OPERATOR MANUAL

Front Loader
with Command Zone - R Includes Information
For The Following Models.
• Atlantic Front Loader
• Pacific Front Loader

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. Publication No. 1274072
Disclaimer:
All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing.
The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product,
service or maintenance improvement. We reserve the right to make any change at any time without notice.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping, or information storage and retrieval systems - without the written permission of McNeilus Truck and
Manufacturing, Inc.

Front Loader © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 FOREWORD
1.0 PURPOSE OF MANUAL 2.0 SCOPE
This Operator Manual provides operation and operator This manual provides information for use by the equipment
maintenance instructions for the Front Loader refuse collection operator under the following headings:
system manufactured by McNeilus Truck and Manufacturing, (1) Safety. Includes important safety information.
Inc.
(2) General. Includes equipment identification.
The information in this operator manual will be your guide to
operation and operator maintenance for this equipment. (3) Operation. Includes control functionality and
normal equipment operation.
Keep this manual with the vehicle at all times. (4) Preventive Maintenance - Packer. Includes
basic preventive maintenance information for the
! WARNING operator.
To order a replacement manual or safety warning labels,
The operator of this vehicle must be properly
contact one of the regional McNeilus Regional Branch/Factory
licensed and trained to operate this vehicle.
Service/Parts locations.
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
Customer Service at (507) 374-6321.

NOTE
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.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. Front Loader
FOREWORD
3.0 FACTORY SERVICE/PARTS LOCATIONS Canada
Ontario and Western Provinces 800-265-1098
Contact your McNeilus Regional Branch/Factory Service/Parts Quebec and Maritime Provinces 800-996-4937
location to order parts, to receive service information, or for
other assistance. A listing of locations and phone numbers is
given below, sorted alphabetically by state:
State City Phone
AZ Phoenix 602-484-4060
CA Colton 909-370-2100
CA Stockton 209-931-4282
CO Commerce City 303-287-7486
CT East Granby 860-653-5548
FL Lakeland 863-510-0070
GA Villa Rica 770-459-6005
IL Sugar Grove 630-466-5100
IN Fort Wayne 260-489-3031
MI Grand Rapids 616-452-0782
MN Dodge Center 507-374-6321
NY Buffalo 800-841-4010
OH Cincinnati 866-294-8884
OH Columbus 614-445-9614
PA Morgantown 610-913-7341
TX Houston 713-672-9799
TX Hutchins 972-225-2313
UT West Valley City 801-954-8709
WA Puyallup 253-904-9400
WI Oshkosh 920-235-8898

Front Loader © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 FOREWORD
4.0 CORPORATE HEADQUARTERS
Contact McNeilus Truck and Manufacturing, Inc. directly at our
corporate headquarters at the following address, phone
numbers and website address:

McNeilus Truck and Manufacturing, Inc.

PO Box 70, 524 County Road 34 East
Dodge Center, MN 55927

Telephone: (507) 374-6321

FAX: (507) 374-6306

Website: www.mcneiluscompanies.com

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. Front Loader
FOREWORD
NOTES

Front Loader © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 TABLE OF CONTENTS
SAFETY
1.0 IMPORTANT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 LOCKOUT/TAGOUT Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.0 SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.0 PRODUCT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2 Cab Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3 Outside Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.5 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.0 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Safety Decal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
GENERAL
1.0 IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.0 INCOMPLETE VEHICLE DOCUMENT DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3.0 EXTERIOR SYSTEMS ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3.1 Street Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
3.2 Curb Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
OPERATION
1.0 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
1.1 CAB CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
1.2 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
1.2.1 Rocker Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
1.2.2 Indicator Light Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
1.2.3 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. i Front Loader
TABLE OF CONTENTS
1.3 Arm and Fork Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3.1 Joystick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3.2 Dual Lever Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Auto-Level Controls (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.5 Outside Control Box (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.0 RESIDENTIAL ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.0 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Pusher or Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.1 Lowering the Pusher or Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.2 Raising the Pusher or Tag Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.0 CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 E-STOP (Emergency Stop) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.1 E-STOP Button In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.2 E-STOP Buttons Outside Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Pack and Sweep Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.1 Automatic Cycling of Pack and Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.2 Manual Cycling of Pack and Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.3 Manual Cycling with Tailgate Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3 Arm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4 Fork Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.5 Auto-Level Functions (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.6 Tailgate Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.6.1 Open Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.6.2 Close Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.7 Top Door Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.7.1 Open Top Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.7.2 Close Top Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.8 Body Raise Functions - Dump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.8.1 Raise Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Front Loader ii © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 TABLE OF CONTENTS
4.8.2 Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
5.0 OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
5.1 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
5.2 Warm-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
5.3 Traveling Procedure - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
5.4 Traveling Procedure - Residential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5.5 Preparation Before Starting Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
5.6 Refuse Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
5.7 Refuse Empty Procedure - Full Eject Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
5.8 Refuse Empty Procedure - Dump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.9 End-of-Day Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
PREVENTIVE MAINTENANCE - PACKER
1.0 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
1.1 DOT Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
2.0 PREVENTIVE MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
3.0 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
3.1 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
3.1.1 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
3.1.1.1 Two Sight Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
3.1.1.2 Temperature/Level Sight Gauge (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
3.1.2 Hydraulic System and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
3.1.3 Hydraulic Hoses, Tubes, and Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
3.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
3.2.1 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
3.2.2 Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
3.3 Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
3.3.1 Pneumatic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
3.3.2 Coalescing Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
3.4 Mechanical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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3.4.1 Packer Body and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4.2 Tailgate Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4.3 Pusher or Tag (Auxiliary) Axle Lug Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.5.1 Packer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.6 Propping the Body for Maintenance (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.6.1 Service Lift (OPTIONAL) – Eject Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.6.1.1 Installing the Body Prop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Removing the Body Prop 106
3.7 Propping the Tailgate for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.7.1 Installing the Tailgate Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.7.2 Removing the Tailgate Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.8 Trash Behind the Pack and Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.9 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.0 HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.1 Hydraulic Oil Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.3 Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.3.1 Standard Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.3.2 Clean-Fill Hydraulic System (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.0 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.1 Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.2 Scheduled PM Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TROUBLESHOOTING
1.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Front Loader iv © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
1.0 IMPORTANT SAFETY INFORMATION
READ AND UNDERSTAND THIS ENTIRE MANUAL individuals should not be allowed to operate this equipment
BEFORE OPERATING, REPAIRING, OR ADJUSTING YOUR until they thoroughly understand all of these materials. Failure
MCNEILUS EQUIPMENT. to do so can result in serious injury or death.
THOSE WHO USE AND MAINTAIN THIS EQUIPMENT MUST Safety and safe working procedures must be followed at all
BE THOROUGHLY TRAINED AND FAMILIAR WITH THE times.
PRODUCT.
OSHA LOCKOUT/TAGOUT procedures must be followed when
IF INCORRECTLY USED OR MAINTAINED, THIS performing Daily Checks or Scheduled PM on this equipment.
EQUIPMENT CAN CAUSE SEVERE INJURY. If you are unfamiliar with the OSHA LOCKOUT/TAGOUT
procedures or any other safety requirements, please contact
Always keep this manual in a location where it is readily McNeilus Truck and Manufacturing, Inc.
available for persons who operate or maintain the product.
Additional copies of this manual are available from McNeilus
Truck and Manufacturing, Inc. Please contact McNeilus Truck
and Manufacturing, Inc. if you require additional manuals or if
you have any questions about the information in this manual,
this product, or safe operating procedures.
THESE SAFETY PROCEDURES ARE FOR YOUR OWN
PROTECTION.
Do not operate this equipment until you have read its contents
thoroughly. 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, then 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 decals on this unit. Such

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 1 Front Loader
SAFETY
1.1 LOCKOUT/TAGOUT Procedure 1.2 Safety Equipment

! DANGER
Every McNeilus Refuse Truck comes equipped with a five
pound fire extinguisher which has an A-B-C rating, and a
LOCKOUT/TAGOUT procedures must be followed reflective warning triangle kit which contains three triangles.
when working on this equipment including, but The fire extinguisher may already be mounted to the Packer,
not limited to, cylinders being changed or otherwise it is temporarily placed into the cab of your truck
maintained. Failure to heed these along with the reflective triangle kit.
instructions/warnings can result in serious
personal injury or death. You are responsible for permanent mounting of this equipment.
The fire extinguisher is required to be securely mounted to
Before entering Packer body, or climbing or getting under truck prevent sliding, rolling, or vertical movement. The placement
to perform any work, read and follow OSHA Regulations and mounting location of the reflective triangles is at your
concerning entry and working in “CONFINED SPACE” OSHA discretion.
1910.146 AND “LOCKOUT/TAGOUT OSHA 1910.147.
Follow OSHA Regulations while performing any work to the
Packer.
Follow all safety instructions in your McNeilus Packer manual.
Shut off truck engine, lock cab doors and keep key in your
pocket before entering or climbing on, or getting under truck to
perform any work to the Packer.
Place magnetic “DANGER” signs on both cab doors.
Lockout supplies are available from McNeilus Truck and
Manufacturing, Inc. Call (507) 374-6321 for assistance.

Front Loader 2 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
2.0 SAFETY NOTICES
Safety notices are one of the primary ways to call your
attention to potential hazards. ! CAUTION


A hazard which might result in personal injury or
damage to property or equipment.

THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY SAFETY NOTICE

MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE
MESSAGE THAT FOLLOWS.
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OPERATOR’S INSTRUCTION
OR DEATH.
The following safety notices are used throughout this manual.
The “signal words” of DANGER, WARNING, and CAUTION
! DANGER have specific meanings to alert you to the relative level of
hazard.
A hazard that will result in death or serious Take the safety warnings seriously. If you do not understand
personal injury. them or have questions about them, call McNeilus Truck and
Manufacturing, Inc.

! WARNING
A hazard which might result in death or serious
personal injury.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 3 Front Loader
SAFETY
3.0 PRODUCT SAFETY INFORMATION
Read, understand, and follow the safety guidelines and heed 3.2 Cab Operation
dangers and warnings listed below and contained in this
manual as well as on the Packer itself to promote reliable
operation and prevent serious personal injury. ! DANGER
Contact McNeilus Truck and Manufacturing, Inc. if you require If the Packer comes into contact or close
assistance or have questions. proximity with a power line or if there is any
arcing, stay in the chassis cab and keep away
3.1 Safety from the metal parts of the unit. Do not let anyone
come close to the Packer. Do not attempt to jump

! WARNING
clear of the Packer. Stay in the cab. The power
company must disconnect the power before you
Immediately replace safety decals if damaged, can safely leave the cab.
unreadable, or missing. Contact McNeilus Truck Minimum clearances from power lines:
and Manufacturing, Inc. for no-charge 50,000 Volts or Less . . . . . . . . . . . . . . . . . . . 4 Feet
replacement decals when required. Failure to 50,000 + Volts . . . . . . . . . . . . . . . . . . . . . . . 10 Feet
replace decals may result in serious personal 345,000 - 750,000 Volts. . . . . . . . . . . . . . . . 16 Feet
injury or death.
Know the clearance of overhead obstructions.
Never drive the Packer under any overhead

! WARNING
obstruction. Failure to do so may result in
damage to the Packer body or chassis, and may
The Packer must not be modified in any way result in serious personal injury or death.
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 or death.

Front Loader 4 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

! DANGER ! WARNING
If chassis is equipped with a stand-up drive Operators must comply with Employee
position, use stand-up position only during Responsibilities as outlined in ANSI Z245 and
refuse pick-up or collection activities for state, federal, and other safety and transportation
distances of less than 2/10 mile. Failure to heed regulations (e.g. OSHA, DOT, Motor Carrier and
this warning may result in serious personal injury FMVSS) when operating this refuse vehicle.
or death. Failure to comply may result in serious personal
injury or death.

! DANGER
Never operate chassis in excess of 15 MPH from
! WARNING
the stand-up position. Failure to do so can result All owners and supervisors should make sure all
in serious personal injury or death. drivers, operators and maintenance personnel
have read and thoroughly understand the decals
affixed to this Packer as well as the safety
! DANGER information and instructions in the McNeilus
Operator Manual. Owners and Supervisors must
Always drive defensively. Never exceed posted comply with ANSI Z245.1 Regulations.
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
! WARNING
control of the vehicle resulting in serious If equipped with optional camera, never rely
personal injury or death. exclusively on the camera. Follow all other safe
driving procedures. Failure to heed this warning
may result in serious personal injury or death.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 5 Front Loader
SAFETY

! WARNING ! CAUTION
No passenger is allowed in the cab unless a Always check indicator lights in the chassis cab
manufacturer’s approved passenger seat and or on the control panel at the front of the Packer.
seat belt are provided. Serious injury or death Replace bulbs or lights when required. (Note: All
can result. models may not have indicator lights.) Failure to
inspect indicator lights may lead to more serious
conditions.
! WARNING
At the landfill or when operating off-road, use the OPERATOR’S INSTRUCTION
lowest transmission gear and proceed at low
speed (3-mph maximum). Failure to comply can Stow arms, forks, and container in hopper at the
cause serious injury or death. lowest height during transit. Be sure containers
are stored at their lowest level in the hopper.
Failure to do so may result in a collision with
! WARNING bridges, overhead power lines, etc.

It is important that the pump ON indicator light is

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

Front Loader 6 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
3.3 Outside Operation
! WARNING
! DANGER Never walk or stand behind Packer while it is
backing up.
Never attempt to clear a jammed Packer or
container lift, enter a body or open an access Failure to heed these instructions/warnings may
door unless power is shut down, LOCKOUT/ result in serious personal injury or death.
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
! WARNING
death. Do not use riding step when speeds are expected
to exceed 10 mph or when distance traveled is in
an excess of two-tenths of one mile. Riding step
! WARNING shall not be used when vehicle is moving
backwards.
Keep access door closed when in operation. Do Do not mount or dismount riding step when
not open access door unless: vehicle is in motion or when ladders or platforms
are wet and slippery.
(1) Engine is stopped
Serious personal injury or death can occur due to
(2) Key is removed from ignition a fall.
(3) Hydraulic pressures are relieved
(4) OSHA LOCKOUT/TAGOUT Regulations are ! WARNING
complied with
Never climb on windshield guard (if equipped).
Failure to heed these instructions/warnings may This is not a ladder. Use the ladder provided on
result in serious personal injury or death. the body. Failure to comply may result in serious
personal injury or death.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 7 Front Loader
SAFETY

! WARNING ! WARNING
Be sure everyone is clear of the area around the Wear the proper protective clothing when
Packer before operating the Packer. Remain operating or maintaining the Packer. Hard hats,
attentive at all times when operating the controls. safety glasses, gloves, and safety shoes should
Watch the mirrors for activity. Never back up the be worn. Reflective clothing is recommended for
Packer unless and until you are completely sure it drivers and employees while operating during
is safe. Use a spotter/observer and/or get out and darkness. Serious injury or death can result
check yourself, if necessary, to ensure it is safe to without proper protective gear.
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. Never exceed the manufacturer’s
! WARNING recommended gross vehicle weight. Do not
overload the Packer and chassis. Gross weights
Before opening the tailgate, be sure you have must meet federal, state, and local laws. Failure
adequate clearance above the tailgate to prevent to comply can cause serious injury or death.
contact with buildings, electrical lines, and any
other overhead obstructions. Failure to comply
can cause damage to the vehicle and serious
personal injury or death.
! 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. or
death

Front Loader 8 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
3.4 Maintenance
! WARNING
Never operate the hydraulic system if a leak is ! DANGER
present. Serious injury or death may result.
LOCKOUT/TAGOUT procedures must be followed
when working on this equipment including, but
not limited to, cylinders being changed or
SAFETY NOTICE maintained. Failure to heed these instructions/
If chassis is equipped with a battery shut-off warnings can result in serious personal injury or
switch it must be turned off anytime the death.
equipment is parked overnight, in a ship, or out of

!
service for any extended period of time. Failure to
do so may result in a fire and personal injury or DANGER
property damage.
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.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 9 Front Loader
SAFETY

! DANGER ! WARNING
Auxiliary pusher or tag axles must be supported Daily inspections should be performed on the
with jack stands, blocks, or similar devices while Packer. This includes proper operation of the
being serviced or maintained to prevent serious controls, hydraulic systems, electrical systems,
personal injury or death if auxiliary axle drops optional cameras are clean and working, camera
unexpectedly. Failure to do so may result in lens is clean, lighting system including turn
serious personal injury or death. signals, back up alarm, brake lights, clearance
lights, head lamps, tail lamps, safety equipment,
and work lights are all operational. The Packer’s
! DANGER air system must operate properly and have no
leaks. Water and moisture should be drained
Use the three-point rule when climbing ladder. from the Packer’s air system daily. Failure to
Failure to heed may cause serious personal ensure all systems are operating properly can
injury. result in serious injury or death.

! DANGER ! WARNING
Never attempt to use extraneous sources of Never wear watches, rings or jewelry while
power or extraneous machines to overcome a working with electrical and mechanical
malfunctioning system. equipment. These items can be hazardous and
Never override with overhead cranes, forklifts, can cause serious and painful injuries or death if
jacks, etc. or alter or modify systems or they come into contact with electrical wires,
equipment that may be malfunctioning. moving parts, or hydraulic equipment.
Failure to heed these instructions/ warnings can
result in serious personal injury or death.

Front Loader 10 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

! WARNING ! WARNING
Use only the access door for entry to the Packer. When working on the Packer, the wheels must be
Remember to follow the LOCKOUT/TAGOUT blocked, the parking brake on, LOCKOUT/
procedures when entering the Packer body. Only TAGOUT procedures in effect, and the key out of
exit the Packer body through the access door. the chassis’s ignition. Failure to do so may result
in serious personal injury or death.

! WARNING
If equipped with optional camera, camera lens
! WARNING
must be kept clean at all times to achieve good Anytime the tailgate is raised in the shop, the
monitor pictures. Failure to heed this warning tailgate must be supported to prevent it from
may result in serious personal injury or death. lowering unexpectedly. When the tailgate is
raised, never allow anyone to work around or to
enter the tailgate area unless the tailgate is
! WARNING properly supported! Failure to follow this
procedure can result in serious injury or death.
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
! WARNING
find electrical wiring or electrical cable with any Do not repair or weld steel or aluminum water
such adverse conditions or damage, they must tanks. Inspect the water tank for rust or corrosion
be replaced with electrical wiring or electrical every 30 days. Inspect the water tank under the
cable of equivalent specifications before the straps, on the exterior and on the interior by
Packer is returned to service! Failure to properly removing the flopper. If any rust or corrosion is
inspect and maintain your Packer may result in a found, replace the water tank with an OEM water
serious personal injury or death. tank from McNeilus. Failure to maintain water
tanks may result in serious personal injury or
death.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 11 Front Loader
SAFETY
3.5 Hydraulics
! CAUTION Call McNeilus Truck and Manufacturing at (507) 374-6321
Disconnect battery before welding on body. anytime you have questions concerning hydraulic hose or
tubing.
Failure to do so might result in personal injury or
damage to property or equipment.
! 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.

Front Loader 12 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

! WARNING ! WARNING
Hydraulic hoses, fittings, tubes, and pipes must Correct hoses, fittings, and adapters with the
be inspected on a daily basis for leaks, cuts, correct SAE rating must be used when replacing
abrasions, damage, aging, improper clearance, hoses to prevent possible serious injury or death.
and along the frame for hidden damage. If you Always replace hoses, fittings, and adapters with
find hoses with any such adverse conditions or replacements that have a proper, suitable
damage, they must be replaced before the Packer working pressure rating. Replacement hoses
is returned to service! In any event, all hydraulic must be of the correct length and must comply
hoses must be replaced every three years or 7500 with the hose manufacturer’s installation
hours. Failure to properly inspect and maintain guidelines and recommendations. Consult hose
your Packer may result in serious personal injury and fitting manufacturers for correct
or death. specifications.

! WARNING ! WARNING
Hydraulic systems are hot. DO NOT TOUCH! Hydraulic hoses have the SAE ratings marked on
Serious personal injury or death may result from the hose to assist in selecting the correct hose.
hot oil. When you have completed working on the Replacement hydraulic hose and fitting
hydraulic systems, thoroughly clean any spilled components must be supplied by the same
oil from the equipment. Do not spill any hydraulic manufacturer to prevent serious injury or death.
fluid on the ground. Clean any hydraulic fluid As an example: Brand “A” hose and brand “B”
from your skin as soon as you have completed fitting will not normally be compatible.
your maintenance and repairs. Dispose of used
oil and filters as required by law.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 13 Front Loader
SAFETY

! WARNING ! WARNING
The hydraulic cylinders can be holding a function Never heat hydraulic tubes and pipes. The carbon
in a certain position when the engine is OFF. An content of this steel pipe is such that if heated for
example of this would be a function being held in bending, and either water or air quenched, the
the lift or partial lift position by the cylinders. If a pipe may lose its ductility and thereby be subject
hydraulic line is removed or the hydraulic circuits to failure under high pressure or hydraulic shock
or controls are being worked on, gravity may conditions. Serious injury or death can result.
allow the function being held in position to drop. Damaged or leaking pipes must be replaced
All workers and personnel must remain clear of before the Packer is returned to service.
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
! WARNING
with this can result in serious injury or death. All hydraulic pressure must be relieved from the
hydraulic system prior to removing any
components from the system. To relieve the
! WARNING hydraulic pressure from the hydraulic system,
turn the chassis engine OFF and operate the
Any hydraulic tubing and pipe that is replaced Packer controls in the cab with the key in the ON
must conform to SAE J1065 specifications. If position. This will allow the spools to shift and
incorrect hydraulic tubing is installed, the relieve the hydraulic pressure. Failure to comply
hydraulic system may fail, serious injury or death can result in serious injury or death.
can result. Damage or leaking tubing must be
replaced before the Packer is returned to service.

Front Loader 14 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

! WARNING ! WARNING
All hydraulic pressures must be relieved from the Increasing hydraulic pressure beyond the
hydraulic system prior to removing any recommendations may result in serious damage
components from the system to prevent oil from to the Packer, serious personal injury or death
spraying or functions or systems from falling. and may void the Packer Warranty.
Failure to follow this procedure can result in
serious injury or death.
! WARNING
! WARNING Do not steam clean or pressure wash hydraulic
hoses or components. Failure to comply can
Hydraulic systems operate under high pressure. result in serious injury or death. Steam cleaning,
Only qualified, experienced people properly using extremely hot water, or pressure washing
trained in hydraulic system maintenance should may damage the hoses and components and
attempt repairs or troubleshoot hydraulic shorten the life or cause failure of the
systems. Use the proper tools and equipment components.
when servicing the hydraulic system. Failure to
comply can cause serious injury or death.
! WARNING
! WARNING Allow no twist when installing hoses. Remember
that 7° of twist per foot decreases hose life by
When performing hydraulic test procedures, use 95%. When installing hydraulic hose, use a
the proper hydraulic gauges. Installing an wrench to hold the hose in its natural position
incorrect test gauge could result in serious injury before tightening the fittings. Failure to comply
or death if the gauge fails. Use properly rated can result in serious injury or death.
hydraulic hoses with adequate length to allow the
test gauge to be used far enough away from
moving parts and functions.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 15 Front Loader
SAFETY

! WARNING ! WARNING
Anticipate a 4% hose shrinkage factor when The tailgate cylinders and body lift cylinders have
determining hose length. When a hose orifices installed in the barrel end ports. These
pressurizes it expands and becomes shorter. orifices limit the amount of hydraulic flow, which
Hose style shrinkage rates vary among different controls the speed of the cylinders. The orifices
size and brand hoses. Allowing 4% will prevent must remain in the cylinders. If a cylinder is
the hose from tugging on the fittings when the changed, the replacement cylinder must have an
hose is pressurized. Failure to comply can result orifice installed to ensure safe and proper
in serious injury or death. Example: a 50" hose operation. Removal of the orifice can cause rapid
would have to be 4% longer or 52" total length. retraction of the cylinder. This can cause severe
injury or death. Check all replacement cylinders
to ensure the orifice is in place before installation
! WARNING and operation.

Many hose coverings are available. Choose the

hose manufacturer's covering which is most
resistant to acid wash. Failure to comply can
! WARNING
result in serious injury or death. Some hose Hydraulic components can be heavy. Use caution
coverings may retain acid wash and cause while lifting these components. Serious personal
premature failure of the hose. injury or death can be avoided with proper
handling of the components.

Front Loader 16 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
3.6 Electrical

! WARNING
Proximity switches must remain functional for
safe operation of the Packer. If a switch does not
work, it must be repaired immediately before the
Packer is returned to service. Failure to comply
can result in serious injury or death.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 17 Front Loader
SAFETY
4.0 SAFETY DECALS
The following safety decals are found on your refuse collection No. Part Number Qty. Description
system and warn of hazards related to the use of this
equipment. Read and understand all safety decals before 1 9590.614298 2 Danger: Stand clear of lift arms,
operating this equipment. forks and hydraulic cylinders
when in motion or emptying
containers.
NOTE
2 1107479 1 Danger: Tailgate Safety Prop
Depending on the Packer configuration and Stop must be engaged and
optional equipment, the actual location of decals appropriate additional supports
and/or placards may vary slightly from the (steel saw horse, overhead chain
examples shown. hoist, etc.) must be utilized to
ensure safety.
If any safety decals on the equipment are not clearly readable, 3 9090.614542 2 Operator’s Instructions: The
contact one of the regional McNeilus Regional Branch/Factory hopper and the area directly
Service/Parts locations listed in the Foreword of this manual for behind the packing panel must
replacements. be cleaned on a regular basis to
ensure proper movement and
The table below contains part numbers for the individual safety packing operation.
decals. See the Figures in this section for decal locations and 4 9190.614301 2 Caution: Stand clear of lift arms,
the remaining pages of this section for decal identification of forks and hydraulic cylinders
each safety decal. when in motion or emptying
containers.
NOTE 5 9090.614430 2 Caution: Stand clear of lift arms,
forks and hydraulic cylinders
Specifications, appearance, and part numbers for when in motion or emptying
safety decals are subject to change without containers.
notice.
6 9790.614304 2 Danger: Whenever the body is
elevated or in a raised position, it
must be securely propped or
blocked so it cannot fall on
anyone.

Front Loader 18 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
No. Part Number Qty. Description No. Part Number Qty. Description
7 9190.614299 3 Danger: Stand clear when 16 9090.614541 1 Operator’s Instructions: The
tailgate is in motion and during hopper and the area directly
unloading cycle. behind the packing panel must
8 9190.614302 1 Operator’s Instruction: be cleaned on a regular basis to
Lubrication Guide. ensure proper movement and
packing operation.
9 9090.614548 1 Operator’s Instruction: Hydraulic
17 1318804 1 Warning: OVERALL HEIGHT
Oil Recommendations.
EMPTY WITH TIRES / RIMS
10 780.214618 1 Operator’s Instruction: All circuit INSTALLED BY
breakers and fuses to the cab MANUFACTURER 13 FT. 6 IN.
control console must be in the off
18 9790.614306 1 Operator’s Instructions: Voltage
position before jump starting or
of electric cables.
charging the battery.
11 9190.614305 1 McNeilus Genuine Replacement 19 9090.614526 1 Operator’s Instructions: Do not
Parts operate ejector with container in
hopper.
12 1140908 1 Hydraulic Oil Only
20 9790.614308 1 Caution: High truck height.
13 9790.614269 2 Danger: LOOK UP AND LIVE.
21 9790.601933 1 Warning: DO NOT FILL the
Make sure there is enough
Packer with refuse that will cause
clearance between a raised
the GVWR or GAWR of the truck
container and overhead power
(as shown on the certification
lines.
label of the vehicle
14 9090.614412 1 Danger: Avoid Turnover You are manufacturer) to be exceeded.
hauling a high center of gravity
22 9790.614276 1 Lift arms must be fully raised
load!
before tailgate can be opened.
15 780.214500 1 Safety Notice: Do not operate or
23 9790.614277 1 Operator’s Instructions: To avoid
service this machine until you
have read and understood the damage to arms and shield, cab
shield extension must be
operation manual supplied with
this equipment. lowered and fastened before
arms are lowered.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 19 Front Loader
SAFETY
No. Part Number Qty. Description No. Part Number Qty. Description
24 9790.614286 1 Operator’s Instructions: This 30 9190.614292 3 Warning: Do not climb on cab
vehicle is equipped with a back- shield, which may be slippery.
up alarm.
31 1133533 1 Operator’s Instruction: Pull and
25 9790.614296 1 Operator’s Instruction: The hold lever while lowering body
hydraulic system on this vehicle service lift.
is equipped with an automatic 32 9090.614583 1 Operator’s Instruction: Tag axle
device to protect the system from
must be down prior to unloading.
being operated at too high an
engine speed. 33 9090.614571 2 Danger: PACKER BODY MUST
BE EMPTY and body lift stand
26 9190.614263 3 Danger: The top hopper opening
assembly employed when
and tailgate opening should not
servicing Packer body in the
be used as an entrance or exit to
raised position.
the body.
34 9090.614392 2 Danger: DO NOT go under the
27 9790.614261 1 Danger: Do not enter under body unless safety props are
chassis unless engine or power
used and secured.
units are stopped, ignition keys
removed and lock out 35 9090.614560 1 Danger: Do not climb on ladder
procedures are followed. while body is tilted or truck is in
motion.
28 9190.614271 4 Safety Notice: Before entering
Packer body, or climbing or 36 9090.614559 1 Caution: Use care when climbing
getting under truck to perform on ladder or platform, which may
any work, read and follow OSHA be slippery.
Regulations concerning entry 37 9190.614285 1 Operator’s Instructions: Use only
and working in “CONFINED the side access door as an
SPACE” OSHA 1910.146 AND entrance or exit to the body.
“LOCKOUT/TAGOUT” OSHA
1910.147. 38 9090.614547 1 Danger: Right side operation for
refuse collection ONLY!
29 9790.614274 1 Warning: Keep access door
closed when ejector panel is in 39 9790.614284 1 Operator’s Instructions: Rated
operation and in motion. lifting capacity
40 9090.602690 1 PowerPak

Front Loader 20 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
No. Part Number Qty. Description
41 9090.612453 1 Prevent damage to overhead
objects!
42 9190.614270 1 Warning: Do not use as a step.
43 9090.614448 2 Caution: DO NOT open unless
system Is shut off and lockout
procedures are followed.
44 9790.614338 1 Danger: Do not use this refuse
collection vehicle to tow other
equipment.
45 1107478 3 Operator’s Instruction: Release
body hold down bolts before
attempting to raise body.
46 1108425 1 Operator’s Instruction:
1. Open the tailgate.
47 1109764 1 Operator’s Instruction: Pump will
fail if supply from hydraulic
reservoir is shutoff and truck is
operated.
48 1225787 2 Danger: Use tailgate props (if
installed on unit), steel saw
horses, overhead chains, jack
stands, forklifts, or similar
devices to to support the tailgate
whenever performing
maintenance with the tailgate
open.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 21 Front Loader
SAFETY
4.1 Safety Decal Locations

36 35 26 34 33 6 28 4 26

7 48 28 45 37 5 3 43

Figure 1

Front Loader 22 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
26 4 28 29 5 8 33

11 43 10 3 45 9 12 6 34 45 28 48 7

47

31

Figure 2

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 23 Front Loader
SAFETY

30

30
13 21
14 22
15 23
16 24
38 17 25
18 32
19 39
20 40
41
2

42 7 44 46 27

Figure 3

Front Loader 24 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY
4.2 Safety Decal Identification
2
1

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 25 Front Loader
SAFETY

3 4

Front Loader 26 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

5 6

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 27 Front Loader
SAFETY

7 8

Front Loader 28 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

9 10

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 29 Front Loader
SAFETY

11 12

Front Loader 30 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

13 14

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 31 Front Loader
SAFETY

15 16

Front Loader 32 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

17 18

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 33 Front Loader
SAFETY

19 20

Front Loader 34 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

21 22

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 35 Front Loader
SAFETY

23 24

Front Loader 36 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

25 26

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 37 Front Loader
SAFETY

27 28

Front Loader 38 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

29 30

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 39 Front Loader
SAFETY

31 32

Front Loader 40 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

33 34

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 41 Front Loader
SAFETY

35 36

Front Loader 42 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

37 38

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 43 Front Loader
SAFETY

39 40

Front Loader 44 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

41 42

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 45 Front Loader
SAFETY

43 44

Front Loader 46 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 SAFETY

45 46

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 47 Front Loader
SAFETY

47 48

Front Loader 48 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 GENERAL
1.0 IDENTIFICATION PLATE
A McNeilus Truck and Manufacturing, Inc. identification plate To serve you better, please fill out the following information and
(Figure 1, 1) is located on the left front side of the body. The have it ready when calling McNeilus Truck and Manufacturing,
identification plate contains the Model Number and Serial Inc. for parts or product information:
Number of your system.
Date of Purchase:

McNeilus Branch:

Model Number of Packer:

Serial Number of Packer:

1 VIN Number of Vehicle*
Figure 1
* Refer to chassis manufacturer literature for location.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 49 Front Loader
GENERAL
2.0 INCOMPLETE VEHICLE DOCUMENT DECAL

NOTE
The location of the Incomplete Vehicle Document
decal may vary.

The Incomplete Vehicle Document decal (Figure 2, 1)

documents the axle load and tire ratings as it left the McNeilus
production line. This decal is located inside the cab, and may
be placed on the driver’s door jam or the seat riser. 2 3 7 8 4 5
This decal includes information such as the gross vehicle
weight (Figure 2, 2), chassis manufacturer (Figure 2, 3),
chassis build date (Figure 2, 4), vehicle (chassis) ID number
(Figure 2, 5), maximum rated weight per axle (Figure 2, 6),
tire and rim size (Figure 2, 7), tire pressure specifications
(Figure 2, 8), and the Packer build date (Figure 2, 9).

6 1 9
Figure 2

Front Loader 50 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 GENERAL
3.0 EXTERIOR SYSTEMS ARRANGEMENT
3.1 Street Side View
5 1

6
3

4 3 2
Figure 3

Ref. No. System Description

1 Cab Control Box and Joystick
2 Fork Assembly
3 Arm Assembly
4 Pack and Sweep
5 Top Door
6 Tailgate

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 51 Front Loader
GENERAL
3.2 Curb Side View

8
7

9 10 11
Figure 4

Ref. No. System Description

7 Body
8 Hopper
9 Side Access Door
10 Hydraulic Oil Reservoir
11 Service Lift Cylinders (OPTIONAL)

Front Loader 52 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1.0 INSTRUMENTS AND CONTROLS
The following figures and tables identify and describe the
controls used on this equipment. Not all of the instruments and
controls shown here are on your equipment. Items covering
various models and options are illustrated.
To make sure you understand proper operating procedures,
read this section and carefully practice with the controls and
instruments to learn how to safely operate the equipment.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 53 Front Loader
OPERATION
1.1 CAB CONTROLS
The in-cab controls consist of a control box (Figure 1, 1). 1

No. Position Normal Use or Reading

1 Control Box Controls Packer functions, lights and
options.

Figure 1

Front Loader 54 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1.2 Control Box
The control box (Figure 2) contains the E-STOP (emergency
stop) button, rocker switches for the Packer functions, lights, 3 4
pump, options, and the LOCKOUT switch.

No. Position Normal Use Or Reading

1 E-STOP Disables all Hydraulic, Pneumatic and
Button Electric Functions.
2 PACK & SWEEP Automatically performs the Pack and Sweep
Button Functions. 6
3 LOCKOUT Disables all Hydraulic, Pneumatic and
Toggle Switch Electric Functions (located on back side of
the control box). 5 OVER
HEIGHT
ACCESS
DOOR
OPEN
ARMS
ABOVE
BODY
®

4 FUSE BLOCK Contains 16 fuses. BODY

PUMP BODY TOP DOOR TAILGATE TAILGATE
ON UP CLOSE TOP COVER OPEN
80 100 80 100

5 TAG AXLE Indicates air pressure when tag axle is 60

40
psi 120

140
60
40
psi 120

140
2
Pressure Gauge lowered.
20 20
160 160
® ®

(OPTIONAL) AUTO
BODY
DOWN
OPEN ACTIVATE TAILGATE
CLOSE
PACK/

6 PUSHER AXLE Indicates air pressure when pusher axle is 1 SWEEP

FORKS
WIDEN
TAG
UP
PUSHER
UP
OUTSIDE
CONTROLS

Pressure Gauge lowered.

(OPTIONAL)
FORKS DOWN DOWN
RET EX NARROW

ARMS OVER HOPPER REAR SIDE

EXTEND STREET BODY SPARE STROBE LIGHTS LIGHTS LIGHTS

RETRACT CURB OVERRIDE

Figure 2

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 55 Front Loader
OPERATION
1.2.1 Rocker Switch Functions No. Switch Normal Use or Reading
Accessories and Packer functions and some options are 9 REAR LIGHT Select top of rocker switch to activate rear
operated by rocker switches on the top of the control box. Rocker Switch lights. Light in rocker switch indicates rear
Accessories vary depending on your model. (OPTIONAL) lights are ON.
Select bottom of rocker switch to turn rear
No. Switch Normal Use or Reading lights OFF.

1 PUMP Select ON to activate Hydraulic Functions. 10 HOPPER Select top of rocker switch to activate hopper
Rocker Switch Select OFF to disable Hydraulic Functions. LIGHT lights. Light in rocker switch indicates
Rocker Switch hopper lights are ON.
2 BODY Press and hold RAISE to raise body. (OPTIONAL) Select bottom of rocker switch to turn hopper
Rocker Switch Press and hold LOWER to lower body. lights OFF.
(OPTIONAL)
11 STROBE LIGHT Select top of rocker switch to activate strobe
3 TOP DOOR Press and hold OPEN to open top door. Rocker Switch lights. Light in rocker switch indicates strobe
Rocker Switch Press and hold CLOSE to close top door. (OPTIONAL) lights are ON.
4 ACTIVATE Press and hold ACTIVATE to enable Top Select bottom of rocker switch to turn strobe
Rocker Switch Door, Tailgate or Body Lift Functions lights OFF.
5 TAILGATE Press and hold OPEN to open tailgate. 12 ARM Press and hold to override interlock to
Rocker Switch Press and hold CLOSE to close tailgate. OVERBODY operate the pack and sweep when arms are
OVERRIDE above body.
6 PUSHER AXLE Press and hold UP to raise pusher axle. Rocker Switch
Rocker Switch Press and hold DOWN to lower pusher axle.
(OPTIONAL) 13 CURB/STREET Select CURB to activate curb side cab
Rocker Switch controls. Select STREET to activate street
7 OUTSIDE Select top of rocker switch to enable outside (OPTIONAL) side cab controls.
CONTROLS controls. Light in rocker switch indicates
Rocker Switch outside controls are enabled. 14 EXTEND/ Press and hold EXTEND to extend pack and
(OPTIONAL) Select bottom of rocker switch to disable RETRACT sweep.
outside controls. Rocker Switch Press and RETRACT to retract pack and
sweep.
8 SIDE LIGHT Select top of rocker switch to activate side
Rocker Switch lights. Light in rocker switch indicates side 15 FORKS WIDEN/ Press and hold FORKS WIDEN to increase
(OPTIONAL) lights are ON. NARROW width between forks.
Select bottom of rocker switch to turn side Rocker Switch Press and hold FORKS NARROW to
lights OFF. (OPTIONAL) decrease width between forks.

Front Loader 56 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
No. Switch Normal Use or Reading 1 2 3 4 5
16 TAG AXLE Press and hold UP to raise tag axle.
Rocker Switch Press and hold DOWN to lower tag axle.
(OPTIONAL) OVER
HEIGHT
ACCESS
DOOR
OPEN
ARMS
ABOVE
BODY
®

16 80 100 80 100
PUMP
ON
BODY
UP
TOP DOOR
CLOSE
BODY
TAILGATE
TOP COVER
TAILGATE
OPEN
60
40

20
psi 120

140
60
40

20
psi 120

140
6
160 160
® ®

AUTO
PACK/
BODY
DOWN
OPEN ACTIVATE TAILGATE
CLOSE
7
SWEEP

FORKS TAG PUSHER OUTSIDE

WIDEN UP UP CONTROLS

FORKS DOWN DOWN

RET EX NARROW

15 ARMS OVER HOPPER REAR SIDE

EXTEND STREET BODY SPARE STROBE LIGHTS LIGHTS LIGHTS

14
RETRACT CURB OVERRIDE
8

13 12 11 10 9
Figure 3

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 57 Front Loader
OPERATION
1.2.2 Indicator Light Functions 1 2 3 4 5 6
The indicator lights are used to display the status of various
functions. OVER
ACCESS
DOOR
ARMS
ABOVE ®
HEIGHT OPEN BODY

No. Light Normal Use or Reading PUMP BODY TOP DOOR

BODY
TAILGATE TAILGATE
ON UP CLOSE TOP COVER OPEN
80 100 80 100

1 OVER HEIGHT Light indicates that both fork and arm

60 60
psi 120 psi 120
40 40

20 140 20 140

Indicator Light assemblies are NOT fully raised when the 160
®
160
®

arm assembly is raised above the body. AUTO

PACK/
BODY
DOWN
OPEN ACTIVATE TAILGATE
CLOSE
SWEEP

2 ACCESS DOOR Light indicates when access door is not in FORKS

WIDEN
TAG
UP
PUSHER
UP
OUTSIDE
CONTROLS

OPEN CLOSED position.

Indicator Light
3 ARMS ABOVE Light indicates when arm assembly is raised 7 RET EX
FORKS
NARROW
DOWN DOWN

8
BODY above body. EXTEND STREET
ARMS OVER
BODY SPARE STROBE
HOPPER
LIGHTS
REAR
LIGHTS
SIDE
LIGHTS

Indicator Light
4 BODY UP Light indicates when body is not lowered to
Indicator Light HOME position.
RETRACT CURB OVERRIDE

5 TOP DOOR Light indicates when top door is not in OPEN

CLOSED position.
Indicator Light
6 TAILGATE Light indicates when tailgate is not in
OPEN CLOSED position. Figure 4
Indicator Light
7 RETRACT Light indicates when pack and sweep is
Indicator Light retracted in HOME position.
8 EXTEND Light indicates when pack and sweep is
Indicator Light extended in EXTEND position.

Front Loader 58 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1.2.3 Fuse Block 1 2
The fuse block protects the control box from an overloaded
condition. Fuses 1 through 8 are controlled by the ignition 15
1
2 15
switch. Fuses 9 through 12 are controlled by the E-STOP. 3 15
3
4
15 4
Fuses 13 and 14 are controlled by the battery switch. Fuse 5 15
5
6 15
6
7
positions 15 and 16 are not used. 15 8 15

7 15
9
10 5 8
11
No. Amp Description 9 5
13
12 5
10
25 14
25
1 15 Spare 11 15
16
12
2 15 Spare 13 14
3 15 Strobe
4 15 Rear Lights
ACCESS ARMS
OVER DOOR ABOVE ®

5 15 Side Lights HEIGHT OPEN BODY

6 15 Hopper Lights 80 100 80 100

PUMP
ON
BODY
UP
TOP DOOR
CLOSE
BODY
TAILGATE
TOP COVER
TAILGATE
OPEN
60 60
psi 120 psi 120

7 15 Spare
40 40

20 140 20 140
160 160
® ®

8 15 Residential / Prox Power AUTO

BODY
DOWN
OPEN ACTIVATE TAILGATE
CLOSE
PACK/
SWEEP

9 15 Command Zone FORKS

WIDEN
TAG
UP
PUSHER
UP
OUTSIDE
CONTROLS

10 5 Top Door
11 5 Outside Controls, Pump On, Curb/Street, RET EX
FORKS
NARROW
DOWN DOWN

Joystick, Pusher, Tag EXTEND STREET

ARMS OVER
BODY SPARE STROBE
HOPPER
LIGHTS
REAR
LIGHTS
SIDE
LIGHTS

12 5 Curb/Street Solenoid
13 25 Battery RETRACT CURB OVERRIDE

14 25 Battery

Figure 5

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 59 Front Loader
OPERATION
1.3 Arm and Fork Controls 1.3.1 Joystick Control
There are two types of controls for the Arm and Fork The single lever joystick (Figure 6) controls the movement of
Functions. A joystick is available that enables the same control both the arm and fork assemblies.
to operate both the Arm and Fork Functions. The second type
The joystick is spring loaded and will automatically return to the
of control is separate control levers for the Arm and Fork
middle (neutral) position when released.
Functions.
Pull the joystick BACK (Figure 6, 1) to the raise arm assembly.

! DANGER Push the joystick FORWARD (Figure 6, 2) to the lower arm

assembly.
Be sure people are at least 20 feet (6 meters)
away from all areas of the body. Push the joystick AWAY (Figure 6, 3) to lower the fork
assembly.
Serious personal injury or death may occur.
Pull the joystick TOWARDS (Figure 6, 4) to raise the fork
assembly.
! DANGER
Make sure the area above the vehicle is clear of
objects and power lines before raising the arm
and fork assemblies.
Serious personal injury or death may occur.

! CAUTION
Use caution when raising the arm assembly with
a container.

Front Loader 60 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION

4 3

Figure 6

(Figure represents view from street side in chassis cab)

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 61 Front Loader
OPERATION
1.3.2 Dual Lever Controls
2
The Dual Lever controls consist of two separate levers. One 3
lever controls the movement of the arm assembly. The other
lever controls the movement of the fork assembly.
The control levers are spring loaded and will automatically
return to the middle (neutral) position when released.
Pull the corresponding control lever BACK (Figure 7, 1) to 1
raise the arm assembly. 4
Push the corresponding control lever FORWARD (Figure 7, 2)
to lower the arm assembly.
Push the corresponding control lever FORWARD (Figure 7, 3)
to lower the fork assembly.
Pull the corresponding control lever BACK (Figure 7, 4) to
raise the fork assembly.

Figure 7

(Figure represents view from street side in chassis cab)

Front Loader 62 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1.4 Auto-Level Controls (OPTIONAL) 1 2
The Auto-Level controls consist of a control lever (Figure 8, 1)
and a toggle switch (Figure 8, 2) located in the cab. With the
Auto-Level Function, the fork assembly is automatically rotated
when the arm assembly is raised or lowered. The fork
assembly is rotated to avoid interference with the body canopy.
The control lever controls the automatic raising and lowering of
the arm assembly
Pull the control lever BACK to automatically raise the arm
assembly.
Push the control lever FORWARD to automatically lower the
arm assembly.
The fork assembly can be adjusted up and down manually if
needed by using the toggle switch.
Figure 8
Push the toggle switch DOWN to lower the fork assembly.
Push the toggle switch UP to raise the fork assembly.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 63 Front Loader
OPERATION
1.5 Outside Control Box (OPTIONAL)
The Arm, Fork, Pack and Sweep, Throttle Advance and
E-STOP Functions can be operated from the outside control
box. The OUTSIDE CONTROL rocker switch on the cab
control box must be ON to enable the outside controls.

No. Position Normal Use or Reading

1 ARM Pull control lever UP to raise arm assembly.
Control Lever Push control lever DOWN to lower arm
assembly.
2 FORK Pull control lever UP to raise fork assembly. 6 1 2
Control Lever Push control lever DOWN to lower fork
assembly. 5
3 THROTTLE Push and hold button to increase chassis
ADVANCE engine RPM. PACK & SWEEP ARMS FORKS
RAISE RAISE
Button
4 E-STOP Disables all Hydraulic, Pneumatic and
Button Electric Functions.
5 PACK & Press and hold button to activate automatic
SWEEP cycling of Pack and Sweep Function. 4
Button
6 FORK Press and hold toggle switch RIGHT to
Toggle Switch narrow forks.
(OPTIONAL) Press and hold toggle switch LEFT to widen
forks. EMERGENCY STOP

3 THROTTLE
ADVANCE
LOWER LOWER

Figure 9

Front Loader 64 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
2.0 RESIDENTIAL ATTACHMENTS
The residential application for a front loader requires the use of routed down the curb side arm assembly with the connections
a carry can. The carry can is mounted and secured to the fork (Figure 10, 1) mounted on the fork assembly. The routing of
assembly. When the carry can is equipped with a cart tipper or hydraulic and electrical lines from the connections to the carry
automated arm the required hydraulic and electrical lines are will vary with different models and manufactures of carry cans.

Figure 10

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 65 Front Loader
OPERATION
The most common manufactures for carry cans used are listed
below. Each manufacturer can provide specific operation, parts
and service information for their models of carry can.

Bayne Machine Works, Inc.

208 Fairforest Way
Greenville, SC 29607
Ph: (864) 288-3877
Fax: (864) 458-7519
www.baynethinline.com

The Curotto-Can, Inc.

850 Knight Street
Sonoma, Ca 95476
Ph: (707) 939-2802
Fax: (413) 521-6644
www.curottocan.com

Perkins Manufacturing Company

423 East Elm Avenue
LaGrange, Il 60525
Ph: (708) 482-9500
Fax: (708) 354-5878
www.perkinsmfg.com

Front Loader 66 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
3.0 OPTIONAL EQUIPMENT
3.1 Pusher or Tag Axle

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

A tag axle (Figure 11, 1) is mounted behind the rear drive axle.
A pusher axle (Figure 11, 2) is mounted in front of the rear
drive axle. They are considered auxiliary axles. The pusher or
tag axle is raised and lowered by a rocker switch located on the 2 1
cab control box.
Figure 11
The pusher or tag axle down force is controlled by regulated air
pressure to the axle suspension air bags. The air pressure is
shown on the gauge located in the cab control box or the
gauge may also be mounted outside the cab.
The regulated air pressure is preset at the factory. If the air
pressure is incorrect for the load the truck is carrying, the air
pressure may require adjustment. To change the air pressure
of the pusher axle refer to the service manual for your vehicle.
Always follow your companies policies and procedures when
adjusting the air pressure. If you have any questions call your
McNeilus Branch. (See “REGIONAL BRANCH/FACTORY
SERVICE/PARTS LOCATION” on page 3) for the branch
nearest you.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 67 Front Loader
OPERATION

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.

3.1.1 Lowering the Pusher or Tag Axle

(1) Bring the truck to a complete stop and apply the
parking brake (refer to the chassis manufacturers
procedure).
(2) Press DOWN on the PUSHER rocker switch.
(3) Resume normal operations.

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

3.1.2 Raising the Pusher or Tag Axle

(1) Bring the truck to a complete stop and apply the
parking brake (refer to the chassis manufacturers
procedure).
(2) Press UP on the PUSHER rocker switch.
(3) Resume normal operations.

Front Loader 68 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
4.0 CONTROL FUNCTIONS
4.1 E-STOP (Emergency Stop) Function 4.1.2 E-STOP Buttons Outside Controls

NOTE NOTE
The E-STOP button remains in a locked down All E-STOP buttons must be in the UP position
position until it is manually released. before the Packer functions can be restored.

Press any of the E-STOP buttons (Figure 12) to

IMMEDIATELY DISABLE Packer functions. NOTE
The E-STOP button is a safety function. If Packer functions are not operational, reset the
controls by pressing DOWN and releasing ALL of
Pressing the red E-STOP button disables all Packer electrical, the E-STOP buttons.
pneumatic, and hydraulic functions.
Two types of E-STOP buttons have been used. The ‘Pull to Pull up or rotate the E-STOP button in a clockwise direction as
Release’ type (Figure 12, 1) is released by pulling up on the E- indicated by the arrows on the button to release the outside
STOP. The ‘Twist to Release’ type (Figure 12, 2) must first be control E-STOP buttons (Figure 13, 2).
turned clockwise before pulling up on the E-STOP button to 2
1
release. All E-STOP button(s) must be released to restore
power to the Packer electrical circuits:

4.1.1 E-STOP Button In-Cab Control Box

Pull up or rotate the E-STOP button in a clockwise direction as
indicated by the arrows on the button to release the in-cab
control box Estop button (Figure 13, 1).

Figure 12

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 69 Front Loader
OPERATION

ACCESS ARMS
OVER DOOR ABOVE ®
HEIGHT OPEN BODY

PACK & SWEEP ARMS FORKS

RAISE RAISE BODY
PUMP BODY TOP DOOR TAILGATE TAILGATE
ON UP CLOSE TOP COVER OPEN
80 100 80 100
60 60
psi 120 psi 120
40 40

20 140 20 140
160 160
® ®

2 AUTO
PACK/
SWEEP
BODY
DOWN

FORKS
WIDEN
OPEN

TAG
UP
ACTIVATE

PUSHER
UP
TAILGATE
CLOSE

OUTSIDE
CONTROLS

1 RET EX

ARMS OVER
FORKS
NARROW
DOWN

HOPPER
DOWN

REAR SIDE
EXTEND STREET BODY SPARE STROBE LIGHTS LIGHTS LIGHTS

EMERGENCY STOP
RETRACT CURB OVERRIDE

THROTTLE LOWER LOWER

ADVANCE

Figure 13

Front Loader 70 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
4.2 Pack and Sweep Functions 4.2.1 Automatic Cycling of Pack and Sweep
The Pack and Sweep Functions are controlled by two switches
located on the cab control box. Automatic cycling of the Pack CONDITIONS
and Sweep Functions is controlled by the PACK & SWEEP • Tailgate OPEN indicator light must be OFF.
button. Manual cycling of the Pack and Sweep Functions is
controlled by the EXTEND/RETRACT rocker switch. • Arms ABOVE BODY indicator light must be OFF.
• Top Door CLOSED indicator light must be OFF.

! DANGER • Engine speed must be below 1600 rpm.

Be sure people are at least 20 feet (6 meters) Press and hold PACK & SWEEP button (for one second) to
away from all areas of the body. activate automatic cycling of the Pack and Sweep Functions.
When activated, the pack and sweep extends from the HOME
Serious personal injury or death may occur. position (Figure 14, 1) into the hopper until it reaches the
EXTEND position (Figure 14, 2). The pack and sweep then
reverses direction and retracts until it returns to the HOME
position.

NOTE
The automatic pack and sweep cycle can be
interrupted by pressing any of the E-STOP
buttons.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 71 Front Loader
OPERATION
1 4.2.2 Manual Cycling of Pack and Sweep

CONDITIONS
(Applies to Extend Function Only)
• Tailgate OPEN indicator light must be OFF.
• Arms ABOVE BODY indicator light must be OFF.
• Top Door CLOSED indicator light must be OFF.
• Engine speed must be below 1600 rpm.
2
Manual cycling of the Pack and Sweep Functions is controlled
by the EXTEND/RETRACT rocker switch located on the cab
control box. With the tailgate CLOSED, the pack and sweep
can only travel to the EXTEND position (Figure 14, 2).
Press and hold EXTEND located on the EXTEND/RETRACT
rocker switch to manually control the extend movement of the
pack and sweep. When the rocker switch is released, the pack
and sweep will stop at its current position.
Figure 14 Press and hold RETRACT located on the EXTEND/RETRACT
rocker switch to retract the pack and sweep. The pack and
sweep will retract to the HOME position (Figure 14, 1). When
RETRACT is released, the pack and sweep will stop at its
current position.

Front Loader 72 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
4.2.3 Manual Cycling with Tailgate Open

CONDITION
(Applies to Extend Function Only)
• Arms ABOVE BODY indicator light must be OFF.
• Top Door CLOSED indicator light must be OFF.
• Engine speed must be below 1600 rpm.
1
When the tailgate is OPEN, the EXTEND/RETRACT rocker
switch controls the Pack and Sweep Functions in the same way
with exception that the pack and sweep can travel into the
body.
With the tailgate OPEN, the pack and sweep will extend past
the EXTEND position. The distance that the pack and sweep
extends into the body is determined by holding EXTEND on
the EXTEND/RETRACT rocker switch.
While holding EXTEND on the rocker switch, the pack and Figure 15
sweep (Figure 15, 1) will extend to the rear of the body to eject
the load.
Press and hold RETRACT on the EXTEND/RETRACT rocker
switch to retract the pack and sweep to the HOME position.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 73 Front Loader
OPERATION
4.3 Arm Functions CONDITIONS
The Arm Functions are controlled from the chassis cab or • Top door CLOSED indicator light must be OFF.
outside control box.
• Pack and sweep RETRACT indicator light must be
ON.
! DANGER • Engine speed must be below 1600 rpm.
Be sure people are at least 20 feet (6 meters) Use the arm controls to raise the arm assembly (Figure 16, 1).
away from all areas of the body. The ARM ABOVE BODY indicator light will turn on once the
Serious personal injury or death may occur. arm assembly is above the body (cab).
Use the arm controls to lower the arm assembly (Figure 16, 2).

! DANGER 1
Make sure the area above the vehicle is clear of
objects and power lines before raising the arm
and fork assemblies.
Serious personal injury or death may occur.

! CAUTION 2
Use caution when raising the arm assembly with
a container.

Figure 16

Front Loader 74 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
4.4 Fork Functions
The Fork Functions are controlled from the chassis cab or
outside control box.

! DANGER
Be sure people are at least 20 feet (6 meters)
away from all areas of the body. 2
Serious personal injury or death may occur.
1

! DANGER
Make sure the area above the vehicle is clear of
objects and power lines before raising the arm
and fork assemblies.
Serious personal injury or death may occur. Figure 17

CONDITION
• Engine speed must be below 1600 rpm.
Use the fork controls to raise the fork assembly (Figure 17, 1).
Use the fork controls to lower the fork assembly (Figure 17, 2).

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 75 Front Loader
OPERATION
4.5 Auto-Level Functions (OPTIONAL) CONDITIONS
The Auto-Level Function are controlled by a lever and a toggle • Top Door CLOSED indicator light must be OFF.
switch located in the cab. With the Auto-Level Function, the
• Pack and Sweep RETRACT indicator light must be
fork assembly is automatically rotated when the arm assembly
ON.
is raised or lowered. The fork assembly is rotated to avoid
interference with the body canopy. • Engine speed must be below 1600 rpm.

! DANGER
Be sure people are at least 20 feet (6 meters)
away from all areas of the body.
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
and fork assemblies.
Serious personal injury or death may occur.

! CAUTION
Use caution when raising the arm assembly with
a container.

Front Loader 76 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
After the forks are positioned in the container pull back on the 1
control lever. The Auto-Level Function will start and continue
as long as the control lever is pulled back.
(1) The arm assembly will begin to raise
(Figure 17, 1) with the container.
(2) As the arm assembly raises above the body
(cab), the fork assembly will automatically lower
to a level position (Figure 17, 2). The ARM 2
ABOVE BODY indicator light will turn on.
(3) The arm assembly will continue to raise until the
arm assembly reaches the arm stops.
(4) The fork assembly will start to raise until the fork
assembly is fully raised and the container is in the
DUMP position (Figure 17, 3).
(5) After the container is emptied, push the control
lever FORWARD and the fork assembly will begin
to lower until the container is out of the hopper.
3
(6) After the fork assembly stops, the arm assembly
will begin to lower.
(7) As the container nears the ground, pull back on
the control lever to stop the container.
(8) Use the toggle switch to adjust the container level
before removing the forks from the container.

Figure 18

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 77 Front Loader
OPERATION
4.6 Tailgate Functions 4.6.1 Open Tailgate
The Tailgate Functions are controlled by the ACTIVATE rocker Press and hold the ACTIVATE rocker switch and OPEN on the
switch and the TAILGATE rocker switch located on the cab TAILGATE rocker switch at the same time to open the tailgate
control box. (Figure 19, 1).

4.6.2 Close Tailgate

! DANGER Press and hold the ACTIVATE rocker switch and CLOSE on
Be sure people are at least 20 feet (6 meters) the TAILGATE rocker switch at the same time to close the
away from all areas of the body. tailgate (Figure 19, 2).
Serious personal injury or death may occur. NOTE
The backup alarm sounds when the tailgate is
! DANGER opening and remains on until the tailgate is
closed.
Make sure the area above the vehicle is clear of The alarm does not sound if the ignition switch is
objects and power lines before raising the body OFF or any of the E-STOP buttons are pressed
or opening the tailgate. down.
Serious personal injury or death may occur.

CONDITION
• Engine speed must be below 1600 rpm.

Front Loader 78 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1

Figure 19

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 79 Front Loader
OPERATION
4.7 Top Door Functions 1
The Top Door Functions are controlled by the TOP DOOR
rocker switch on the cab control box.

! DANGER
Be sure people are at least 20 feet (6 meters)
away from all areas of the body.
Serious personal injury or death may occur.
2
CONDITION
• Engine speed must be below 1600 rpm.

4.7.1 Open Top Door

Press and hold the ACTIVATE rocker switch and OPEN on the
TOP DOOR rocker switch at the same time to open the top
door (Figure 20, 1).

4.7.2 Close Top Door

Figure 20
Press and hold the ACTIVATE rocker switch and CLOSE on
the TOP DOOR rocker switch at the same time to close the top
door (Figure 20, 2).

Front Loader 80 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
4.8 Body Raise Functions - Dump Model 4.8.1 Raise Body
The Body Raise Functions are controlled by the BODY rocker (1) Open the tailgate.
switch located on the cab control box. (2) Press and hold the ACTIVATE rocker switch and
BODY rocker switch at the same time to raise the

!
body (Figure 21, 1). Both the BODY UP indicator
DANGER light and tailgate alarm will be ON whenever the
body is not in the HOME position.
Be sure people are at least 20 feet (6 meters)
away from all areas of the body. 4.8.2 Lower Body
Serious personal injury or death may occur. (1) Press and hold the ACTIVATE rocker switch and
BODY rocker switch at the same time to lower the

!
body. The BODY UP light will be OFF when the
DANGER body is in the HOME position.
Make sure the area above the vehicle is clear of (2) Close the tailgate
objects and power lines before raising the body
or opening the tailgate. 1
Serious personal injury or death may occur.

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

CONDITION Figure 21
• Engine speed must be below 1600 rpm.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 81 Front Loader
OPERATION
5.0 OPERATING PROCEDURES

! DANGER ! CAUTION
Be sure people are at least 20 feet (6 meters) If you detect a problem with any control
away from all areas of the Packer. functions, it must be repaired immediately. DO
Serious personal injury or death may occur. NOT operate the Packer with malfunctioning
controls.

NOTE (1) Cycle through each of the following operations:

Turn the pump ON and idle the truck for a (a) Pack and Sweep Functions - Cycle three (3)
minimum of five minutes before operating the times.
hydraulic functions when the air temperature is (b) Tailgate Functions - Cycle one (1) time.
50° F (10° C) or below. (c) Top Door Functions - Cycle three (3) times.
5.1 Start-Up Procedure (d) Fork and Arm Functions - Cycle ten (10)
times.
Before starting the VEHICLE, make certain that: (e) Body Raise Function (OPTIONAL) - Cycle
(1) Battery switch is ON. one (1) time.
(2) Daily checks have been completed and verified. (2) After completing the cycle tests, inspect the
Packer for any hydraulic leaks. If leaks are
5.2 Warm-Up Procedure detected, correct them BEFORE the Packer is
placed into actual operation.
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 fluid is up to
operating temperature and is present throughout the system.

Front Loader 82 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
5.3 Traveling Procedure - Standard
Before beginning travel to the next site, be sure that all 1
hydraulic functions are in their HOME positions. This means
that the:
(1) Body is fully lowered.
(2) Tailgate is fully closed.
(3) The arms and forks must be positioned properly
for travel. Figure 22
(4) The arms and forks can either be positioned with
the arms lowered and forks raised (Figure 22, 1),
with the forks raised and arms raised above the 2
windsheild (Figure 23, 2), or with the forks tucked
and arms fully raised (Figure 24, 3).
(5) Turn PUMP rocker switch OFF to disable
hydraulic functions.
(6) Turn strobe light ON.
Figure 23

Figure 24

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 83 Front Loader
OPERATION
5.4 Traveling Procedure - Residential
Before beginning travel to the next site, be sure that all
hydraulic functions are in their HOME positions. This means 1
that the:
(1) Body is fully lowered.
(2) Tailgate is fully closed.
(3) The arms and forks must be positioned properly
for travel. Figure 25
(4) For a residential application equipped with a
carry can the arms can either be positioned low 2
(Figure 25, 1) or with the arms fully raised with
the carry can inserted into the hopper
(Figure 26, 2).
(5) Turn PUMP rocker switch OFF to disable
hydraulic functions.
(6) Turn strobe light ON.

Figure 26

Front Loader 84 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
5.5 Preparation Before Starting Route 5.6 Refuse Loading Procedure
(1) Turn LOCKOUT toggle switch ON.
(2) If necessary, turn rear and side lights ON to ! DANGER
enhance vision.
Be sure people are at least 20 feet (6 meters)
(3) Turn pump rocker switch ON. away from all areas of the Packer.
(4) Activate all E-STOP buttons. Serious personal injury or death may occur.

(1) Make certain the top door is OPEN and the pack
and sweep is in the HOME position.
(2) Lower the fork and arm assemblies into position
to lift the container.
(3) Position the vehicle in line with the container, and
drive the vehicle forward until the forks are all the
way through the container fork pockets.
(4) Adjust the fork assembly so the container is level.

! CAUTION
Use caution when raising the arm assembly with
a container.

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

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 85 Front Loader
OPERATION
(5) Raise the arm assembly until the fork assembly is
visible at the top of the windshield.
(6) Lower fork assembly to level the container.
(7) Continue to raise the arm assembly until arm
assembly reaches the arm stops.
(8) Completely raise fork assembly to empty
container.
(9) Lower the fork assembly until the container has
cleared the hopper and the forks are vertical.
(10) Lower the arm assembly to return the container
to the ground.
(11) Adjust the fork assembly as needed to allow the
vehicle to back away from the container.
(12) Place the fork and arm assemblies in the travel
position.

! CAUTION
Do not operate ejector with container in hopper.
Serious damage may result to the Packer.

(13) Execute a Pack and Sweep Function.

(14) Close the top door.
(15) Travel to the next pickup site.
Figure 27

Front Loader 86 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
5.7 Refuse Empty Procedure - Full Eject Models (8) Raise the tag axle, if equipped.

! DANGER
Be sure people are at least 20 feet (6 meters)
away from all areas of the body.
Serious personal injury or death may occur.

! DANGER 1
Make sure the area above the vehicle is clear of
objects and power lines before raising the
tailgate.
Serious personal injury or death may occur.

(1) Position rear of the Packer as appropriate.

(2) Verify the top door is open, the fork and arm
assemblies are fully retracted.
(3) If the vehicle is equipped with a tag axle, lower Figure 28
the tag axle.
(4) Open the tailgate fully (Figure 28, 1).
(5) Extend the pack and sweep to the rear
(Figure 28, 2) of the body to eject the load.
(6) Retract the pack and sweep to the HOME
position.
(7) Inspect and clean the tailgate seal and sealing
areas of the body, and then fully close the
tailgate.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 87 Front Loader
OPERATION
5.8 Refuse Empty Procedure - Dump Model (8) Inspect and clean the tailgate seal and sealing
areas of the body, and then fully close the

! DANGER
tailgate.
(9) Raise the tag axle, if equipped.
Be sure people are at least 20 feet (6 meters)
away from all areas of the body.
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 personal injury or death may occur.

(1) Position rear of the Packer as appropriate.

(2) Verify the top door is open, the fork and arm
assemblies are fully retracted.
(3) Open the tailgate fully (Figure 29, 1).
(4) Raise the body fully (Figure 29, 2).
(5) Extend the pack and sweep (Figure 29, 3) to
verify that the entire refuse load has been
ejected.
(6) Retract the pack and sweep to the HOME
position.
(7) Lower the body to the HOME position.

Front Loader 88 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 OPERATION
1

Figure 29

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 89 Front Loader
OPERATION
5.9 End-of-Day Checks
At the end of the day, make certain that:
(1) Pack and sweep is fully retracted.
(2) Fork and arm assemblies are fully raised.
(3) Tailgate is fully closed.
(4) Body (OPTIONAL) is fully lowered.
(5) All equipment is properly shut down (see the
Chassis Manual for more information on proper
shut-down procedures for the engine).

Front Loader 90 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 PREVENTIVE MAINTENANCE - PACKER
1.0 PREVENTIVE MAINTENANCE
The unit must be checked or inspected each day or before
each new shift of operation. Report any deficiencies 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 Packer according to
all federal, state, and local laws.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 91 Front Loader
PREVENTIVE MAINTENANCE - PACKER
2.0 PREVENTIVE MAINTENANCE INTERVALS
Performing preventive maintenance on your Packer will prolong The Daily Checks under the Operator group heading identify
the life of its equipment, help prevent expensive downtime and procedures that can be performed by either the operator or
minimize the potential for problems arising on the route. skilled service personnel.
The following Preventive Maintenance Chart summarizes the All intervals listed under the Service group heading must be
requirements to properly maintain your Packer. performed by skilled service personnel. Refer to the product
Service Manual for description of maintenance procedures.
The chart specifies the recommended interval when each item
should be performed. Maintenance procedures are listed under the system of the
Packer that is affected.
Intervals are listed in calendar and hours-of-use increments.
Maintenance should be performed at the increment that occurs
first. SAFETY NOTICE
The preventive maintenance intervals listed under the Service Before entering Packer body read and follow
group heading are the maximum days or hours allowed for OSHA Regulations concerning entry and working
each maintenance procedure. Continue to repeat the in “CONFINED SPACE” OSHA 1910.146 and
maintenance procedures at the listed intervals. “LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
NOTE work to the Packer.
If the Packer is operated more hours per day or Follow all safety instructions in your McNeilus
double shifted, the maintenance interval must be Packer Manual.
adjusted accordingly. Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
The Preventive Maintenance Chart identifies the performing any work to the Packer.
responsibilities to be performed by both the operator and Place magnetic “DANGER” signs on both cab
service personnel. doors.
Some maintenance procedures are listed under both the Failure to do so can result in serious personal
Operator group heading and Service group heading. injury or death.

Front Loader 92 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 PREVENTIVE MAINTENANCE - PACKER
LEGEND Operator Service
R Replace P Perform

rs M

(5 n n s )

)
ou l
ou P

H a
rs

rs

rs
H rs
)
I Inspect L Lubricate

r
0 nu
)

H ed

ou

ou

ou
0 ea
rs

rs

0 al
25 An

50 lly
50 ul
ou

ou

00 u
H

50 Y
s

0 ly

(2 a
(1 hed
ck
T Torque C Clean

( 1 i-

(7 ee
0
(5 ek
H

u
C ily

(1 ily

-A
he

r
e
0
a

Se

An
Sc

Th
W

Bi
D

D
Hydraulic System
Hydraulic Oil Level P P
Hydraulic System and I I
Components
Hydraulic Hoses I I R
Hydraulic Tubes and Pipes I I
Breather Filter I/R R
Return Line Filter R
Hydraulic Oil Test P
HOC Operation Test P
Main Relief Valve Setting P
Hydraulic Oil R1 R2
- Reservoir Drain Plug I / P1 I / P2
- Suction Line Strainer R1 R2
1 Applies to Standard Hydraulic System
2 Applies to OPTIONAL Clean-Fill Hydraulic System

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 93 Front Loader
PREVENTIVE MAINTENANCE - PACKER
LEGEND Operator Service
R Replace P Perform

rs M

(5 n n s )

)
ou l
ou P

H a
rs

rs

rs
H rs
)
I Inspect L Lubricate

r
0 nu
)

H ed

ou

ou

ou
0 a
rs

rs

0 al

e
25 An

50 lly
50 ul
ou

ou

00 u
H

50 Y
s

0 ly

(2 ua
(1 hed
ck
T Torque C Clean

( 1 i-

(7 e
0
(5 ek
H

H
C ily

(1 ily

e
m

-A
he

r
e
0
a

Se

An
Sc

Th
W

Bi
D

D
Electrical System
Lighting System I I
Wire Harness I I
Pneumatic Systems
Air Hoses and Fittings I I
Coalescing Filter P I/R R
Mechanical
Packer Body and I I
Components
Tailgate Seal Condition I I
Tailgate Lock Clearance I
Top Door I
Pack and Sweep Assembly I
Pack and Sweep Track I
Clearance
Arm Assembly I
Fork Assembly I

Front Loader 94 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 PREVENTIVE MAINTENANCE - PACKER
LEGEND Operator Service
R Replace P Perform

rs M

(5 n n s )

)
ou l
ou P

H a
rs

rs

rs
H rs
)
I Inspect L Lubricate

r
0 nu
)

H ed

ou

ou

ou
0 ea
rs

rs

0 al
25 An

50 lly
50 ul
ou

ou

00 u
H

50 Y
s

0 ly

(2 a
(1 hed
ck
T Torque C Clean

( 1 i-

(7 ee
0
(5 ek
H

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C ily

(1 ily

-A
he

r
e
0
a

Se

An
Sc

Th
W

Bi
D

D
Mechanical (Continued)
Pusher Axle Lug Nuts T
Tag Axle Lug Nuts T
Operation
Packer Controls P P
Trash Behind Pack and Sweep I/P I/P
Safety Decals I
Lubrication
Daily L
Scheduled PM L

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 95 Front Loader
PREVENTIVE MAINTENANCE - PACKER
3.0 DAILY CHECKS
3.1 Hydraulic System Check the hydraulic oil level with all hydraulic cylinders in their
fully RETRACTED position.
SAFETY NOTICE 3.1.1.1 Two Sight Gauges

Before entering Packer body read and follow The hydraulic oil must be checked with all the hydraulic
OSHA Regulations concerning entry and working cylinders in the fully RETRACTED position.
in “CONFINED SPACE” OSHA 1910.146 and On a reservoir with two sight gauges, the lower sight gauge
“LOCKOUT/TAGOUT” OSHA 1910.147. (Figure 2, 1) should be completely filled, and the hydraulic oil
Follow OSHA Regulations while performing any should be slightly visible in the bottom half of the upper sight
work to the Packer. gauge (Figure 2, 2).
Follow all safety instructions in your McNeilus
Packer Manual.
2
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

3.1.1 Hydraulic Oil Level

1
• 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. Figure 1

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3.1.1.2 Temperature/Level Sight Gauge (OPTIONAL)
The gauge contains a thermometer which indicates the
temperature of the hydraulic oil in the reservoir.
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 2, 1) the oil level should be halfway between the red 3
line (Figure 2, 2) and the black line (Figure 2, 3) on the sight ºc

80

gauge. 70
60

1 50
40
30
20
10
0
-10

Figure 2

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PREVENTIVE MAINTENANCE - PACKER
3.1.2 Hydraulic System and Components
1
• Daily Checks - The hydraulic system and components are
inspected by the operator or skilled service personnel.
Inspect the hydraulic system and components for leaks and 2
damage. Inspect around all fittings and connections. Look for
any fresh puddles or drips under the Packer.
Ensure that all components are securely mounted and that all
bolts and nuts are in place and secure. 4
Inspect for cracks or other damage to the mounting brackets.

3.1.3 Hydraulic Hoses, Tubes, and Pipes 3

• Daily Checks - The hydraulic hoses , tubes, and pipes are
inspected by the operator or skilled service personnel.
5
Inspect hydraulic hoses, tubes, and pipes for damage and
proper clearance with other components.
The following are examples of hydraulic hose damage to
inspect for:
• Bulging (Figure 3, 1)
• Cracks (Figure 3, 2) 6
• Cuts (Figure 3, 3)
• Abrasion (Figure 3, 4)
• Twisting (Figure 3, 5)
• Bending (Figure 3, 6)
Figure 3

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3.2 Electrical System 3.2.2 Wire Harnesses
• Daily Checks - The wire harnesses are inspected by the
SAFETY NOTICE operator or skilled service personnel.

Before entering Packer body read and follow Inspect the wiring harnesses for damage and proper clearance
OSHA Regulations concerning entry and working with other components.
in “CONFINED SPACE” OSHA 1910.146 and The following are examples of wire harness damage to inspect
“LOCKOUT/TAGOUT” OSHA 1910.147. for:
Follow OSHA Regulations while performing any • Cracks (Figure 4, 1)
work to the Packer.
• Cuts (Figure 4, 2)
Follow all safety instructions in your McNeilus
Packer Manual. • Abrasion (Figure 4, 3)
Shut off truck engine, lock cab doors and keep • Twisting (Figure 4, 4)
key in your pocket before entering body, or
performing any work to the Packer.
1 2
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal 3 4
injury or death.

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 Packer and
chassis are functioning correctly. Replace any burned-out
bulbs with the same type. Figure 4

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PREVENTIVE MAINTENANCE - PACKER
3.3 Pneumatic System 3.3.2 Coalescing Filter
• Daily Checks - The coalescing filter is drained by the operator
SAFETY NOTICE or skilled service personnel.

Before entering Packer body read and follow Locate the drain fitting (Figure 5, 1) on the bottom of the
OSHA Regulations concerning entry and working coalescing filter.
in “CONFINED SPACE” OSHA 1910.146 and
“LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
work to the Packer. FLOW

Follow all safety instructions in your McNeilus

Packer Manual.
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

3.3.1 Pneumatic Lines and Fittings

1
• Daily Checks - The pneumatic lines and fittings are inspected
by the operator or skilled service personnel. Figure 5

Check the pneumatic lines and fittings for leaks, wear, Drain the filter by turning the drain fitting counterclockwise.
abrasion, damage and proper clearance. Ensure that all fittings Turn the drain fitting clockwise after all moisture and
are secure. contaminants have drained from the canister.

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3.4 Mechanical System 3.4.2 Tailgate Seal
• Daily Checks - The tailgate seal is inspected by the operator
SAFETY NOTICE or skilled service personnel.

Before entering Packer body read and follow Inspect the tailgate seal for tears, damage or excessive wear.
OSHA Regulations concerning entry and working Ensure that the seal is fully seated in the tailgate channel.
in “CONFINED SPACE” OSHA 1910.146 and Inspect the mounting straps to ensure they are secure.
“LOCKOUT/TAGOUT” OSHA 1910.147. 3.4.3 Pusher or Tag (Auxiliary) Axle Lug Nuts
Follow OSHA Regulations while performing any
• Weekly Checks - The pusher or tag axle lug nuts must be
work to the Packer.
checked for tightness weekly. Refer to the specifications below
Follow all safety instructions in your McNeilus for the correct torque.
Packer Manual.
• If it is a hub piloted wheel tighten to 450-500 lb - ft. It should be
Shut off truck engine, lock cab doors and keep checked again after the initial 50-100 miles or 24 hours.
key in your pocket before entering body, or
performing any work to the Packer. • If it is a stud piloted wheel tighten to 450-500 lb - ft.
Place magnetic “DANGER” signs on both cab • If it is a open rim and has five or six lug nuts per wheel tighten
doors. to 200-260 lb - ft.
Failure to do so can result in serious personal
injury or death.

3.4.1 Packer Body and Components

• Daily Checks - The Packer body and components are
inspected by the operator or skilled service personnel.
Inspect the body and all components for binding, damage,
loose or missing parts.

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PREVENTIVE MAINTENANCE - PACKER
3.5 Operation 3.5.1 Packer Controls
• Daily Checks - The Packer controls are checked for proper
! DANGER operation by the operator or skilled service personnel.

Be sure people are at least 20 feet (6 meters) Operate all functions to validate they are operational. Verify
away from all areas of the Packer. that all indicator lights and alarms are operational.
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 personal injury or death may occur.

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3.6 Propping the Body for Maintenance 3.6.1 Service Lift (OPTIONAL) – Eject Model
(OPTIONAL) 3.6.1.1 Installing the Body Prop
When performing maintenance of the chassis that requires the (1) Place the fork and arm assemblies in the fully
body to be raised, the following procedure must be followed to RAISED position.
raise and prop the body.

! DANGER
! WARNING
Packer must be disabled by the following steps
Be sure people are at least 20 feet (6 meters) before proceeding.
away from all areas of the Packer.
(1) Place transmssion in NEUTRAL.
Serious personal injury or death may occur.
(2) Apply chassis parking brake.

! DANGER (3) Shut engine OFF.

Make sure the area above the vehicle is clear of (4) Remove chassis ignition key and maintain
objects and power lines before raising the body in personal possession.
or opening the tailgate.
(2) Shut off the engine and disable the Packer
Serious personal injury or death may occur.
functions.

! DANGER
PACKER BODY MUST BE EMPTY and body props
employed when servicing Packer body in the
raised position. Body props are meant to support
only the empty body. Never overload. Failure to
empty body or employ body props may cause
serious personal injury or death.

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PREVENTIVE MAINTENANCE - PACKER
(3) Loosen the nuts (Figure 6, 1) on each side of the
chassis frame. Swing the bolt out of the slot. ! DANGER
Do not climb on ladder while body is tilted or
truck is in motion. Serious personal injury can
occur due to a fall.

NOTE
Tailgate alarm will sound whenever the body is
raised.

(4) Pull the lever (Figure 7, 1) away from the frame

to activate the electric pump. Raise the body all
the way until the cylinders are at the end of their
travel.

1
1

Figure 6

Figure 7

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 PREVENTIVE MAINTENANCE - PACKER
(5) Remove the pins (Figure 8, 1) from each of the (6) Pull the rod (Figure 9, 1) towards the rear of the
props. Pivot the props (Figure 8, 2) around the chassis and hold it.
cylinder rods (Figure 8, 3). (7) Push the lever (Figure 9, 2) towards the chassis
frame and slowly lower the body onto the props
(Figure 9, 2).
2

1 1
Figure 9
Figure 8

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PREVENTIVE MAINTENANCE - PACKER
3.6.1.2 Removing the Body Prop
! DANGER After completing the maintenance on the chassis that required
Verify that the body props are properly positioned the body to be propped, the following procedure must be
around the rods of the cylinders. followed to remove the props and lower the body.
Serious personal injury or death may occur. (1) Turn battery switch ON.
(2) Raise the body as needed to provide the
(8) Apply LOCKOUT/TAGOUT procedure to the necessary clearance to remove the props from
Packer before performing any maintenance around the cylinder rods.
procedures.
(3) Pull the lever (Figure 10, 1) away from the frame
to activate the electric pump.
SAFETY NOTICE
Before entering Packer body read and follow
OSHA Regulations concerning entry and working 1
in “CONFINED SPACE” OSHA 1910.146 and
“LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
work to the Packer.
Follow all safety instructions in your McNeilus
Packer Manual.
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death. Figure 10

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(4) Rotate each prop to the stored position and install
the retaining pin (Figure 11, 1).

Figure 11 Figure 12
(5) Lower the body onto the chassis frame. (7) Completely remove the LOCKOUT/TAGOUT
(6) Install the bolts (Figure 12, 1) into the slots on procedure from the Packer.
both sides of the body. Tighten the nuts.

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PREVENTIVE MAINTENANCE - PACKER
3.7 Propping the Tailgate for Maintenance
When performing maintenance procedures that require the ! DANGER
tailgate to be open, the following procedure must be followed to Stand clear when tailgate is in motion and during
open and prop the tailgate. unloading cycle. Do not stand under or cross
under raised tailgate.
! DANGER Serious personal injury or death may occur.
Whenever the body is elevated or in a raised
position, it must be securely propped or blocked CONDITION
so it cannot fall on anyone.
• Arms and forks must be in the HOME position.
Serious personal injury or death may occur.

! DANGER
Be sure people are at least 20 feet (6 meters)
away from all areas of the body.
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 buckets, or opening the tailgate.
Serious personal injury or death may occur.

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3.7.1 Installing the Tailgate Prop (3) Disable the Packer and shut the chassis engine
(1) Standing behind the tailgate, release the pin off.

!
(Figure 13, 1) and swing the prop (Figure 13, 2)
towards the truck frame. WARNING
(2) Start the engine and raise the tailgate. Packer must be disabled by the following steps
before proceeding.
(5) Place transmssion in NEUTRAL.
(6) Apply chassis parking brake.
(7) Shut engine OFF.
(8) Remove chassis ignition key and maintain
in personal possession.
(9) Turn chassis BATTERY switch OFF.

1 2

Figure 13

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PREVENTIVE MAINTENANCE - PACKER
(4) Apply LOCKOUT/TAGOUT procedure to the (5) Position the end of the prop (Figure 14, 1) over
Packer before performing any maintenance the pocket (Figure 14, 2).
procedures.

SAFETY NOTICE
Before entering Packer body read and follow
OSHA Regulations concerning entry and working
in “CONFINED SPACE” OSHA 1910.146 and
“LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
work to the Packer.
Follow all safety instructions in your McNeilus
Packer Manual.
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or 2
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

Figure 14

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! CAUTION ! DANGER
Do not POWER DOWN the tailgate against the Verify that the tailgate prop is properly secured
prop. seated in the pocket in the body compartment.
Damage may occur to the prop. Serious personal injury or death may occur.

(6) Turn ignition switch to the ON position. Do not (7) Turn ignition switch to the OFF position.
start engine. Lower the tailgate until the prop
(Figure 15, 1) is fully seated in the pocket
(Figure 15, 2).

Figure 15

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PREVENTIVE MAINTENANCE - PACKER
3.7.2 Removing the Tailgate Prop (4) Standing behind the tailgate remove the prop
from the pocket and swing the prop
After completing the maintenance procedures on the body that (Figure 16, 1) away to the stored position and
require the tailgate to be propped, the following procedure install retaining pin (Figure 16, 2).
must be followed to remove the prop and close the tailgate.
(1) Remove LOCKOUT/TAGOUT procedure from the
Packer.
(2) Start the engine and open the tailgate as needed
to provide the necessary clearance to disengage
the prop from the pocket in the body
compartment.

! WARNING
Packer must be disabled by the following steps
before proceeding.
(10) Place transmssion in NEUTRAL.
(11) Apply chassis parking brake.
1
(12) Shut engine OFF. 2

(13) Remove chassis ignition key and maintain

in personal possession.
Figure 16
(14) Turn chassis BATTERY switch OFF.
(5) Start the chassis engine and enable the Packer
(3) Disable the Packer functions and shut engine functions.
OFF.
(6) Close the tailgate.

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3.8 Trash Behind the Pack and Sweep
• Daily Checks - The Packer is inspected for trash behind the SAFETY NOTICE
pack and sweep by the operator or skilled service personnel. Before entering Packer body read and follow
When the Packer is operated on the route, trash can pass-by OSHA Regulations concerning entry and working
the pack and sweep. If the trash is not cleaned from behind the in “CONFINED SPACE” OSHA 1910.146 and
pack and sweep, the Packer can be damaged. “LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
NOTE work to the Packer.
Packer body must be empty when performing this Follow all safety instructions in your McNeilus
procedure. Packer Manual.
Shut off truck engine, lock cab doors and keep
(1) Raise the fork assembly fully. key in your pocket before entering body, or
(2) Raise the arm to the home position. performing any work to the Packer.
(3) While pressing the ARM OVERBODY Place magnetic “DANGER” signs on both cab
OVERRIDE switch, extend the pack and sweep. doors.
Failure to do so can result in serious personal
(4) Apply LOCKOUT/TAGOUT procedure to the
injury or death.
Packer before performing any maintenance
procedures.

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PREVENTIVE MAINTENANCE - PACKER
(5) Fold down the ladder (Figure 17, 1).
(6) Unlatch the side door handle (Figure 17, 2) and
open the side door. 2
(7) Inspect behind the pack and sweep for
accumulation of trash.

! CAUTION
Do not damage the pack and sweep cylinder rods
when cleaning out trash.
Never use metal objects or tools to clean out
trash from around pack and sweep cylinders.

(8) Remove the trash from behind the pack and

sweep using a cleanout tool or a plastic shovel. 1
(9) After the trash is removed, close and secure the
side door and fold up the ladder. Figure 17
(10) Remove LOCKOUT/TAGOUT.
(11) Retract the Pack and Sweep.

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 PREVENTIVE MAINTENANCE - PACKER
3.9 Safety Decals
• Daily Checks - A complete walk around of the vehicle to
inspect the safety decals should be performed every day
before operation. If any of the safety decals are damaged,
illegible or missing they must be replaced before operation.
For the proper location and part numbers of the safety decals
for the Packer (See “SAFETY DECALS” on page 18). If you are
unable to determine the proper safety decal or its placement
on the Packer call McNeilus Truck and Manufacturing, Inc.
(507) 374-6321 for assistance.
For information on any of the chassis safety decals, please
contact the chassis manufacturer.

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PREVENTIVE MAINTENANCE - PACKER
4.0 HYDRAULIC SYSTEM
4.1 Hydraulic Oil Requirements
The lubrication requirements for your McNeilus Packer are
common for hydraulic oils. Hydraulic oils differ from other oils.
Hydraulic oils have additives to inhibit water, rust, oxidation and
foaming.
The table below lists the hydraulic oil specifications.

Hydraulic Oil Specifications

McNeilus Part Number 1273280
ISO Grade 46
Viscosity @ 100° F, SUS 256
Viscosity @ 210° F, SUS 50 - 60
Viscosity Index (Min.) 100
Pour Point -49° F (-45° C)
Gravity, API 31.2
Zinc 416 PPM
Phosphorus 334 PPM
Calcium 71 PPM

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4.2 Hydraulic Oil Reservoir 2
Hydraulic oil reservoir styles may vary due to the various
chassis configurations, but all reservoirs are either 40 or 50
gallon capacity. The reservoirs typically use the same hydraulic
return filter (Figure 18, 1) and breather filter (Figure 18, 2).
The reservoir is mounted to the side of the chassis frame.
1
The drain plug (Figure 18, 3) is a magnetic plug located at the 4
bottom of the reservoir.
The level sight gauges (Figure 18, 4) are located on either end
of the reservoir.
Make sure the shut-off valve (Figure 18, 5) is fully open and
not partially closed. A nylon strap (Figure 18, 6) must be
installed on the shut-off valve to prevent vibration from closing 6
the shut-off valve or inadvertent closing of the valve.
Anytime the shut-off valve is closed and reopened, the nylon
strap must be replaced.
5 3
Figure 18

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4.3 Adding Hydraulic Oil 1
With all hydraulic functions in their home positions, pack and
sweep in HOME or retracted position, tailgate in DOWN
position, top door OPEN position, and the fork and arm
assemblies are fully raised, check the hydraulic oil level (See
“Hydraulic Oil Level” on page 96).

4.3.1 Standard Hydraulic System

To add hydraulic oil, remove the filler cap (Figure 19, 1) and
add oil as necessary.

NOTE
When adding hydraulic oil, take every precaution
to prevent contaminants from entering the
hydraulic system.
Cleanliness is extremely important when working
with hydraulics.
Figure 19
NOTE
If it is necessary to add hydraulic oil often or in
large quantities, inspect the hydraulic system for
leaks and repair before operating the Packer.

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4.3.2 Clean-Fill Hydraulic System (OPTIONAL)
Some units are equipped with a clean fill option. The fill cap is
replaced by two quick disconnects. To add oil, a mobile
filtration system is required. The quick disconnects are
provided to connect the mobile filtration system. One quick
1
disconnect (Figure 20, 1) is located in the hydraulic suction
line to the hydraulic pump or on the hydraulic reservoir. A
second quick disconnect (Figure 20, 2) is located in the
hydraulic return line prior to the hydraulic return filter.

NOTE
When adding hydraulic oil, take every precaution
to prevent contaminants from entering the
hydraulic system. 2
3
Cleanliness is extremely important when working
with hydraulics.
Figure 20

NOTE
If it is necessary to add hydraulic oil often or in
large quantities, inspect the hydraulic system for
leaks and repair before operating the Packer.

To add hydraulic oil, connect the mobile filtration system to the

quick disconnects. Oil that is added is filtered through the
hydraulic return filter (Figure 20, 3).

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PREVENTIVE MAINTENANCE - PACKER
The return line filter of the clean-fill system is equipped with a
test port (Figure 21, 1) and poppet valve (Figure 21, 2). The
test port is used to withdraw a hydraulic oil sample.

Figure 21

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5.0 LUBRICATION
5.1 Daily Lubrication

SAFETY NOTICE
Before entering Packer body read and follow
OSHA Regulations concerning entry and working
in “CONFINED SPACE” OSHA 1910.146 and
“LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
work to the Packer.
Follow all safety instructions in your McNeilus
Packer Manual.
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

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

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PREVENTIVE MAINTENANCE - PACKER

Lubricate Daily or
Daily Lubrication Points Every 10 Hours
Ref. Description No. of Fittings Comments
A1 Pack and Sweep Cylinders - Base End 2 Two Cylinders - One Per Side
A2 Pack and Sweep Cylinders - Rod End 2 Two Cylinders - One Per Side
B Arm Cylinders - Base End 2 Two Cylinders - One Per Side
B Arm Cylinders - Rod End 2 Two Cylinders - One Per Side
C1 Arm Pillow Blocks 2 Street Side and Center
C2 Arm Pillow Blocks 1 Curb Side
D1 Fork Cylinders - Base End 2 Two Cylinders - One Per Side
D2 Fork Cylinders - Rod End 2 Two Cylinders - One Per Side
E Fork Assembly Pivot 4 Two Pivots - Two Fittings Per Side

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A1 A2 B C1 C2

C2 D1 A2 A1

B D2 E C1

D1 D2 E

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NOTES

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 PREVENTIVE MAINTENANCE - PACKER
5.2 Scheduled PM Lubrication

SAFETY NOTICE
Before entering Packer body read and follow
OSHA Regulations concerning entry and working
in “CONFINED SPACE” OSHA 1910.146 and
“LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
work to the Packer.
Follow all safety instructions in your McNeilus
Packer Manual.
Shut off truck engine, lock cab doors and keep
key in your pocket before entering body, or
performing any work to the Packer.
Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

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PREVENTIVE MAINTENANCE - PACKER
Lubricate all the following points with a high quality EP No. 2 Scheduled PM lubrication intervals are based on 3 weeks or
lithium grease. 150 hours. If Packer is operated more hours or double shifted,
the maintenance interval must be adjusted accordingly.

Lubricate Every 3
Scheduled PM Lubrication Points Weeks or 150 Hours
Ref. Description No. of Fittings Comments
F Tailgate Cylinder - Base End 2 Two Cylinders - One Per Side
F Tailgate Cylinder - Rod End 2 Two Cylinders - One Per Side
G Tailgate Latch Pin 2 Two Latch Pins - One Per Side
H Tailgate Hinge Pin 2 Two Hinge Pins - One Per Side
J1 Top Door - Base End 1
J2 Top Door - Rod End 1
K Body Pivot Pin 2 Two Pivot Pins - One Per Side
L Service Lift Cylinder - Base End 2 Two Cylinders - One Per Side
(OPTIONAL)
L Service Lift Cylinder - Rod End 2 Two Cylinders - One Per Side
(OPTIONAL)
M Body Dump Cylinder - Base End 2 Two Cylinders - One Per Side
(OPTIONAL)
M Body Dump Cylinder - Rod End 2 Two Cylinders - One Per Side
(OPTIONAL)
N PTO Shaft U-Joints 3
P Ladder Pivot 1

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F G H J1 J2

J1 H F J2

K G N P L M

K L M N P

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NOTES

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 TROUBLESHOOTING
1.0 TROUBLESHOOTING
When a problem or malfunction occurs, follow these steps. The (4) If your particular problem is not listed, or the
sequence below will help isolate the problem and often permit remedial actions provided do not resolve the
a quick repair. If further assistance is required, refer to the problem, we suggest that you take the vehicle to
applicable section of this manual or contact one of the regional a service shop, refer to the appropriate service
McNeilus Regional Branch/Factory Service/Parts locations manual, or contact McNeilus Truck and
listed in the Foreword of this manual. Manufacturing, Inc. for service assistance.
(5) If you have questions or need help please contact
NOTE one of the regional McNeilus Regional
Isolate the problem before taking any remedial Branch/Factory Service/Parts locations listed in
actions. the Foreword of this manual.

(1) Unless further damage will occur, repeat the SAFETY NOTICE
steps that caused the problem. Refer to the
Operation section of this manual to be sure that Before entering Packer body read and follow
the correct operating procedures have been OSHA Regulations concerning entry and working
followed. Often a simple step in the standard in “CONFINED SPACE” OSHA 1910.146 and
operating procedure has been forgotten. “LOCKOUT/TAGOUT” OSHA 1910.147.
Follow OSHA Regulations while performing any
(2) Refer to the troubleshooting chart. It is designed
work to the Packer.
to help you troubleshoot problems at your
location, and is organized in a logical sequence. Follow all safety instructions in your McNeilus
Look under the appropriate equipment section, Packer Manual.
and for the specific problem within the chart. Shut off truck engine, lock cab doors and keep
(3) Perform the checkout procedure and remedial key in your pocket before entering body, or
actions listed within the chart to isolate the performing any work to the Packer.
problem. Place magnetic “DANGER” signs on both cab
doors.
Failure to do so can result in serious personal
injury or death.

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 129 Front Loader
TROUBLESHOOTING
Problem Probable Cause Action
All functions not working 1. BATTERY switch is OFF. 1. Turn BATTERY switch ON.
2. IGNITION switch is OFF. 2. Turn IGNITION switch ON.
3. LOCKOUT TOGGLE switch is OFF. 3. Turn LOCKOUT TOGGLE switch ON.
4. One or more E-STOP buttons is DOWN. 4. Release all E-STOP buttons.
5. PUMP rocker switch is OFF. 5. Turn PUMP rocker switch ON.
6. Side door is OPEN. 6. CLOSE side door.
7. System air pressure to low. 7. Wait for chassis air system to build pressure above 80 psi.
8. System problem. 8. Requires shop service and repair.
Joystick Functions not 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
working 2. Pack and sweep not in HOME position. 2. Manually RETRACT pack and sweep to HOME position.
3. Top door not fully OPEN. 3. Fully OPEN top door.
4. System air pressure to low 4. Wait for chassis air system to build pressure above 80 psi.
5. System problem. 5. Requires shop service and repair.
Automatic Pack and 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
Sweep Functions not 2. Tailgate is OPEN. 2. CLOSE tailgate.
working
3. Top door not fully OPEN. 3. Fully OPEN top door.
4. Arms are ABOVE the body. 4. LOWER arms below body.
5. Check pack and sweep proximity switches for 5. Requires shop service and repair.
proper operation.
6. System problem. 6. Requires shop service and repair.
Manual Pack and Sweep 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
Functions not working 2. Top door not fully OPEN. 2. Fully OPEN top door.
3. Arms are ABOVE the body. 3. LOWER arms below body.
4. System problem 4. Requires shop service and repair

Front Loader 130 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.
 TROUBLESHOOTING
Problem Probable Cause Action
Tailgate Functions not 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
working 2. ACTIVATE switch not pressed. 2. Press ACTIVATE switch while pressing TAILGATE
switch.
3. System problem. 3. Requires shop service and repair.
Top Door Functions not 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
working 2. ACTIVATE switch not pressed. 2. Press ACTIVATE switch while pressing TOP DOOR
3. System problem. switch.
3. Requires shop service and repair.
Body Functions Not 1. Engine rpm too HIGH. 1. REDUCE engine speed to below 1600 rpm.
Working (Dump Model 2. ACTIVATE switch not pressed. 2. Press ACTIVATE switch while pressing TOP DOOR
Only) switch.
3. System problem.
3. Requires shop service and repair

© 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 131 Front Loader
TROUBLESHOOTING
NOTES

Front Loader 132 © 02/2007 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.