McNeilus Zero Radius ZR 6 ft. Reach, Zero Radius ZR 12 ft. Operator's Manual

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OPERATOR’S MANUAL

Zero Radius

Includes information for:

• ZR 6 ft. Reach

• ZR 12 ft. Extended Reach

Publication No. 1416362

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 OSHA Publications, contact:

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

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

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 refuse vehicle

body. The identication plate contains the Model Number and

Serial Number of your refuse vehicle 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

Zero Radius Side Loader

Foreword

2.0 Complete Vehicle Document Decal

The Complete Vehicle Document decal (Figure 2, Item 1) 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 (GVW) (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

20,000

22,800

20,000

22,800

11,020

VEHICLE TYPE CLASSIFICATION

9,072

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

3.0 Purpose of Manual

NOTE

This Operator Manual provides operation and operator

maintenance instructions for the Zero RadiusTM Side 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 the McNeilus parts and service number listed in the Foreword of

this manual.

Zero Radius Side 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

4.0 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

Table of Contents

SAFETY

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

1.1 Battery Disconnect .......................................................................................................................................................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 Outside Operation ........................................................................................................................................................8

3.4 Maintenance ............................................................................................................................................................... 11

3.5 Hydraulics ...................................................................................................................................................................15

3.6 Electrical .....................................................................................................................................................................19

4.0 SAFETY SIGNS ..................................................................................................................................................................20

4.1 Safety Sign Locations .................................................................................................................................................22

GENERAL INFORMATION

1.0 EXTERIOR SYSTEMS ARRANGEMENT ...........................................................................................................................25

1.1 Curb Side View ...........................................................................................................................................................25

1.2 Street Side View .........................................................................................................................................................26

Zero Radius Side Loader

Table of Contents

OPERATION

1.0 INSTRUMENTS AND CONTROLS .....................................................................................................................................27

1.1 Cab Controls...............................................................................................................................................................27

1.1.1 Control Box .....................................................................................................................................................28

1.1.1 Refuse Vehicle Button Functions....................................................................................................................29

1.1.3 LED Indicator Light Functions ........................................................................................................................32

1.2 Remote Control Box Buttons (Optional) .....................................................................................................................35

1.3 Arm and Grabber Controls..........................................................................................................................................36

1.3.1 Joystick Control ..............................................................................................................................................37

1.4 Fuse Block ..................................................................................................................................................................39

1.4.1 Fuse Block (Legacy) .......................................................................................................................................40

2.0 CONTROL FUNCTIONS .....................................................................................................................................................41

2.1 E-STOP (Emergency Stop) Function .........................................................................................................................41

2.1.1 In-Cab Control Box E-STOP Button ...............................................................................................................41

2.1.2 Arm Remote Control Box E-STOP Button ......................................................................................................41

2.1.3 E-STOP on Diagnostic Display .......................................................................................................................42

2.2 Packing Functions ......................................................................................................................................................43

2.2.1 Automatic Cycling of Packing Panel ...............................................................................................................43

2.2.2 Setting Pack Count .........................................................................................................................................44

2.2.3 Manual Cycling of Packing Panel ...................................................................................................................46

• 2.2.3.1 Extend Packing Panel ................................................................................................................46

Zero Radius Side Loader

Table of Contents

• 2.2.3.2 Retract Packing Panel ................................................................................................................46

2.3 Top Door/Hopper Assist Panel Functions ...................................................................................................................47

2.3.1 Open Top Door ...............................................................................................................................................47

2.3.2 Close Top Door ............................................................................................................................................... 47

2.4 Arm Functions.............................................................................................................................................................48

2.4.1 Arm Assembly Extend and Retract Functions ................................................................................................49

• 2.4.1.1 Extend Arm Assembly .................................................................................................................49

• 2.4.1.2 Retract Arm Assembly ................................................................................................................49

2.4.2 Arm Assembly Raise and Lower Functions ....................................................................................................50

• 2.4.2.1 Raise Arm Assembly ...................................................................................................................50

• 2.4.2.2 Lower Arm Assembly ..................................................................................................................50

2.5 Grabber Functions ......................................................................................................................................................51

2.5.1 Open Grabber Fingers....................................................................................................................................51

2.5.2 Close Grabber Fingers ...................................................................................................................................51

2.6 Tailgate Functions ....................................................................................................................................................... 52

2.6.1 Open Tailgate .................................................................................................................................................52

2.6.2 Close Tailgate ................................................................................................................................................. 52

3.0 OPERATING PROCEDURES .............................................................................................................................................53

3.1 Start-Up Procedure.....................................................................................................................................................53

3.2 Warm-Up Procedure ...................................................................................................................................................53

3.3 Traveling Procedure ...................................................................................................................................................54

III

Zero Radius Side Loader

Table of Contents

3.4 Preparation Before Starting Route .............................................................................................................................56

3.5 Daily Maintenance Reminder Screen .........................................................................................................................57

3.6 Refuse Loading Procedure .........................................................................................................................................57

3.7 Refuse Dumping Procedure .......................................................................................................................................58

3.8 Refuse Empty Procedure ...........................................................................................................................................59

3.9 End-of-Day Checks ....................................................................................................................................................61

4.0 OPTIONAL EQUIPMENT ....................................................................................................................................................62

4.1 Pusher or Tag Axle .....................................................................................................................................................62

4.1.1 Lowering the Pusher or Tag Axle ....................................................................................................................62

4.1.2 Raising the Pusher or Tag Axle ......................................................................................................................62

4.2 Preco Radar Systems.................................................................................................................................................63

4.3 Water Tank..................................................................................................................................................................65

4.3.1 Water Tank Safety ..........................................................................................................................................65

4.3.2 Introduction .....................................................................................................................................................65

4.3.3 Daily Inspection ..............................................................................................................................................66

• 4.3.3.1 Tank Integrity ..............................................................................................................................66

• 4.3.3.2 Pressure Regulator Valve ...........................................................................................................66

• 4.3.3.3 Pressure Relief Valve .................................................................................................................67

4.3.4 Daily Operation ...............................................................................................................................................67

4.3.5 Vehicle Handling Characteristics ....................................................................................................................67

4.3.6 Water Tank Sign Identication ........................................................................................................................67

Zero Radius Side Loader

Table of Contents

PREVENTIVE MAINTENANCE

1.0 PREVENTIVE MAINTENANCE...........................................................................................................................................69

1.1 DOT Pre-Trip ..............................................................................................................................................................69

2.0 PREVENTIVE MAINTENANCE INTERVALS ......................................................................................................................69

3.0 DAILY PREVENTIVE MAINTENANCE CHECKS ...............................................................................................................74

3.1 Hydraulic System........................................................................................................................................................74

3.1.1 Hydraulic Oil Level..........................................................................................................................................74

• 3.1.1.1 Temperature / Level Sight Gauge ............................................................................................... 74

3.2 Electrical System ........................................................................................................................................................76

3.2.1 Lighting System ..............................................................................................................................................76

3.3 Pneumatic System......................................................................................................................................................76

3.3.1 Coalescing Filter .............................................................................................................................................76

3.4 Mechanical System ....................................................................................................................................................77

3.4.1 Refuse Vehicle Body and Components ..........................................................................................................77

3.4.2 Tailgate Seal ................................................................................................................................................... 77

3.5 Operation ....................................................................................................................................................................77

3.5.1 Refuse Vehicle Controls .................................................................................................................................77

3.6 Trash Behind the Packing Panel ................................................................................................................................78

3.7 Safety Signs ...............................................................................................................................................................79

4.0 PROPPING THE TAILGATE ................................................................................................................................................80

4.1 Engaging the Tailgate Prop ........................................................................................................................................80

Zero Radius Side Loader

Table of Contents

4.2 Disengaging the Tailgate Prop .................................................................................................................................... 83

5.0 LUBRICATION .....................................................................................................................................................................85

5.1 Daily Lubrication .........................................................................................................................................................85

5.2 Scheduled PM Lubrication..........................................................................................................................................93

5.2.1 Zero Radius 6 ft. and Zero Radius 12 ft. Extended Reach Weekly Preventive Maintenance ........................93

5.2.2 Zero Radius 6 ft. and Zero Radius 12 ft. Extended Reach Every 3 Weeks Preventive Maintenance ............95

TROUBLESHOOTING

1.0 TROUBLESHOOTING ........................................................................................................................................................97

1.1 Troubleshooting Chart ................................................................................................................................................98

INDEX

INDEX........................................................................................................................................................................................101

Zero Radius Side 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 of 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 and all other material provided with the truck.

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.

Zero Radius Side Loader

Safety

1.1 Battery Disconnect

If your 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

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.

the vehicle cannot be accidently started.

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). NOTE: Figure 3 represents a typical switch.

For trucks without a battery disconnect switch, to prevent accidental vehicle start-up, which could cause death or serious injury, disconnect

WARNING

battery cables (negative cable first) before proceeding.

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which

Figure 3

could result in death or serious injury.

Zero Radius Side Loader

Safety

1.2 Safety Equipment

Some McNeilus refuse vehicles 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 body, 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.

Zero Radius Side 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.

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 warnings seriously. If you do not understand them or have questions about them, call McNeilus Truck and

Manufacturing, Inc.

Zero Radius Side 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 vehicle itself to promote reliable operation and prevent serious personal injury.

Contact McNeilus Truck and Manufacturing, Inc. 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

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

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.

Zero Radius Side Loader

Safety

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.

3.2 Cab Operation

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.

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.

Zero Radius Side 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

All owners and supervisors should make sure all drivers, operators, and maintenance personnel have read and thoroughly understand the decals affixed to this Packer as well as the safety information and instructions in the McNeilus Operator Manual. Owners and supervisors must comply with ANSI Z245.1 Regulations.

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.

Zero Radius Side Loader

Safety

WARNING

It is important that the pump ON indicator light be 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.

CAUTION

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

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.

3.3 Outside Operation

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.

Zero Radius Side 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.

Zero Radius Side Loader

Safety

WARNING

Be sure all non-operator personnel are clear of the area around the truck 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

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

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

Never operate the hydraulic system if a leak is present. Serious injury may result.

SAFETY NOTICE

If chassis is equipped with a battery shut-off 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.

Zero Radius Side Loader

Safety

3.4 Maintenance

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.

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.

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.

Zero Radius Side Loader

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, hydraulics, lockout systems, electrical systems, auto neutral and neutral interlock 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.

The truck’s air system must operate properly and have no leaks. Water and moisture should be drained from the truck’s air system daily.

Failure to ensure all systems are operating properly can result in serious injury. Call McNeilus Truck and Manufacturing, Inc. at 888-686-7278 for assistance.

Zero Radius Side Loader

Safety

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.

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

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.

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.

Zero Radius Side Loader

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 supported! Failure to follow this procedure can result in serious injury or death. Call McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you have any questions or require assistance supporting the tailgate.

CAUTION

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

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

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.

Zero Radius Side Loader

Safety

3.5 Hydraulics

Call McNeilus Truck and Manufacturing, Inc. 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.

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.

Zero Radius Side Loader

Safety

WARNING

Use correct hoses, fittings, and adapters with the correct SAE rating when replacing hoses to prevent possible serious injury. Always replace hoses, fittings, and adapters with replacements that have a proper, suitable, working pressure rating. Replacement hoses must be of the correct length and must comply with the hose manufacturer’s installation guidelines and recommendations. Consult hose and fitting manufacturers for correct specifications or contact McNeilus at 888-686-7278.

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.

Zero Radius Side Loader

Safety

WARNING

Any hydraulic tubing that is replaced must conform to SAE J1065 specifications. If incorrect hydraulic tubing is installed, the hydraulic system may fail, serious injury or death can result. Damage or leaking tubing must be replaced before the Packer is returned to service.

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

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

All hydraulic pressure must be relieved from the hydraulic system prior to removing any components from the system. To relieve the hydraulic pressure from the hydraulic system, turn the chassis engine OFF and operate the Packer controls with the key in the ON position. This will allow the spools to shift and relieve the hydraulic pressure. Failure to comply can result in serious injury or death.

Zero Radius Side Loader

Safety

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

When performing hydraulic test procedures, use the proper hydraulic gauges. Installing an incorrect test gauge could result in serious injury or death if the gauge fails. Use properly rated hydraulic hoses with adequate length to allow the test gauge to be used far enough away from moving parts and functions.

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.

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.

Zero Radius Side Loader

Safety

WARNING

The tailgate cylinders and body lift cylinders have orifices installed in the barrel end ports. These orifices limit the amount of hydraulic flow, which controls the speed of the cylinders. The orifices must remain in the cylinders. If a cylinder is changed, the replacement cylinder must have an orifice installed to ensure safe and proper operation. Removal of the orifice can cause rapid retraction of the cylinder. This can cause severe injury or death. Check all replacement cylinders to ensure the orifice is in place before installation and operation.

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.

Zero Radius Side Loader

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, contact McNeilus Parts and Service at 888-686-7278 or 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

If front mounted pump is installed, place one sign on

1 1523421 1

2 1466637 1

3 1523442 2

4 1523422 2

5 1538022 1

6 1523431 1

7 1523426 1

8 1523427 2

9 1523425 2

10 1526758 1

11 1523435 1

12 1523438 1

13 1523447 1

14 1523450 2

front bumper. If rear mounted pump is installed, place one

sign on either side of truck at

pump.

If tool box is equipped in the middle, place one sign on

each side. If no tool box is

equipped, place one sign only in the middle of the bumper.

Zero Radius Side Loader

Safety

No. Part Number Qty. Comments

15 1523817 1

16 1523431 1

17 1524503 1

18 1523436 1

19 1523479 1

20 1523440 1

21 1523443 1

22 1523439 1

23 1523433 2

24 1523446 1

25 1523445 1

26 1523448 1

27 1523451 1

28 1527015 1

29 1525226 1

30 1525227 1

31 1523444 1

32 1518818 1

33 1537820 1

34 1537821 1

35 1523534 1

No. Part Number Qty. Comments

36 1265704 Varies

37 1260913 Varies

38 1260914 Varies

Zero Radius Side Loader

Safety

4.1 Safety Sign Locations

Figure 4

Zero Radius Side Loader

Safety

17 28 26

Figure 5

Zero Radius Side Loader

Safety

23 24 35

Tailgate Side Cab Side

Use #38 - 2” alternating red/white conspicuity tape for locations shown here

Zero Radius Side Loader

Without Tool Box

With Tool Box

Figure 6

1.0 Exterior Systems Arrangement

1.1 Curb Side View

General Information

Ref. No. System Description

1 Cab Control Box and Joystick

2 Arm and Grabber Remote Control Box

3 Arm Assembly

4 Grabber Assembly

Figure 7

Ref. No. System Description

5 Grabber Fingers

6 Top Door

7 Clean Out Door

Zero Radius Side Loader

General Information

1.2 Street Side View

Figure 8

Ref. No. System Description

8 Side Access Door

9 Tailgate

10 Packing Panel

11 Hydraulic Oil Reservoir

12 Clean Out Door

13 Access Panel

Zero Radius Side Loader

1.0 Instruments and Controls

The following gures and tables identify and describe the

controls used on the control box. 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.

1.1 Cab Controls

The in-cab controls consist of a joystick (Figure 9, Item 1) and control box (Figure 9, Item 1). The control box can be

mounted externally to the dash as shown or mounted in the dash. No matter which way it is mounted, the icons and the

buttons are the same.

Operation

Figure 9

Zero Radius Side Loader

Operation

1.1.1 Control Box

The control box (Figure 10) contains the E-STOP (emergency stop) button, red LED warning light, buttons for the refuse vehicle functions, lights, pumps, and options.

No. Description Normal Use or Reading

1 E-STOP Button

Red LED Warning

Light

Switches and LED

Lights

Disables all Hydraulic and Electric refuse vehicle functions.

If light is on or ashing, it

indicates an unsafe condition. Look at the LED lights on the

control box to determine what

the unsafe condition is. Under

normal operating conditions, the light will be off.

Controls refuse vehicle

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

WARNING

Figure 10

Zero Radius Side Loader

Operation

1.1.1 Refuse Vehicle Button Functions

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

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

No. Description Normal Use or Reading

Press to activate Hydraulic functions.

1 PUMP Button

TAILGATE

OPEN Button

ACTIVATE

Button

REMOTE

Button

TAG AXLE

RAISE Button (OPTIONAL)

ARM ON

Button

Press again to disable Hydraulic functions.

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

Press and hold the ACTIVATE button to enable the Tailgate functions or the Arm functions.

Press the REMOTE button to enable

the remote control button panel.

Press the button again to disable the

remote control button panel.

Press the button to raise the tag axle.

Press and hold the enable the Arm

functions. You must also press and hold the ACTIVATE button while

holding the ARM ON button.

No. Description Normal Use or Reading

Press the button to turn on the work

WORK

LIGHT Button

(OPTIONAL)

lights. Press the button again to turn

off the work lights. The truck must be moving less than 10 mph for the work

lights to come on.

Press the button to turn on the strobe

STROBE

LIGHT Button

(OPTIONAL)

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 off when the pump is on.

PUSHER AXLE RAISE

Button

Press the button to raise the pusher

axle.

(OPTIONAL)

PUSHER

AXLE LOWER

Button

Press the button to lower the pusher

axle.

(OPTIONAL)

TAG AXLE LOWER

Button

Press the button to lower the tag axle.

(OPTIONAL)

TOP DOOR

CLOSE Button

Press and hold the button to close the

top door.

Zero Radius Side Loader

Operation

No. Description Normal Use or Reading

EJECTOR PANEL

EXTEND Button

EJECTOR PANEL

RETRACT Button

AUTO PACK

Button

TOP DOOR

OPEN Button

TAILGATE

CLOSE Button

SIDE DOOR

Button

Press this button to extend the ejector panel. Pressing the button will stop the auto pack mode if active.

Press this button to retract the ejector panel to the HOME position.

Press this button to start the auto

pack cycle.

Press and hold the button to open the top door.

Press and hold button to close the

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

This button is non functional. It is a

warning light for an open or closed

side door. See the LED indicator light

functions pages for more information.

Zero Radius Side Loader

1 2

3 4 5 6

91011

131415

Operation

WARNING

Figure 11

Zero Radius Side Loader

Operation

1.1.3 LED Indicator Light Functions

The LED indicator lights are used to display the status of various functions and operations (Figure 12). 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. Description Normal Use or Reading

The LED will be green when the pump is on and operational. If there is a pump fault such as,

1 Pump On LED

Tailgate Open

LED

Error Code

LED

4 Activate LED

but not limited to, low hydraulic oil, high oil temperature or a clogged lter, the light will ash and the pump will not be operational.

The green LED will be lighted when the tailgate is fully closed.

There are six LEDs that will be on or off depending on the error code.

If any of these LEDs are lighted, refer to your Zero Radius Service Manual.

If a button is pressed that requires the ACTIVATE button to be pressed, the LED will ash,

indicating the ACTIVATE button

must also be pressed.

No. Description Normal Use or Reading

The LED will be green when the

Remote

Switch LED

REMOTE button is activated.

The remote button panel is now operational.

If the LED is off, the hydraulic oil

is at the proper level. If the red LED is on, the oil level is low and the hydraulic pump will be shut

Hydraulic Oil

Level LED

off. When the red LED is on, you can press and hold the low oil level icon for 30 seconds to allow Hydraulic functions to stow the arm and grabber assemblies and put

the refuse vehicle in a condition for road travel.

Hydraulic Oil

Filter Bypass

LED

Arm Stowed

LED

If the light comes on during

operation, the oil lter is being bypassed and needs to be

serviced immediately.

When the light is off, the arm is in the STOWED (HOME) position.

Zero Radius Side Loader

Operation

No. Description Normal Use or Reading

There are three oil temperature LEDs. If the rst one (blue) is lit, it

indicates that the oil is cold. If the second one (amber) is lit, it

Hydraulic Oil

Temperature

LEDs

indicates the oil is warmer than

recommended. If the three one (red) is lit, it indicates that the oil is too hot and

immediate service is required.

If none of the lights are lit, the

oil is at the correct operating temperature.

10 Arm On LED

Work Light

LED

Strobe Light

LED

Tag Axle Up

LED

Pusher Axle

Up LED

The arm on LED will be green when the arm is activated.

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

The green LED will be lit when the

strobe lights are on.

The red LED will be lit when the

tag axle is in the fully RAISED

position.

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

No. Description Normal Use or Reading

Tag Axle Down

LED

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

When the side door is fully closed, both LEDs will be off. When the

Side Door LEDs

side door is opened, it activates the E-STOP, shuts off the hydraulic pump and the two red LEDs will ash.

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

Pusher Axle

DOWN LED

The red LED will light when the ejector panel is extended. The ejector panel will not extend to the full eject mode unless the tailgate

Ejector Panel

Extend LED

is fully open.

The green LED will be lit when the ejector panel is retracted into the HOME position.

Ejector Panel

Retract LED

The red LED will ash when the top door is not closed in the HOME position. The LED will be on when the top door is not in the OPEN

Top Door

Close LED

position.

Zero Radius Side Loader

Operation

1314

17 1516

181920

23 46798 1

No. Description Normal Use or Reading

Auto Pack

LEDs

Top Door

Open LED

Tailgate Open/

Closed LED

The two red LEDs will ash when the ejector panel is in the auto pack mode.

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

The LED will be red when the tailgate is fully open. The light will ash if the tailgate is not fully

closed.

WARNING

Zero Radius Side Loader

Figure 12

Operation

1.2 Remote Control Box Buttons (Optional)

The Arm Assembly functions can also be operated from the remote control box when the operator is outside the

cab (Figure 13). The remote control box is normally located inside the curb side door of the chassis cab. The OUTSIDE CONTROL button in the cab must be activated to enable the use of the remote control box.

NOTE

The LED lights on the remote control box buttons work the same way as the buttons on the control box in the cab.

No. Position Normal Use or Reading

AUTO PACKING

Button

GRABBER OPEN

Button

EJECTOR PANEL

RETRACT Button

Press this button to start the

auto packing cycle.

Press and hold button to

open grabber ngers.

Press this button to retract

the ejector panel to the HOME position.

No. Position Normal Use or Reading

Press this button to extend

EJECTOR PANEL

EXTEND Button

GRABBER CLOSE

Button

6 E-STOP Button

7 ARM DOWN Button

TAILGATE CLOSE

Button

TAILGATE OPEN

Button

10 ARM UP Button

11 ACTIVATE Button

12 ARM ON Button

the ejector panel. Pressing the button will stop the auto pack mode if active.

Press and hold button to

close grabber ngers.

Disables all Hydraulic and Electric functions.

Press and hold button to

lower arm.

Press and hold button to close the tailgate. You must

also press and hold the

ACTIVATE button.

Press and hold button to

open the tailgate. You must also press and hold the

ACTIVATE button.

Press and hold button to raise arm.

Press and hold the ACTIVATE button to enable the Tailgate functions.

Press to enable the Arm functions.

Zero Radius Side Loader

Operation

1.3 Arm and Grabber Controls

Control of the Arm Assembly functions are combined into a

single joystick. All functions of the joystick are momentary.

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.

Zero Radius Side Loader

Figure 13

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.

Operation

1.3.1 Joystick Control

The single-lever joystick (Figure 14) controls the in-and-out and up-and-down movement of the arm and the opening and closing of the grabber ngers. The joystick can also control the Auto Pack function if it is equipped with the optional AUTO PACK button on the joystick.

The OPERATOR PRESENCE switch must be depressed to allow any Arm functions with the joystick.

NOTE

Joystick functions are disabled if the OPERATOR PRESENCE switch is pressed and held for more than 60 seconds. Release the switch and press it again to enable the Arm functions.

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

No. Position Normal Use or Reading

1 Joystick - FORWARD Lowers arm assembly

2 Joystick - BACK Raises arm assembly

3 Joystick - RIGHT Extends arm assembly out

4 Joystick - LEFT Retracts arm assembly in

OPERATOR

PRESENCE Switch

Must be pressed and held

to enable Arm functions

No. Position Normal Use or Reading

Rolling the wheel up will open the grabber ngers. Rolling the wheel down will close the grabber

6 Thumb Wheel

THUMB Switch -

BOTTOM

8 THUMB Switch - TOP

ngers. The farther you move the wheel, the faster the grabbers will open or close. When released, the wheel will go back to the NEUTRAL position.

Activates the Auto Load

functions, if equipped.

Function is to raise and

dump the container. Use the joystick to return

container to ground.

Activates the Auto Pack

functions, if equipped. Auto Pack packs the refuse for 1 to 2 cycles, depending on pack count programming.

Zero Radius Side Loader

Operation

Figure 14

Zero Radius Side Loader

1.4 Fuse Block

The fuse block protects the refuse vehicle electrical system

from an overloaded condition.

Identify and replace fuses as required (Figure 15). If fuses are continually blowing, check for an electrical problem.

No. Amp Description

F1 25 E-Stop Body Function Power

F2 10 Option Power

F3 10 Body Function Power

F4 10 Fan

F5 10 Not Used

F6 2 Sensor Power

F7 10 Cab/HMI Power

F8 20 Tailgate Module

F9 10 Option Power

F10 10 Option Power

F11 10 Option Power

F12 10 Option Power

F13 10 Option Power

F14 10 Option Power

F15 10 Option Power

F16 10 Main Control Module Power

Operation

Figure 15

Zero Radius Side Loader

Operation

IGNITION RELA

1.4.1 Fuse Block (Legacy)

The fuse block protects the refuse vehicle electrical system

from an overloaded condition.

Identify and replace fuses as required (Figure 16). If fuses are continually blowing, check for an electrical problem.

No. Amp Description

F1 5 Spare E-Stop

F2 15 Side Lights

F3 15 Front Work Lights

F4 15 Front Lights

F5 15 Tailgate Work Lights

F6 15 Tailgate Strobe Lights

F7 15 Tailgate Lighting

F8 2 Sensor Power

F9 10 Arm Packer

F10 5 Axles/Chassis

F11 10 Cab Power

F12 15 E-Stop Power

F13 10 Chassis E-Stop

F14 10 Body E-Stop

F15 10 Body E-Stop

F16 2 Module Power

Red = E-STOP ON

E-STOP RELAY

Green = SYSTEM ON

F15

F14

F13

F12

F11

F10 F9

F6 F5

IGNITION RELAY 1

Y 2

Figure 16

F16-2 Amp MODULE +

FRONT

WORK

LIGHTS

REAR

WORK

LIGHTS

STROBES

SPARE

MC3

MC2

MC1

Zero Radius Side Loader

Operation

2.0 Control Functions

2.1 E-STOP (Emergency Stop) Function

Press any of the E-STOP buttons (Figure 17) to IMMEDIATELY DISABLE refuse vehicle and Hydraulic functions.

The E-STOP button is a safety function.

Pressing the red E-STOP button disables all refuse vehicle

Electrical, Pneumatic, and Hydraulic functions.

NOTE

The E-STOP button remains in a locked DOWN position until it is manually released.

2.1.1 In-Cab Control Box E-STOP Button

Pull up on the button to release the in-cab control box E-STOP

button (Figure 18, Item 1).

2.1.2 Arm Remote Control Box E-STOP Button

Pull up on the button to release the arm remote control box E-STOP button (Figure 18, 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.

NOTE

The E-Stop will not be illuminated if the side door is opened or the remote E-Stop is pushed.

Figure 17

Zero Radius Side Loader

Operation

2.1.3 E-STOP on Diagnostic Display

Zero Radius Side Loader

Figure 18

WARNING

Description

E-STOP Display

This screen appears when the E-STOP circuit is triggered by a software interlock OR by the operator pressing either one of the E-STOP buttons. This function will disable all of the

hydraulic functions and shut the load sense solenoids OFF.

Navigation

The Cont. button jumps to the “HOME” screen

Operation

2.2 Packing Functions

The packing functions are controlled by buttons located on the cab control box. Automatic cycling of the packing panel

functions is controlled by the Auto Packing button. The Auto

Packing function will begin to operate after dumping refuse in the hopper, depending on what the pack count is set to. Manual cycling of the packing functions is controlled by the

EXTEND and RETRACT buttons. Pressing the EXTEND or

RETRACT buttons during an automatic packing cycle will stop

the Auto Packing function.

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.

2.2.1 Automatic Cycling of Packing Panel

Conditions

• Tailgate closed LED light must be green

• Side door LED lights must be off

• Engine speed must be below 1700 rpm

• Top door must be up (open)

• Grabber must not be in the STOWED position

NOTE

If the packing panel is not in the HOME position, press the RETRACT button to retract it to the HOME position to start the cycle.

NOTE

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

Press and hold AUTO PACKING button (for 1 second) to activate automatic cycling of the packing panel functions. When activated, the packing panel extends from the HOME position (Figure 19, Item 1) into the hopper until it reaches the EXTEND position (Figure 19, Item 2). The packing panel then

reverses direction and retracts until it returns to the HOME

position.

Zero Radius Side Loader

Operation

2.2.2 Setting Pack Count

Your refuse vehicle has a factory set pack count of one. This setting can be changed to two. To change the pack count:

1. Turn the IGNITION switch to the ON position. You do not have to start the engine.

2. Hold the ACTIVATE button (Figure 20, Item 1) and the AUTOMATIC button (Figure 20, Item 2) on the main

control box.

3. In approximately 5 seconds, the automatic packing button

LEDs will ash, indicating that the system is in calibration

mode.

NOTE

Figure 19

To remain in calibration mode, the AUTOMATIC PACK and SWEEP switch must be released before the ACTIVATE switch is released.

4. Release the AUTOMATIC PACKING button rst, then the ACTIVATE button.

Zero Radius Side Loader

Operation

1 2

6. The pack count is displayed by the number of LEDs that

are lighted on the error code display (Figure 22, Item 1).

7. Press the AUTOMATIC PACKING button to save the

current pack count and return to work mode.

Figure 20

5. Push the WORK LIGHT button (Figure 21, Item 1) to increase the pack count and push the STROBE LIGHT button (Figure 21, Item 2) to decrease the pack count.

Figure 21

WARNING

Figure 22

Zero Radius Side Loader

Operation

2.2.3 Manual Cycling of Packing Panel

Manual cycling of the packing functions is controlled by the EXTEND/RETRACT button located on the cab control box. With the tailgate closed, the packing panel can only travel to the EXTEND position (Figure 23, Item 1).

Conditions

• Tailgate closed LED light must be green

• Side door LED lights must be off

• Engine speed must be below 1700 rpm

• Top door must be up (open)

• Grabber must not be in the STOWED position

• 2.2.3.1 Extend Packing Panel

Press the EXTEND switch to manually control the extend movement of the packing panel. When the packing panel reaches the EXTEND PROXIMITY switch, it will stop at the EXTEND position. The red LED will be lighted when the packing panel is extended.

• 2.2.3.2 Retract Packing Panel

Press the RETRACT switch to retract the packing panel. The packing panel will retract to the HOME position (Figure 23, Item 2). The green LED will be lighted when the packing panel is retracted in the HOME position.

Figure 23

Zero Radius Side Loader

Operation

2.3 Top Door/Hopper Assist Panel

Functions

The Top Door functions are used to close off the refuse hopper during travel to keep the trash from blowing out of the hopper. The Top Door functions are controlled by the TOP DOOR

OPEN and CLOSE buttons.

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 LED lights must be off

• Engine speed must be below 1700 rpm

NOTE

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 if used as a pack assist panel.

2.3.1 Open Top Door

Press and hold TOP DOOR OPEN button to open the top door (Figure 24, Item 2). The green LED light will be lit when the top door is fully open.

2.3.2 Close Top Door

Press and hold TOP DOOR CLOSE button to close the top door (Figure 24, Item 1). The orange LED will ash when the top door is not closed in the HOME position.

NOTE

An optional alarm will sound if vehicle speed is over 25 mph and the top door, if equipped, is not closed.

Zero Radius Side Loader

Operation

Figure 24

2.4 Arm Functions

The Arm functions are controlled from the joystick in the

chassis cab or the remote control box.

You must press and hold the ARM ON switch to enable the joystick in the cab. The green LED will be lighted when the

arm is enabled.

You must press the REMOTE switch to enable the remote control switch panel. The green LED will be lighted when the REMOTE switch is activated.

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.

Zero Radius Side Loader

Operation

CAUTION

Use caution when raising the arm assembly with a container.

2.4.1 Arm Assembly Extend and Retract Functions

The extend and retract movements of the arm assembly are controlled by the joystick. See Figure 25.

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

• Truck travel speed must be less than 7 mph

• Engine speed must be below 1700 rpm

• Green Arm On LED must be lighted

• Green Pump On LED must be lighted

• OPERATOR PRESENCE switch on joystick or outside

ACTIVATE switch must be pressed

• 2.4.1.1 Extend Arm Assembly

Move the joystick to the right to extend the arm assembly.

• 2.4.1.2 Retract Arm Assembly

Move the joystick to the left to retract the arm assembly.

Figure 25

Zero Radius Side Loader

Operation

2.4.2 Arm Assembly Raise and Lower Functions

The raise and lower movements of the arm assembly are controlled by the joystick (Figure 26).

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

• The top door open green LED must be lit to raise arm to the DUMP position

• Truck travel speed must be less than 7 mph

• Engine speed must be below 1700 rpm

• Green arm on LED must be lighted

• Green pump on LED must be lighted

• OPERATOR PRESENCE switch on joystick must be

pressed

• 2.4.2.1 Raise Arm Assembly

Pull the joystick back to raise the arm assembly

Arm Assembly Raise and Lower Functions

Figure 26

• 2.4.2.2 Lower Arm Assembly

Push the joystick forward to lower the arm assembly

Zero Radius Side Loader

2.5 Grabber Functions

The open and close motion of the grabber is controlled by the thumb wheel on the joystick.

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

• Truck travel speed must be less than 7 mph

• Engine speed must be below 1700 rpm

• Green Arm On LED must be lighted

• Green Pump On LED must be lighted

• OPERATOR PRESENCE switch on joystick must be

pressed

2.5.1 Open Grabber Fingers

Roll the thumb wheel up to open the grabber ngers (Figure 27, Item 1).

Operation

2.5.2 Close Grabber Fingers

Roll the thumb wheel down to close the grabber ngers (Figure 27, Item 2).

Figure 27

Zero Radius Side Loader

Operation

2.6 Tailgate Functions

The Tailgate functions are controlled by the TAILGATE OPEN and CLOSE switches and the ACTIVATE switch on the 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 or opening the tailgate. Serious personal injury or death may occur.

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.

Conditions

• Engine speed must be below 1700 rpm

2.6.1 Open Tailgate

Press and hold the ACTIVATE and the OPEN TAILGATE switches at the same time to open the tailgate (Figure 28, Item

1).

2.6.2 Close Tailgate

Press and hold the ACTIVATE and the CLOSE TAILGATE switches at the same time to close the tailgate (Figure 28,

Item 2).

Zero Radius Side Loader

Figure 28

Operation

3.0 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.

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.

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.

3.1 Start-Up Procedure

Before starting the vehicle, make certain that:

1. BATTERY switch is ON.

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

3.2 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.

Zero Radius Side Loader

Operation

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. Start the vehicle and idle for 5 minutes with the pump turned off. (Do not attempt to run any functions during this period.)

2. Turn the pump on to activate the heater function for 5 minutes.

a. For the heater to work, which operates the Tailgate

Close solenoid and Top Door open, these conditions need

to be met:

i. Pump needs to be on.

ii. All other functions need to be off.

iii. Auto Heater needs to be set to Enabled. See Zero

Radius Service Manual for Enable parameters.

iv. Oil temperature needs to be below 109°F.

v. Tailgate must be closed.

3. Cycle through each of the following operations:

a. Packing Functions - Cycle three (3) times.

b. Top Door Functions - Cycle three (3) times.

Zero Radius Side Loader

c. Grabber and Arm Functions - Cycle ve (5) times.

4. 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.

3.3 Traveling Procedure

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

Hydraulic functions are in their HOME positions. This means:

1. That the arm assembly is retracted to its STOWED position and is secured in place with the hook and with

the arm transit latch chain (Figure 29 for arm transit

latch chain). Stowed means that the arm is retracted into the body and the grabber is in the hopper with the ngers closed. The hook will automatically latch when the ARM switch is pressed off; the arm transit latch chain is

manually latched.

Figure 29

NOTE

Arm assembly must first be retracted and then the top door fully closed in order to place arm assembly in the STOWED position.

2. That the top door is fully closed.

3. That the grabber ngers (Figure 30, Item 1) are in their

fully CLOSED position and in the fully RAISED/STOWED position in the hopper. When the arm and grabber assembly are properly stowed, the arm stowed LED light will be off.

4. That the tailgate is fully closed.

5. That the PUMP switch is off.

6. Push any of the E-STOP buttons to disable all refuse vehicle functions.

7. Refer to your company’s policy on the use of safety lights.

NOTE

Operation

Alarm will sound if grabber is not in the stowed position when truck is driven over 7 mph.

Figure 30

Zero Radius Side Loader

Operation

3.4 Preparation Before Starting Route

1. If necessary, turn work lights on to enhance vision.

2. Activate all E-STOP buttons.

3. Press PUMP switch to activate the hydraulics.

4. Lower the grabber assembly from the STOWED position

in the hopper.

5. Open the grabber ngers (Figure 31, Item 1).

6. Open the top door.

7. Disconnect the arm transit latch from the arm, and stow the chain by hooking the clip to the larger hole on the boom retainer plate (Figure 32, Item 1). If the operator attempts to extend the arm with the chain still latched, the chain will break and it will need replacing.

Figure 31

Zero Radius Side Loader

Figure 32

Operation

3.5 Daily Maintenance Reminder Screen

Daily Maintenance Reminder Screen

Description

This screen displays reminders to the Operator to perform

daily checks on:

• Inspect Electrical Components

• Inspect Hydraulic Components

• Inspect Mechanical Components

Operator should press the “OK” button upon completion of vehicle inspection to continue to the Home Screen.

3.6 Refuse Loading Procedure

Loading a refuse container quickly with the arm assembly involves minimum work on the part of the operator. See

Figure 33.

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.

1. Position the vehicle properly at the collection site, staying close to the curb side to achieve a distance of 3-6 ft (1-2 m).

2. Maximum efciency can be obtained when the containers are positioned 3-6 ft (1-2 m) from the truck and they are spread in a line.

3. Extend the arm assembly to grab the container.

4. Position the grabber ngers around the container.

NOTE

To improve the ability to select an individual container, it may be necessary to partially close the grabber fingers before extending the arm assembly to the container.

Zero Radius Side Loader

Operation

Zero Radius Side Loader

Figure 33

3.7 Refuse Dumping 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.

NOTE

The grabber assembly will not raise to the full DUMP position unless the arm assembly is in the fully RETRACTED position.

1. Start raising the grabber assembly and at the same time,

retract the arm assembly until the container is emptied

(Figure 34).

2. Once the container is emptied, lower the grabber assembly and then extend the arm assembly.

3. Open the grabber ngers to release the container.

4. If additional containers are present at the same location, retract the arm assembly slightly, and move the vehicle as needed to load additional containers.

5. When nished at a site, retract the arm assembly and

raise the grabber into the STOWED position.

6. Travel to next pickup site.

Operation

DANGER

The arm assembly and grabber MUST be stowed and secured while traveling when the arm assembly is not in use. Serious personal injury or death may occur.

Figure 34

3.8 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.

1. If equipped with a pusher axle, make sure the pusher axle

is raised.

2. If equipped with a tag axle, make sure the tag axle is

lowered.

3. Position rear of refuse vehicle as appropriate.

4. Open the tailgate fully.

NOTE

Do not extend the packing panel to the full EJECT position when moving the packing panel from the HOME position for the first time. Refuse may fall behind the packing panel causing the load not to be completely ejected.

5. Extend the packing panel from the HOME position (Figure

35, Item 1) to the middle of the body (Figure 35, Item 2).

6. Retract the packing panel to the HOME position. This will

prevent refuse from falling behind the packing panel.

Zero Radius Side Loader

Operation

7. Once again, extend the packing panel from the HOME position to the middle of the body.

8. Retract the packing panel back to the HOME position.

9. Extend the packing panel to the fully EXTENDED position (Figure 35, Item 3) and move the truck forward to verify

that the entire refuse load has been ejected.

10. Lower and prop the tailgate.

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

Zero Radius Side Loader

Figure 35

Operation

3.9 End-of-Day Checks

At the end of the day, make certain that:

1. Packing panel is in the HOME position and the tailgate is

fully closed.

NOTE

Do not place packing panel in the HOME position during cold weather conditions.

2. Arm assembly is retracted to the STOWED position.

DANGER

The arm assembly and grabber MUST be stowed and secured while traveling when the arm assembly is not in use. Serious personal injury or death may occur.

3. Grabber ngers are in their fully CLOSED position and

raised to the STOW position (Figure 36, Item 1).

4. Top Door is closed.

5. All equipment is properly shut down (see the Chassis

Manual for more information on proper shutdown procedures for the engine).

Figure 36

Zero Radius Side Loader

Operation

NOTE

4.0 Optional Equipment

4.1 Pusher or Tag Axle

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.

Zero Radius Side Loader

A tag axle is mounted behind the rear drive axle. A pusher axle

is mounted in front of the rear drive axle. They are considered

auxiliary axles. The pusher or tag axle is raised and lowered by switches located on the cab control box. When the vehicle is placed in reverse drive gear, the axles will raise.

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.

4.1.1 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. Press the PUSHER or TAG AXLE LOWER button.

3. Resume normal operations.

4.1.2 Raising 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. Press the PUSHER or TAG AXLE RAISE button.

3. Resume normal operations.

Operation

4.2 Preco Radar Systems

There is an optional integrated Preco radar system for

CODE controlled refuse systems. Refer to the Preco manual

that came with the vehicle or visit Preco.com for a product manual (Side Defender or Sentry systems). The following images describe the screens that will display on the CODE display system when the Preco radar system is installed and operational.

Vehicle Command Image on CODE Display

Vehicle is placed in reverse and vehicle is approaching an object.

Vehicle is placed in forward drive and vehicle is approaching an object.

Vehicle Command Image on CODE Display

Vehicle left turn signal is

activated and object is detected

on the left.

Vehicle right turn signal is

activated and object is detected

on the right.

Zero Radius Side Loader

Operation

Vehicle Command Image on CODE Display

Proximity of vehicle to an object (front and rear object detection).

NOTE: This is not a screen on

the CODE display, but a legend to the color patterns shown when an object is detected.

No object

detected

Object

extremely close

Distance

Vehicle Command Image on CODE Display

If a Preco sensor has failed (is missing or has an error), a

screen will display on the CODE control display system with the

failure condition.

Missing Sensor

Front/Rear

Sensor Error

Front/Rear

Side

Zero Radius Side Loader

Operation

4.3 Water Tank

4.3.1 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.

4.3.2 Introduction

Your refuse vehicle may be equipped with a pressurized water tank. This tank is used to rinse debris off the refuse 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 refuse 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.

Zero Radius Side Loader

Operation

4.3.3 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.

• 4.3.3.1 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.

• Inspect Exterior with Pressure: If there are no signs

of 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.

• 4.3.3.2 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 used 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.

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.

Zero Radius Side Loader

Operation

• 4.3.3.3 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 a 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.

4.3.4 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.

4.3.5 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.

4.3.6 Water Tank Sign 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.

(Side Tank Mount)

Zero Radius Side Loader

Operation

NOTES

Zero Radius Side 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.

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

Zero Radius Side Loader

Preventive Maintenance

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.

Zero Radius Side 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

R Replace

I Inspect

T Torque

P Perform

L Lubricate

C Clean

Operator

Daily

Weekly

Hydraulic System

Hydraulic Oil Level P P

Hydraulic System and Components I I

Hydraulic Hoses and Fittings I I

Hydraulic Tubes and Fittings I I

Breather Filter I / R R

Return Line Filter R

Hydraulic Oil Test P

Main Relief Valve Setting P

Hydraulic Oil R R

Reservoir Drain Plug I / P I / P

Suction Line Strainer R R

High Pressure Filter (If Applicable) R

Hydraulic Cooler I

Service

)

Zero Radius Side 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

R Replace

I Inspect

T Torque

P Perform

L Lubricate

C Clean

Operator

Daily

Weekly

Electrical System

Lighting System I I

Wire Harness I I

Audible Backup Alarm I

Pneumatic System

Air Hoses and Fittings I I

Coalescing Filter P I / R R

Mechanical System

Refuse Vehicle Body & Components I I

Tailgate Seal Condition I I

Tailgate Lock Clearance I

Packing Panel Assembly I

Top Door I

Arm Assembly I

Grabber Fingers and Wheels I

Pusher or Tag Axle Lug Nuts T

Service

)

Zero Radius Side 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

R Replace

I Inspect

T Torque

P Perform

L Lubricate

C Clean

Operator

Daily

Weekly

Operation

Refuse Vehicle Controls P P

Trash Behind Packing Panel I / P I / P

Safety Signs I

Ladders and/or Associated Equipment I

Hinges and Latching Mechanisms I

Pump Driveshaft Couplers I

Proper Operation of Proximity Switches P P

Lubrication

Daily L

Scheduled PM L

Service

)

Zero Radius Side 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 37) is distinguished by the word “LOW” below the sight glass. The second type (Figure 38) 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 37), 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 37, 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 37, 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.

Zero Radius Side Loader

Preventive Maintenance

The second type of temperature/level sight gauge (Figure 38,

MAX FILL HOT

°F °C

100

200

150

100

LOW

Figure 37

Item 1) will not have the word “LOW”. Keep the oil level to the top of the black line (Full) (Figure 38, Item 2), but don’t over ll. If the oil level gets to the red line (Figure 38, Item 3), oil

must be added.

°F °C

100

200

150

100

Figure 38

Zero Radius Side Loader

Preventive Maintenance

SAFETY NOTICE

3.2 Electrical 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.

3.2.1 Lighting System

• Daily Checks - The lighting system is inspected by the

operator or skilled service personnel.

Check to ensure that all exterior lights on the refuse vehicle

and chassis are functioning correctly. Replace any burned-out bulbs with the same type.

3.3 Pneumatic 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.

3.3.1 Coalescing Filter

• Daily Checks - The coalescing lter is drained by the

operator or skilled service personnel.

Locate the drain tting (Figure 39, Item 1) on the bottom of the coalescing lter.

Figure 39

Drain the lter by turning the drain tting counterclockwise. Turn the drain tting clockwise after all moisture and

contaminants have drained from the canister.

Zero Radius Side Loader

Preventive Maintenance

SAFETY NOTICE

3.4 Mechanical 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.

3.4.1 Refuse Vehicle Body and Components

• Daily Checks - The refuse vehicle body and components

are inspected by the operator or skilled service personnel.

Inspect the body and all components for binding, damage, and loose or missing parts.

3.4.2 Tailgate Seal

• Daily Checks - The tailgate seal is inspected by the

operator or skilled service personnel.

Inspect the tailgate seal for cuts, tears, damage, or excessive wear. Ensure that the seal is fully seated in the tailgate channel. Inspect the mounting straps to ensure they are

secure.

3.5 Operation

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 body or opening the tailgate.

Serious personel injury or death may occur.

3.5.1 Refuse Vehicle Controls

• Daily Checks - The refuse vehicle controls are checked

for proper operation by the operator or skilled service personnel.

Operate all functions to validate they are operational. Verify that all indicator lights and alarms are operational.

Zero Radius Side Loader

Preventive Maintenance

NOTE

3.6 Trash Behind the Packing Panel

• Daily Checks - The refuse vehicle is inspected for trash

behind the packing panel by the operator or skilled service personnel.

When the refuse vehicle is operated on the route, trash can pass by the packing panel. If the trash is not cleaned from behind the packing panel, the refuse vehicle can be damaged.

1. Shut the engine off and disable the refuse vehicle.

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.

2. 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.

There are clean out doors on both sides of the refuse vehicle. Open each door to properly clean behind the packing panel.

3. Unhook the clamp (Figure 40, Item 1) holding the clean out door closed.

4. Open the clean out door (Figure 40, Item 2).

Figure 40

Zero Radius Side Loader

5. Inspect behind the packing panel (Figure 41, Item 1) for accumulation for trash.

Preventive Maintenance

6. Without reaching your arm into the refuse vehicle, remove the trash from behind the packing panel using the appropriate clean out tool.

7. After the trash is removed, close and secure the clean out

door.

Figure 41

3.7 Safety Signs

• Daily Checks - A complete walk around of the vehicle to

inspect the safety signs should be performed every day before operation. If any of the safety signs are damaged, illegible, or missing, they must be replaced before operation.

For the proper location and part numbers of the safety signs for the refuse vehicle, see “SAFETY SIGNS”. If you are unable to determine the proper safety sign or its placement

on the refuse vehicle, call McNeilus Truck and Manufacturing,

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

signs.

For information on any of the chassis safety signs, please

contact the chassis manufacturer.

Zero Radius Side Loader

Preventive Maintenance

4.0 Propping the Tailgate

When performing maintenance procedures that require the tailgate to be open, the following procedure must be followed to open and prop the tailgate.

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 or opening the tailgate. Serious personal injury or death may occur.

4.1 Engaging the Tailgate Prop

1. Start the engine and raise the tailgate approximately 2.5-3 ft.

2. Shut the chassis engine off and disable the refuse vehicle.

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.

3. Standing behind the tailgate, release the pin (Figure 42, Item 1) and swing the prop (Figure 42, Item 2) toward the

truck frame.

Zero Radius Side Loader

Preventive Maintenance

Figure 42

4. Position the end of the prop (Figure 43, Item 1) over the pocket (Figure 43, Item 2) and lock in place with springloaded pin.

Figure 43

5. Turn chassis BATTERY switch ON.

DANGER

Verify that the tailgate props are properly seated in the pockets off the body compartment.

Serious personal injury or death may occur.

Zero Radius Side Loader

Preventive Maintenance

CAUTION

Do not POWER DOWN the tailgate against the props. Damage may occur to the props.

6. Start chassis engine and lower the tailgate until the prop is fully seated in the pocket (Figure 44, Item 1).

Figure 44

7. Shut the chassis engine off and disable the refuse vehicle.

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.

8. 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.

Zero Radius Side Loader

Preventive Maintenance

4.2 Disengaging the Tailgate Prop

After completing the maintenance procedures on the body that require the tailgate to be propped, the following procedure must be followed to disengage the prop and close the tailgate.

1. Remove the Lockout/Tagout procedure from the refuse vehicle. If your company does not have a Lockout/ Tagout procedure, follow OSHA 1910.147 and 1910.146 Conned Space as appropriate.

2. Open the tailgate as needed to provide the necessary clearance to disengage the prop from the pocket in the body compartment.

3. Disable the refuse vehicle functions.

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.

4. Standing behind the tailgate, remove the prop from the pocket and swing the prop (Figure 45, Item 1) away from the chassis frame to the STORED position and install the retaining pin (Figure 45, Item 2).

Zero Radius Side Loader

Preventive Maintenance

Figure 45

5. Turn chassis BATTERY switch ON.

6. Start the chassis engine.

7. Close the tailgate.

Zero Radius Side Loader

Preventive Maintenance

5.0 Lubrication

5.1 Daily Lubrication

Lubricate all the following points with a high-quality EP No. 2

lithium grease.

Daily lubrication intervals are based on a 10-hour day. If the refuse vehicle is operated more hours per day or double-shifted, the maintenance interval must be adjusted

accordingly.

If your refuse vehicle is equipped with a tag axle, refer to the Operator’s and Service Manuals supplied by the manufacturer for the proper lubrication and maintenance.

The lubrication charts in the following pages are divided between Zero Radius and Zero Radius Extended Reach. Refer to the appropriate illustrations for your model.

SAFETY NOTICE

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.

WARNING

Items G, H, I, J, K, and L must be greased with the grabber fully lowered on mast, or if raised, chocked with a jack stand or blocked to prevent the grabber from lowering. Failure to comply may injure or kill.

Zero Radius Side Loader

Preventive Maintenance

Zero Radius 6 ft. Reach Daily Lubrication Points Lubricate Daily or Every 10 Hours

Ref. Description

A1 Packing Panel Cylinder - Curb Side - Rod End 1

A2 Packing Panel Cylinder - Street Side - Rod End 1

A3 Packing Panel Cylinders - Base End 2 Two Cylinders - One Per Side

B Arm Cylinder - Base End 1

C Arm Rollers - Rear 1

D Arm Rollers - Mid 2 Two Rollers - One Per Side

E Arm Rollers - Front 2 Two Rollers - One Per Side

F Arm Rollers - Bottom 2 Two Rollers - One Per Side

No. of

Fittings

Comments

Zero Radius Side Loader

Preventive Maintenance

D E F

Zero Radius Side Loader

Preventive Maintenance

Zero Radius 6 ft. Reach Daily Lubrication Points Lubricate Daily or Every 10 Hours

Ref. Description

G Grabber Assembly Rollers - Upper 2 Two Rollers - One Per Side

H Grabber Assembly Rollers - Lower 2 Two Rollers - One Per Side

J Grabber Finger Pivots - Upper 2 Two Pivot Pins - One Per Side

J Grabber Finger Pivots - Lower 2 Two Pivot Pins - One Per Side

K Grabber Fingers Cylinders - Base End 2 Two Cylinders - One Per Side

L Grabber Fingers Cylinders - Rod End 2 Two Cylinders - One Per Side

M Grabber Roller Gear 2 Two Lubrication Locations

No. of

Fittings

Comments

WARNING

Zero Radius Side Loader

McNeilus Zero Radius ZR 6 ft. Reach, Zero Radius ZR 12 ft. Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual