truck key from ignition.

11. Attach carry can safety chain or strap to or around fork tube.

12. Attach hydraulic quick disconnects and electrical

connections (if carry can has hydraulic tipper).

13. Start truck, clear the area, and verify the tipper works properly.

14. Reverse the above process to remove carry can.

15. Call McNeilus Truck and Manufacturing, Inc. at 888-6867278 if you require further assistance or have questions.

Contender Front Loader

Operation

4.2 Pusher Axle or Tag Axle

NOTE

The following information is for auxiliary axles installed by McNeilus Truck and Manufacturing, Inc. Refer to chassis manufacturer information for axle installed by the chassis manufacturer or a third party.

The auxiliary axle down force is controlled by regulated air pressure to the axle suspension air springs. The regulated air pressure is preset at the factory to a common pressure setting. Determine the actual regulated air pressure by driving the vehicle over a truck scale at the various weights the vehicle will be operated at up to the GVWR as shown on the Final Stage Manufacturer Label located on the driver’s side cab doorjamb (see Section 2 in the Foreword). Adjust the regulated air pressure according to the auxiliary axle manufacturer’s pressure/weight chart located in the cab information packet supplied with the vehicle. The air pressure gauge is located in the cab of the vehicle and may also be

located outside of the cab.

Always follow your company’s policies and procedures when adjusting the air pressure. If you have any questions, call McNeilus Parts and Service branches at 888-686-7278.

A tag axle (Figure 34, Item 1) is mounted in behind the rear drive axle. A pusher axle (Figure 34, Item 2) is mounted in

front of the rear drive axle. They are considered auxiliary

axles. The pusher or tag axle is raised and lowered by a

button located on the cab control box.

Figure 34

NOTE

Only lower the pusher or tag axle after you have started your route. Never lower the axles when the Packer is empty. When emptying the Packer the pusher axle must be in the RAISED position and the tag axle in LOWERED position.

Contender Front Loader

Operation

1504929

4.2.1 Lowering the Pusher or Tag Axle

1. Bring the truck to a complete stop and apply the parking brake (refer to the chassis manufacturer’s procedure).

2. Push the PUSHER AXLE or TAG AXLE LOWER button.

3. Resume normal operations.

NOTE

The tag axle is designed to lift automatically when the vehicle is put in reverse. The tag axle must be lowered again before beginning forward travel.

4.2.2 Raising the Pusher Axle or Tag Axle

1. Bring the truck to a complete stop and apply the parking brake (refer to the chassis manufacturer’s procedure).

2. Press the PUSHER AXLE or TAG AXLE RAISE button.

3. Resume normal operations.

4.3 Fall Protection Equipment

4.3.1 Fall Protection Roof Anchors

Your waste collection vehicle may be equipped with anchors, loops, holes, or other features where it is possible to attach ropes, chains, hooks, or straps. These features may be

Contender Front Loader

intended only for use with optional equipment not provided on your vehicle, or for use during the manufacturing process. Never use features on your waste collection vehicle to lift, tow, move, or otherwise manipulate your waste collection vehicle.

If your vehicle is equipped with anchors intended to be used for fall protection, they will be indicated as such with the following label.

W0014

not

paint over this label.

Replace if damaged

or lost.

These anchors are provided either as specied by your company, or as a means of complying with ANSI Z245.1

Mobile Wastes and Recyclable Materials Collection, Transportation, and Compaction Equipment - Safety Requirements. Any use of these anchors must only be as

part of a fall protection system designed and certied by your employer. Never use these anchors in any other way than that prescribed by your employer’s safety manager.

4.3.2 Fall Protection Systems

Your Waste Collection vehicle may be equipped with a tarpARMORTM Bi-LINETM fall protection system. This system must be used only with the belts, clips, harnesses, tethers, and other necessary accessories as approved by tarpARMORTM and your employer’s safety manager. Do not attempt to use this system unless you are trained, experienced, properly equipped, and authorized to do so. Understand and follow the limitations of the system as explained by your tarpARMORTM supplied instructions and your safety manager’s training.

4.3.3 Working on the Roof

If your employer’s safety procedures direct you to work on the roof of your waste collection vehicle without a fall protection system, only do so while maintaining three points of contact at all times. Never step, stand, or walk on a surface that is not provided with a slip resistant feature.

WARNING

Fall Hazard - Railings NOT provided. Never step, stand, or walk on a surface that is not provided with a slip resistant feature. Use fall protection devices any time three points of contact cannot be maintained. Fall could injure or kill.

Operation

Contender Front Loader

Operation

4.4 Water Tank

4.4.1 Water Tank Safety

WARNING

IMPORTANT ALUMINUM AND STEEL WATER TANK INFORMATION.

1. Inspect water tank on a daily basis for any damage including, but not limited to, dents, gouges in metal, or leaks.

2. Do not weld on or repair water tank. Instead, replace water tank with a new OEM water tank.

3. Never pressure test an empty water tank. Only pressure test a full water tank.

4. Never remove pressure regulator or pressure safety valve from tank.

• If regulator or safety valve is defective, it must be replaced before Packer is put into service.

5. Do not pressurize water tank beyond its working pressure.

• If pressure exceeds the working pressure, immediately depressurize water tank and replace pressure regulator and pressure safety valve.

WARNING

CONTINUED

6. Never drive the truck with the water tank pressurized.

• Depressurize water tank prior to transit to or from job site.

• Water tank should be pressurized only when being used.

7. Never modify water tank in any way.

8. Immediately replace safety decals with McNeilus decals if decals are missing or difficult to read.

9. Refer to the McNeilus Operator’s Manual or contact McNeilus at 1-888-686-7278 if you have questions or require assistance.

4.4.2 Introduction

Your vehicle may be equipped with a pressurized water tank. This tank is used to rinse debris off the vehicle. Air pressure from the truck’s brake system is used to provide pressure to the tank. Use these instructions for the safe operation and inspection of all McNeilus, Oshkosh, and London pressurized water tanks.

If your vehicle is equipped with a non-pressurized water tank (a system that uses a water pump to provide pressure), refer to the instructions provided with the refuse vehicle.

Contender Front Loader

Operation

4.4.3 Daily Inspection

• Inspect tank daily for damage or leaks.

• Replace (do not repair) damaged or leaking tank.

• Drain pressure before driving.

• Do not weld or repair tank.

• Never exceed stated psi in tank.

• Bursting tank may injure or kill.

4.4.3.1 Tank Integrity

At the start of each shift:

• Inspect Interior: Drain the tank of water and use a ashlight to look into the tank through the ll opening. Look for signs of corrosion on the inside of the tank which may indicate that the tank has been weakened and is in need of replacement.

• Inspect Exterior without Pressure: If the interior

inspection indicates that the tank is in good condition, ll the tank with water and inspect the exterior of the tank thoroughly for signs of leaks. Inspect the ller neck and ll opening. Look for signs of damage. Look for cracks in the weld joints or seams. Check that all fastening hardware is tight and undamaged. Inspect ttings for signs of damage,

cracks, or looseness.

• Inspect Exterior with Pressure: If there are no signs

or exterior leakage, pressurize the tank and repeat the inspection.

• Depressurize Tank: Release the pressure in the tank as soon as you are nished inspecting and before moving

the truck.

Replace Defective Tank: Water tanks with any leak or signicant signs of internal or external damage or corrosion should be replaced. DO NOT ATTEMPT TO REPAIR.

4.4.3.2 Pressure Regulator Valve

Inspect Pressure Regulator: The pressure regulator is used

to reduce the air brake system pressure to a pressure that is safe to be in the water tank. It must be undamaged and in proper working order. Look and listen for signs of leaking. Ensure that the valve and associated hoses and ttings are undamaged.

Adjust Pressure to Correct Setting: Many pressure regulators are set at the factory and cannot be adjusted. If your water tank has an adjustable regulator, set it to 50 psi. When setting the regulator, always begin by turning the adjusting knob counterclockwise rst to reduce the pressure slightly. Then turn it clockwise slowly to bring the pressure up to the correct setting. Never continue to turn the valve past the

correct setting.

Contender Front Loader

Operation

Replace Defective Regulator Valve: Any water tank with a damaged or missing pressure regulator valve must be removed from service immediately. Do not pressurize the tank until a functioning pressure regulator valve has been installed.

4.4.3.3 Pressure Relief Valve

Inspect the Relief Valve: The pressure relief valve is a

safety device that will release air or water from the tank if it is inadvertently pressurized over the relief setting. The relief setting on most water tanks is set at the factory and cannot be adjusted. Identify the pressure relief valve and ensure that it has not been damaged or tampered with.

Replace Defective Relief Valve: Any water tank with a damaged or missing pressure relief valve must be removed from service immediately. Do not pressurize the tank until a functioning pressure relief valve has been installed.

4.4.4 Daily Operation

The water tank is designed to be used during stationary operation at the yard or the landll site only. It is not necessary or benecial for the tank to be pressurized while driving, and a pressurized tank is an added hazard in the event of a crash or

a rollover.

4.4.5 Vehicle Handling Characteristics

Safe operation of any vehicle is the responsibility of the driver. The water tank is a uid load that can increase the rollover tendency if the truck is driven with the water tank partially full. To reduce the risk of rollover, only drive the truck with the water tank either completely full or completely empty. Avoid making sharp turns at excessive speeds and other abrupt maneuvers.

In the event of a rollover or crash, an unbelted person is signicantly more likely to become injured or die than a person wearing a seat belt. ALWAYS WEAR YOUR SEAT BELT.

Contender Front Loader

Operation

(Side Tank Mount)

4.4.6 Water Tank Decal Identication

No. Part

Number

A 1449162 1 Use if equipped with 55 psi tank.

A 1449165 1 Use if equipped with 95 psi tank.

A 1503949

B 1449164 1

Qty. Comments

Use if equipped with 120 psi

tank.

4.4.7 Water Tank Operation

The water tank (Figure 35, Item 1) can be mounted in any one of several locations, depending on the options your refuse vehicle is equipped with. The system will be equipped with a pressure gauge (Figure 35, Item 2), an air pressure control

valve (Figure 35, Item 3), and a drain valve (Figure 35, Item

4).

RES

U R

IZE

E E

XHAUST XH

AUST

8 0

ESSUR

A T

SYS

TEM

ARN

ADVERTENCIA

Figure 35

Contender Front Loader

Operation

WARNING

Pressure in the water tank should never exceed 55 psi. If pressure exceeds 55 psi, depressurize tank immediately and replace with new McNeilus air regulator valve.

NEVER pressurize an empty tank. NEVER modify tank in any way.

Operating in excess of 55 psi, pressurizing an empty tank, or modifying the tank may cause serious personal injury or death.

4.4.7.1 Filling the Tank

The tank can be lled through the opper valve (Figure 36, Item 1) or through the optional gate valve (Figure 36, Item 2).

Contender Front Loader

Figure 36

4.4.7.2 Pressurizing the Water Tank

WARNING

Never drive the truck with the water tank pressurized.

Serious personal injury or death may occur.

WARNING

Never pressurize an empty water tank.

Serious personal injury or death may occur.

1. Fill the tank to the desired level.

Operation

2. Turn the air pressure control valve to the PRESSURIZE position (Figure 37, Item 1). The water tank will be pressurized from the chassis air system.

3. The air gauge (Figure 37, Item 2) will read the pressure in the water tank. The pressure must not exceed 55 psi.

PRESSUR

IZE

ADVERTENCIA

SURE

SYSTEM

Figure 37

100

WAR

EXHAUST

OFF

4. Connect a hose to the tting (Figure 38, Item 1).

WARNING

Do not drink the water.

Serious internal injury may result.

5. Open the valve (Figure 38, Item 2).

Figure 38

Contender Front Loader

Operation

4.4.7.3 Depressurizing the Water Tank

1. Turn air pressure control valve to the EXHAUST position (Figure 39, Item 1). Make sure the gauges (Figure 39,

Item 2) read 0 psi.

PRESSUR

IZE

RES

ADVERTENCIA

SURE

SYSTEM

WAR

Figure 39

EXHAU

EXHAUST

OFF

2. After pressure in the water tank has been completely exhausted, turn the air pressure control valve to the OFF position (Figure 40, Item 1).

PRESSURI

ADVERTENCIA

PRESSURE

WATER SYSTEM

100

WARNIN

Figure 40

EXHAUST

OFF

Contender Front Loader

Operation

RESS

U R

IZE

XHAUST

P R

SURE

ER S

YSTEM

ADVERTENCIA

100

XHAU

4.4.7.4 Draining the Water Tank

WARNING

Never allow the water from the tank to drain onto a public sidewalk or roadway. Water may cause the sidewalk or roadway to become slippery. Always drain the water system at a location designated by the job site manager or in compliance with your company policy.

Failure to comply may result in serious personal injury or death.

WARNING

Do not drink the water.

Serious internal injury may result.

CAUTION

Be sure to drain the water tank, hoses, and pipes when operating in temperatures below freezing.

Failure to drain the system may cause damage to equipment.

When operating in temperatures below freezing, the water system must be drained after every use.

1. Depressurize the water tank.

2. Open the tank drain valve (Figure 41, Item 1) and allow

the water to drain. When water is drained, close the drain

valve.

Figure 41

Contender Front Loader

Operation

3. Open ball valve(s) (Figure 42, Item 1) and drain all hose(s) and pipe(s). Operate hose to drain hose and pipes.

Figure 42

Contender Front Loader

Preventive Maintenance

1.0 Preventive Maintenance

The unit must be checked or inspected each day or before each new shift of operation. Report any deciencies to your Maintenance Department for correction by skilled service personnel.

CAUTION

Correct all identified deficiencies BEFORE operating the Packer. Failure to correct deficiencies may cause damage to equipment.

1.1 DOT Pre-Trip

Perform pre-trip inspection of chassis and refuse vehicle according to all federal, state, and local laws.

2.0 Preventive Maintenance Intervals

Performing preventive maintenance on your refuse vehicle will prolong the life of its equipment, help prevent expensive downtime, and minimize the potential for problems arising on

the route.

The following Preventive Maintenance Chart summarizes the requirements to properly maintain your refuse vehicle.

The chart species the recommended interval when each item should be performed.

Intervals are listed in calendar and hours-of-use increments. Maintenance should be performed at the increment that occurs rst.

The preventive maintenance intervals listed under the Service group heading are the maximum days or hours allowed for each maintenance procedure. Continue to repeat the maintenance procedures at the listed intervals.

NOTE

If the Packer is operated more hours per day or double-shifted, the maintenance interval must be adjusted accordingly.

Contender Front Loader

Preventive Maintenance

The Preventive Maintenance Chart identies the responsibilities to be performed by both the operator and service personnel.

Some maintenance procedures are listed under both the Operator group heading and Service group heading.

The Daily Checks under the Operator group heading identify procedures that can be performed by either the operator or skilled service personnel.

All intervals listed under the Service group heading must be performed by skilled service personnel. Refer to the product Service Manual for maintenance procedures.

Maintenance procedures are listed under the system of the refuse vehicle that is affected. Refer to the product Service Manual for maintenance procedures.

Perform your company’s Lockout/Tagout procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA 1910.147 and 1910.146 Conned Space as appropriate.

Contender Front Loader

Preventive Maintenance

Daily Checks

(10 Hours)

(50 Hours)

Scheduled PM

(150 Hours)

Semi-Annual

(1250 Hours)

Annuall

(2500 Hours

Bi-Annua

(5000 Hours)

LEGEND

Operator

R Replace P Perform

I Inspect L Lubricate

T Torque C Clean

Hydraulic System

Check Hydraulic Oil Level I I

Hydraulic System and Components I I

Hydraulic Hoses I I

Hydraulic Tubes and Fittings I I

Breather Filter I R

Return Line Filter R

Hydraulic Oil Test P

HOC Operation Test P

Test Main Relief Valve Setting P

Change Hydraulic Oil P

Change Hydraulic Oil OPTIONAL Clean Fill System

Reservoir Drain Plug I

Reservoir Drain Plug - OPTIONAL Clean Fill System

Daily

Weekly

Service

)

Contender Front Loader

Preventive Maintenance

Daily Checks

(10 Hours)

(50 Hours)

Scheduled PM

(150 Hours)

Semi-Annual

(1250 Hours)

Annuall

(2500 Hours

Bi-Annua

(5000 Hours)

LEGEND

Operator

R Replace P Perform

I Inspect L Lubricate

T Torque C Clean

Suction Line Strainer R

Suction Line Strainer - OPTIONAL Clean Fill System

High Pressure Filter (If Applicable) R

Electrical System

Lighting System I I

Wire Harness I I

Audible Back-Up Alarm I

Pneumatic System

Drain and Inspect Coalescing Filter I/P I/P

Coalescing Filter R

Air Hoses and Fittings I I

Mechanical

Refuse Vehicle Body and Components I I

Tailgate Seal Condition I I

Tailgate Lock Clearance I

Daily

Weekly

Service

)

Contender Front Loader

Preventive Maintenance

Daily Checks

(10 Hours)

(50 Hours)

Scheduled PM

(150 Hours)

Semi-Annual

(1250 Hours)

Annuall

(2500 Hours

Bi-Annua

(5000 Hours)

LEGEND

Operator

R Replace P Perform

I Inspect L Lubricate

T Torque C Clean

Proper Operation of Tailgate/Body Cylinder Props

Top Door I

Pack/Eject Assembly I

Pack/Eject Track Clearance I

Arm Assembly I

Arm Torque Tube Bolts I/T

Fork Assembly I

Pusher Axle Lug Nuts T

Tag Axle Lug Nuts T

Body Tie-Down Components (used during propping of the body)

• Missing nuts or pins

• Broken or damaged springs or brackets

Daily

Weekly

Service

)

Contender Front Loader

Preventive Maintenance

Daily Checks

(10 Hours)

(50 Hours)

Scheduled PM

(150 Hours)

Semi-Annual

(1250 Hours)

Annuall

(2500 Hours

Bi-Annua

(5000 Hours)

LEGEND

Operator

R Replace P Perform

I Inspect L Lubricate

T Torque C Clean

Operation

Ladders and/or Associated Equipment I I

Hinges and Latching Mechanisms I

Pump Driveshaft Couplers I

Proper Operation of Proximity Switches P P

Refuse Vehicle Controls I I

Remove Trash Behind Pack/Eject P P

Safety Signs I

Lubrication

Daily L L

Scheduled PM L

Daily

Weekly

Service

)

Contender Front Loader

Preventive Maintenance

SAFETY NOTICE

3.0 Daily Preventive Maintenance Checks

3.1 Hydraulic System

Perform your company’s Lockout/Tagout procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA

1910.147 and 1910.146 Confined Space as appropriate.

3.1.1 Hydraulic Oil Level

• Daily Checks - The oil level is checked by the operator or

skilled service personnel.

NOTE

Check hydraulic oil level during start-up when the oil temperature is still cold.

• Check the hydraulic oil level with all hydraulic cylinders in their fully RETRACTED position.

3.1.1.1 Temperature / Level Sight Gauge

The gauge contains a thermometer which indicates the temperature of the hydraulic oil in the reservoir. The reservoir could have one of two gauges. The rst type (Figure 43) is distinguished by the word “LOW” below the sight glass. The second type (Figure 44) does not have the word “LOW” on the

gauge.

The hydraulic oil must be checked with all the hydraulic cylinders in the fully RETRACTED position.

On a reservoir with a temperature/level sight gauge option (Figure 43), oil level at 60 - 70°F should be at the black line in the center of the green zone (Item 1). Oil should not be above the “Max Fill Hot” line (Figure 43, Item 2) when the system is at operating temperature. If there is too much oil in the reservoir (above the “Max Fill Hot” line), there is a possibility of the oil coming out of the breather at the top of the hydraulic reservoir. Do not operate the system with oil below the “low” line (Figure 43, Item 3) or damage to the system may result.

CAUTION

Do not operate the hydraulic system with oil below the “low” line on the temperature/level sight gauge.

Damage to the system may result.

Contender Front Loader

Preventive Maintenance

Figure 43

MAX FILL HOT

°F °C

100

200

150

100

LOW

The second type of temperature/level sight gauge (Figure 44, Item 1) will not have the word “LOW”. Keep the oil level to the top of the black line (Full) (Figure 44, Item 2), but don’t over ll. If the oil level gets to the red line (Figure 44, Item 3), oil must be added.

°F °C

200

150

100

Figure 44

Contender Front Loader

McNeilus Contender Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual