McNeilus Zero Radius ZR 12 ft. Extended Reach, Operator'S Manual

Page 1: ...OPERATOR S MANUAL Zero RadiusTM 2010 McNeilus Truck and Manufacturing Inc Publication No 1416362 Includes information for ZR 6 ft Reach ZR 12 ft Extended Reach Rev 0918...

Page 2: ...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 Go to www streetsmartparts com for current i...

Page 3: ...dy The identification plate contains the Model Number and Serial Number of your refuse vehicle system To serve you better please fill out the following information and have it ready when calling McNei...

Page 4: ...ID INCOMPLETE VEHICLE MFD BY DATE TRUCK nnnnnnnnnnnnnnnnn LB 9 072 W 445 65R22 5 TIRES ON 22 5 X 13 0 RIMS 120 PSI COLD KPA 830 22 800 LB 10 342 W 445 65R22 5 TIRES ON 22 5 X 13 0 RIMS 120 PSI COLD KP...

Page 5: ...ow to operate this Packer inform your supervisor or contact McNeilus Truck and Manufacturing Inc at 888 686 7278 N O T E This manual is limited to the operation and light maintenance of the refuse col...

Page 6: ...Villa Rica IL Sugar Grove IN Fort Wayne MN Dodge Center NY Bronx OH Cincinnati OH Columbus PA Morgantown TX Houston TX Hutchins UT West Valley City WI Oshkosh Canada Ontario and Western Provinces 800...

Page 7: ...nnect 2 1 2 Safety Equipment 3 1 3 Reporting Safety Defects 3 2 0 SAFETY NOTICES 4 3 0 PRODUCT SAFETY INFORMATION 5 3 1 Safety 5 3 2 Cab Operation 6 3 3 Outside Operation 8 3 4 Maintenance 11 3 5 Hydr...

Page 8: ...ons Optional 35 1 3 Arm and Grabber Controls 36 1 3 1 Joystick Control 37 1 4 Fuse Block 39 1 4 1 Fuse Block Legacy 40 2 0 CONTROL FUNCTIONS 41 2 1 E STOP Emergency Stop Function 41 2 1 1 In Cab Contr...

Page 9: ...and Retract Functions 49 2 4 1 1 Extend Arm Assembly 49 2 4 1 2 Retract Arm Assembly 49 2 4 2 Arm Assembly Raise and Lower Functions 50 2 4 2 1 Raise Arm Assembly 50 2 4 2 2 Lower Arm Assembly 50 2 5...

Page 10: ...of Day Checks 61 4 0 OPTIONAL EQUIPMENT 62 4 1 Pusher or Tag Axle 62 4 1 1 Lowering the Pusher or Tag Axle 62 4 1 2 Raising the Pusher or Tag Axle 62 4 2 Preco Radar Systems 63 4 3 Water Tank 65 4 3 1...

Page 11: ...aulic System 74 3 1 1 Hydraulic Oil Level 74 3 1 1 1 Temperature Level Sight Gauge 74 3 2 Electrical System 76 3 2 1 Lighting System 76 3 3 Pneumatic System 76 3 3 1 Coalescing Filter 76 3 4 Mechanica...

Page 12: ...N 85 5 1 Daily Lubrication 85 5 2 Scheduled PM Lubrication 93 5 2 1 Zero Radius 6 ft and Zero Radius 12 ft Extended Reach Weekly Preventive Maintenance 93 5 2 2 Zero Radius 6 ft and Zero Radius 12 ft...

Page 13: ...OTECTION Do not operate this equipment until you have read its contents thoroughly Read and understand the Waste Collection Vehicle Safety Guide and all other material provided with the truck Please c...

Page 14: ...NOTE Figure 3 represents a typical switch ON 1 2 Figure 3 1 1 1 Battery Cable Disconnect If the vehicle is not equipped with a battery disconnect switch disconnect the negative black battery cable fir...

Page 15: ...he reflective triangles are at your discretion 1 3 Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediatel...

Page 16: ...Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury Danger is used in the most extreme situations WARNING Warning indicates a potentially haz...

Page 17: ...eilus Truck and Manufacturing Inc at 888 686 7278 WARNING Operators must comply with Employee Responsibilities as outlined in ANSI Z245 and state federal and other safety and transportation regulation...

Page 18: ...lt are provided Serious injury or death can result DANGER If the Packer comes into contact or close proximity with a power line or there is any arcing stay in the truck cab and keep away from the meta...

Page 19: ...e lower speeds when going around curves corners or freeway on off ramps You are carrying a high center of gravity load Failure to comply can lead to a roll over or other loss of control of the vehicle...

Page 20: ...e to inspect indicator lights may lead to more serious conditions WARNING If equipped with optional camera or object detection system do not rely exclusively on the camera or object detection system F...

Page 21: ...tion Do not open access door unless 1 Engine is stopped 2 Key is removed from ignition 3 Hydraulic pressures are relieved 4 OSHA LOCKOUT TAGOUT Regulations are complied with Failure to heed these inst...

Page 22: ...injury or death WARNING The Packer and chassis should never be overloaded Do not exceed the manufacturer s recommended gross vehicle weight Do not overload the Packer and chassis Gross weights must me...

Page 23: ...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 malfunc...

Page 24: ...formed on the Packer This includes proper operation of the controls hydraulics lockout systems electrical systems auto neutral and neutral interlock systems optional cameras are clean and working came...

Page 25: ...hen working on the Packer the wheels must be blocked the parking brake on LOCKOUT TAGOUT procedures in effect and the keys out of the truck s ignition Failure to do so may result in serious personal i...

Page 26: ...CAUTION Disconnect battery before welding on body Failure to do so might result in personal injury or damage to property or equipment WARNING Do not repair or weld steel or aluminum water tanks Inspec...

Page 27: ...complications may arise if not treated immediately DANGER WARNING Hydraulic hoses and tubing must be inspected on a daily basis for leaks cuts abrasions damage aging improper clearance and along the f...

Page 28: ...rers for correct specifications or contact McNeilus at 888 686 7278 WARNING The hydraulic cylinders can be holding a function in a certain position when the engine is OFF An example of this would be a...

Page 29: ...eaking tubing must be replaced before the Packer is returned to service Please contact McNeilus Truck and Manufacturing Inc at 888 686 7278 if you require assistance or have questions WARNING All hydr...

Page 30: ...ious injury or death if the gauge fails Use properly rated hydraulic hoses with adequate length to allow the test gauge to be used far enough away from moving parts and functions WARNING Increasing hy...

Page 31: ...ion of the cylinder This can cause severe injury or death Check all replacement cylinders to ensure the orifice is in place before installation and operation WARNING Hydraulic components can be heavy...

Page 32: ...to order replacements Use only McNeilus replacement safety signs The table below contains part numbers for the individual safety signs See the Figures in this section for safety sign locations NOTE Sp...

Page 33: ...17 1524503 1 18 1523436 1 19 1523479 1 20 1523440 1 21 1523443 1 22 1523439 1 23 1523433 2 24 1523446 1 25 1523445 1 26 1523448 1 27 1523451 1 28 1527015 1 29 1525226 1 30 1525227 1 31 1523444 1 32 1...

Page 34: ...22 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Safety 4 1 Safety Sign Locations 19 9 4 8 3 5 2 3 4 38 Figure 4...

Page 35: ...23 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Safety 34 32 31 6 17 28 26 33 29 18 25 8 4 9 38 Figure 5 30...

Page 36: ...Zero Radius Side Loader Safety 20 15 10 36 38 37 Figure 6 14 14 14 With Tool Box With Tool Box Without Tool Box 7 13 23 11 21 24 12 22 27 23 24 35 1 Tailgate Side Cab Side Use 38 2 alternating red whi...

Page 37: ...mation 1 0 Exterior Systems Arrangement 1 1 Curb Side View 5 2 4 3 7 6 1 Figure 7 Ref No System Description 1 Cab Control Box and Joystick 2 Arm and Grabber Remote Control Box 3 Arm Assembly 4 Grabber...

Page 38: ...turing Inc Zero Radius Side Loader General Information 1 2 Street Side View 13 11 8 9 12 10 Figure 8 Ref No System Description 8 Side Access Door 9 Tailgate 10 Packing Panel 11 Hydraulic Oil Reservoir...

Page 39: ...us 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...

Page 40: ...r Reading 1 E STOP Button Disables all Hydraulic and Electric refuse vehicle functions 2 Red LED Warning Light If light is on or flashing it indicates an unsafe condition Look at the LED lights on the...

Page 41: ...ote control button panel 5 TAG AXLE RAISE Button OPTIONAL Press the button to raise the tag axle 6 ARM ON Button Press and hold the enable the Arm functions You must also press and hold the ACTIVATE b...

Page 42: ...ract the ejector panel to the HOME position 15 AUTO PACK Button Press this button to start the auto pack cycle 16 TOP DOOR OPEN Button Press and hold the button to open the top door 17 TAILGATE CLOSE...

Page 43: ...31 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Operation STOP WARNING E MERGENCY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 18 Figure 11...

Page 44: ...code If any of these LEDs are lighted refer to your Zero Radius Service Manual 4 Activate LED If a button is pressed that requires the ACTIVATE button to be pressed the LED will flash indicating the A...

Page 45: ...e fully RAISED position 14 Pusher Axle Up LED The red LED will be lit when the pusher axle is in the fully RAISED position No Description Normal Use or Reading 15 Tag Axle Down LED The red LED will be...

Page 46: ...h when the ejector panel is in the auto pack mode 22 Top Door Open LED The green LED will be lit when the top door is fully open 23 Tailgate Open Closed LED The LED will be red when the tailgate is fu...

Page 47: ...o open grabber fingers 3 EJECTOR PANEL RETRACT Button Press this button to retract the ejector panel to the HOME position No Position Normal Use or Reading 4 EJECTOR PANEL EXTEND Button Press this but...

Page 48: ...le joystick All functions of the joystick are momentary Be sure all non operator personnel are at least 20 feet 6 meters away from all areas of the Packer Serious personal injury or death may occur WA...

Page 49: ...o the middle NEUTRAL position when released No Position Normal Use or Reading 1 Joystick FORWARD Lowers arm assembly 2 Joystick BACK Raises arm assembly 3 Joystick RIGHT Extends arm assembly out 4 Joy...

Page 50: ...38 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Operation 6 1 3 2 4 8 7 5 Figure 14...

Page 51: ...5 If fuses are continually blowing check for an electrical problem No Amp Description F1 25 E Stop Body Function Power F2 10 Option Power F3 10 Body Function Power F4 10 Fan F5 10 Not Used F6 2 Sensor...

Page 52: ...15 Side Lights F3 15 Front Work Lights F4 15 Front Lights F5 15 Tailgate Work Lights F6 15 Tailgate Strobe Lights F7 15 Tailgate Lighting F8 2 Sensor Power F9 10 Arm Packer F10 5 Axles Chassis F11 10...

Page 53: ...on until it is manually released Figure 17 2 1 1 In Cab Control Box E STOP Button Pull up on the button to release the in cab control box E STOP button Figure 18 Item 1 2 1 2 Arm Remote Control Box E...

Page 54: ...on Diagnostic Display E STOP Display Description This screen appears when the E STOP circuit is triggered by a software interlock OR by the operator pressing either one of the E STOP buttons This fun...

Page 55: ...eas of the Packer Serious personal injury or death may occur WARNING 2 2 1 Automatic Cycling of Packing Panel Conditions Tailgate closed LED light must be green Side door LED lights must be off Engine...

Page 56: ...tion You do not have to start the engine 2 Hold the ACTIVATE button Figure 20 Item 1 and the AUTOMATIC button Figure 20 Item 2 on the main control box 3 In approximately 5 seconds the automatic packin...

Page 57: ...se the pack count and push the STROBE LIGHT button Figure 21 Item 2 to decrease the pack count 1 2 Figure 21 6 The pack count is displayed by the number of LEDs that are lighted on the error code disp...

Page 58: ...peed must be below 1700 rpm Top door must be up open Grabber must not be in the STOWED position 2 2 3 1 Extend Packing Panel Press the EXTEND switch to manually control the extend movement of the pack...

Page 59: ...ff Engine speed must be below 1700 rpm N O T E Use the top door only to seal off the hopper area when traveling The top door should not be used as a pack assist panel when using the Pack and Sweep fun...

Page 60: ...green LED will be lighted when the arm is enabled You must press the REMOTE switch to enable the remote control switch panel The green LED will be lighted when the REMOTE switch is activated Be sure a...

Page 61: ...at least 20 feet 6 meters away from all areas of the Packer Serious personal injury or death may occur WARNING Conditions Truck travel speed must be less than 7 mph Engine speed must be below 1700 rpm...

Page 62: ...onal injury or death may occur WARNING Conditions The top door open green LED must be lit to raise arm to the DUMP position Truck travel speed must be less than 7 mph Engine speed must be below 1700 r...

Page 63: ...e Packer Serious personal injury or death may occur WARNING Conditions Truck travel speed must be less than 7 mph Engine speed must be below 1700 rpm Green Arm On LED must be lighted Green Pump On LED...

Page 64: ...power lines before raising or opening the tailgate Serious personal injury or death may occur DANGER NOTE The warble alarm sounds when the tailgate is opening and remains on until the tailgate is clo...

Page 65: ...om McNeilus Truck and Manufacturing Inc by calling 888 686 7278 Failure to comply may result in serious personal injury or death or damage to equipment NOTE Turn the pump ON and idle the truck for a m...

Page 66: ...o be below 109 F v Tailgate must be closed 3 Cycle through each of the following operations a Packing Functions Cycle three 3 times b Top Door Functions Cycle three 3 times c Grabber and Arm Functions...

Page 67: ...1 are in their fully CLOSED position and in the fully RAISED STOWED position in the hopper When the arm and grabber assembly are properly stowed the arm stowed LED light will be off 4 That the tailgat...

Page 68: ...hydraulics 4 Lower the grabber assembly from the STOWED position in the hopper 5 Open the grabber fingers Figure 31 Item 1 6 Open the top door 7 Disconnect the arm transit latch from the arm and stow...

Page 69: ...nimum work on the part of the operator See Figure 33 Be sure all non operator personnel are at least 20 feet 6 meters away from all areas of the Packer Serious personal injury or death may occur WARNI...

Page 70: ...ully RETRACTED position 1 Start raising the grabber assembly and at the same time retract the arm assembly until the container is emptied Figure 34 2 Once the container is emptied lower the grabber as...

Page 71: ...th a pusher axle make sure the pusher axle is raised 2 If equipped with a tag axle make sure the tag axle is lowered 3 Position rear of refuse vehicle as appropriate 4 Open the tailgate fully N O T E...

Page 72: ...dy 8 Retract the packing panel back to the HOME position 9 Extend the packing panel to the fully EXTENDED position Figure 35 Item 3 and move the truck forward to verify that the entire refuse load has...

Page 73: ...her conditions 2 Arm assembly is retracted to the STOWED position The arm assembly and grabber MUST be stowed and secured while traveling when the arm assembly is not in use Serious personal injury or...

Page 74: ...he cab of the vehicle and may also be located outside of the cab Always follow your company s policies and procedures when adjusting the air pressure If you have any questions call McNeilus Parts and...

Page 75: ...ems The following images describe the screens that will display on the CODE display system when the Preco radar system is installed and operational Vehicle Command Image on CODE Display Vehicle is pla...

Page 76: ...is not a screen on the CODE display but a legend to the color patterns shown when an object is detected Distance No object detected Object extremely close Vehicle Command Image on CODE Display If a Pr...

Page 77: ...pressure safety valve WARNING CONTINUED 6 Never drive the truck with the water tank pressurized Depressurize water tank prior to transit to or from job site Water tank should be pressurized only when...

Page 78: ...nk as soon as you are finished inspecting and before moving the truck Replace Defective Tank Water tanks with any leak or significant signs of internal or external damage or corrosion should be replac...

Page 79: ...l site only It is not necessary or beneficial for the tank to be pressurized while driving and a pressurized tank is an added hazard in the event of a crash or a rollover 4 3 5 Vehicle Handling Charac...

Page 80: ...68 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Operation NOTES...

Page 81: ...quipment help prevent expensive downtime and minimize the potential for problems arising on the route The following Preventive Maintenance Chart summarizes the requirements to properly maintain your r...

Page 82: ...skilled service personnel All intervals listed under the Service group heading must be performed by skilled service personnel Refer to the product Service Manual for maintenance procedures Maintenanc...

Page 83: ...rvice LEGEND R Replace I Inspect T Torque P Perform L Lubricate C Clean Hydraulic System Hydraulic Oil Level P P Hydraulic System and Components I I Hydraulic Hoses and Fittings I I Hydraulic Tubes an...

Page 84: ...rvice LEGEND R Replace I Inspect T Torque P Perform L Lubricate C Clean Electrical System Lighting System I I Wire Harness I I Audible Backup Alarm I Pneumatic System Air Hoses and Fittings I I Coales...

Page 85: ...nually 2500 Hours Bi Annual 5000 Hours Operator Service LEGEND R Replace I Inspect T Torque P Perform L Lubricate C Clean Operation Refuse Vehicle Controls P P Trash Behind Packing Panel I P I P Safet...

Page 86: ...he reservoir could have one of two gauges The first type Figure 37 is distinguished by the word LOW below the sight glass The second type Figure 38 does not have the word LOW on the gauge The hydrauli...

Page 87: ...100 LOW MAX FILL HOT 1 3 2 The second type of temperature level sight gauge Figure 38 Item 1 will not have the word LOW Keep the oil level to the top of the black line Full Figure 38 Item 2 but don t...

Page 88: ...cle and chassis are functioning correctly Replace any burned out bulbs with the same type 3 3 Pneumatic System SAFETY NOTICE Perform your company s Lockout Tagout procedure If your company does not ha...

Page 89: ...or skilled service personnel Inspect the tailgate seal for cuts tears damage or excessive wear Ensure that the seal is fully seated in the tailgate channel Inspect the mounting straps to ensure they...

Page 90: ...lace transmission in NEUTRAL 2 Apply chassis parking brake 3 Shut engine OFF 4 Remove chassis ignition key and maintain in personal possession 5 Turn chassis BATTERY switch OFF Failure to disable the...

Page 91: ...of the safety signs are damaged illegible or missing they must be replaced before operation For the proper location and part numbers of the safety signs for the refuse vehicle see SAFETY SIGNS If you...

Page 92: ...e raising or opening the tailgate Serious personal injury or death may occur DANGER 4 1 Engaging the Tailgate Prop 1 Start the engine and raise the tailgate approximately 2 5 3 ft 2 Shut the chassis e...

Page 93: ...Position the end of the prop Figure 43 Item 1 over the pocket Figure 43 Item 2 and lock in place with spring loaded pin Figure 43 1 2 5 Turn chassis BATTERY switch ON Verify that the tailgate props ar...

Page 94: ...nd disable the refuse vehicle WARNING Packer must be disabled by the following steps before proceeding 1 Place transmission in NEUTRAL 2 Apply chassis parking brake 3 Shut engine OFF 4 Remove chassis...

Page 95: ...Open the tailgate as needed to provide the necessary clearance to disengage the prop from the pocket in the body compartment 3 Disable the refuse vehicle functions WARNING Packer must be disabled by...

Page 96: ...84 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance 1 2 Figure 45 5 Turn chassis BATTERY switch ON 6 Start the chassis engine 7 Close the tailgate...

Page 97: ...rator s and Service Manuals supplied by the manufacturer for the proper lubrication and maintenance The lubrication charts in the following pages are divided between Zero Radius and Zero Radius Extend...

Page 98: ...scription No of Fittings Comments A1 Packing Panel Cylinder Curb Side Rod End 1 A2 Packing Panel Cylinder Street Side Rod End 1 A3 Packing Panel Cylinders Base End 2 Two Cylinders One Per Side B Arm C...

Page 99: ...87 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance A3 A1 B A2 C D E F A1 A2 A3 B C D E F...

Page 100: ...ne Per Side J Grabber Finger Pivots Upper 2 Two Pivot Pins One Per Side J Grabber Finger Pivots Lower 2 Two Pivot Pins One Per Side K Grabber Fingers Cylinders Base End 2 Two Cylinders One Per Side L...

Page 101: ...89 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance G H K L J J H K L J G J M M...

Page 102: ...e 1 F1 Arm Rollers Bottom Truck Mounted Receiver 2 Two Rollers Two Rollers per grease fitting F2 Arm Rollers Bottom Intermediate Boom 2 Two Rollers One Per Side G Grabber Assembly Rollers Upper 2 Two...

Page 103: ...91 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance A3 A1 A2 C1 C2 A1 A2 A3 D F1 F2 L K E1 G H J J J C1 C2 D E2 E1 D E2...

Page 104: ...92 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance G H J K L F1 F2 M D F1 F2 L K E1 G H J J J M...

Page 105: ...weekly or every 50 hours If the refuse vehicle is operated more hours or double shifted the maintenance interval must be adjusted accordingly SAFETY NOTICE Perform your company s Lockout Tagout proced...

Page 106: ...Radius Extended Reach Weekly Lubrication Points Lubricate Weekly or Every 50 Hours Ref Description No of Fittings Comments I Grabber Gear 4 Two fittings per spline hub lubricate minimum one per hub Q...

Page 107: ...usted accordingly Zero Radius and Zero Radius Extended Reach Scheduled Preventive Maintenance Lubrication Points Lubricate Every 3 Weeks or Every 150 Hours Ref Description No of Fittings Comments M Ta...

Page 108: ...96 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Preventive Maintenance M N P R S M R P N S...

Page 109: ...rocedures have been followed Often a simple step in the standard operating procedure has been forgotten 2 Refer to the Troubleshooting Chart It is designed to help you troubleshoot problems at your lo...

Page 110: ...2 Turn IGNITION switch on 3 Release all E STOP buttons 4 Turn PUMP switch on 5 Close side door 6 Close clean out door 7 Requires shop service and repair Joystick functions not working 1 Engine rpm to...

Page 111: ...uires shop service and repair 7 Requires shop service and repair Packing panel stalls in any position other than HOME 1 Engine rpm too high 2 Side door is open 3 Clean out door is open 4 Material prev...

Page 112: ...ress ACTIVATE button while pressing TAILGATE button 3 Close clean out door 4 Close side door 5 Requires shop service and repair Grabber assembly will not dump 1 Engine rpm too high 2 Arm assembly not...

Page 113: ...ic Cycling of Packing Panel 43 Manual Cycling of Packing Panel 46 Setting Pack Count 44 Tailgate Functions 52 Top Door Hopper Assist Panel Functions 47 D Daily Preventive Maintenance Checks 74 Electri...

Page 114: ...tion 66 Daily Operation 67 Introduction 65 Vehicle Handling Characteristics 67 Water Tank Decal Identification 67 Water Tank Safety 65 P Parts and Service Branch Locations 4 Preventive Maintenance 69...

Page 115: ...103 2010 McNeilus Truck and Manufacturing Inc Zero Radius Side Loader Index T Trash Behind the Packing Panel 78 Troubleshooting 97 Troubleshooting Chart 98 W Warning Triangle Kit 3...

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Page 118: ...888 686 7278 www StreetSmartParts com...