SOFT-STOP SYSTEM. Manual P/N:

Transcription

1 Recycler SOFT-STOP SYSTEM Manual P/N: 43356

2 TABLE OF CONTENTS FOREWORD Purpose of Manual... Scope... Branch/Factory Service/Parts Locations... 2 Corporate Headquarters... 2 Patents Pending... 2 SAFETY Important Safety Information... 3 LOCKOUT/TAGOUT Procedure... 4 Safety Notices... 5 Product Safety Information... 6 Safety... 6 Operation... 6 Maintenance... 8 Hydraulics... 9 PACKING LIST Packing List... 3 Single Bucket... 3 Dual Bucket... 4 SYSTEM INSTALLATION LOCKOUT/TAGOUT Procedures... 5 Installation Guidelines... 5 Mounting Control Box... 6 Connecting Control Box Power... 7 Installation of Power Stub Harness... 8 Power Stub Harness Test... 9 Connection of Control Box Connecting Proximity Switch(es)... 2 Installation of Proximity Switch(es)... 2 Connection of Proximity Switch(es) Proximity Switch(es) Adjustment Connection of Air Lines Replace the Air Actuator and Centering Spring Replace Spool Centering Spring Replace Spool Seals... 3 Installation of Air Actuator Connecting Air Lines Installation of Regulator/Water Separator Start-Up Procedure Recycler Soft-Stop System 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

3 TABLE OF CONTENTS PREVENTIVE MAINTENANCE Design Maintenance Intervals LOCKOUT/TAGOUT Procedures Daily (0 Hours) Inspection and Check Packer Coalescing Filter Daily (0 Hours) Semi-Annual (250 Hours) Water Separator... 4 Daily (0 Hours)... 4 Semi-Annual (250 Hours)... 4 ILLUSTRATIONS and PARTS LISTS How To Use Control Box (Single Bucket) Control Box (Dual Bucket) Power Stub Harness Bracket, Proximity Switch Proximity Switch Target, Proximity Switch Air Actuator Kit Seal Kit, VA Air Line Kit Air Supply Assembly Tools Supplies /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. Recycler Soft-Stop System

4 FOREWORD Purpose of Manual This manual provides safety, operation, installation, maintenance, troubleshooting and parts information for the Recycler Soft-Stop System. The Recycler Soft-Stop System was developed and is manufactured by McNeilus Street Smart Parts and Service. The Recycler Soft-Stop System regulates the air controls during a determined travel position of the Recycler bucket function. The travel position is sensed with the use of a proximity switch. The use of the Recycler Soft-Stop System cushions the bucket functions for smoother operation resulting in lower maintenance costs. The Recycler Soft-Stop System is intended to be an addition to the original controls. The information in this manual will be your guide to operation, installation and maintenance for the Recycler Soft-Stop System. A different Recycler Soft-Stop System is required for single or dual bucket recycler applications. This manual covers the installation of both kits. Scope This manual provides information for use by the equipment operator and service personnel under the following headings: Safety Packing List System Installation Preventive Maintenance Illustrations and Parts Lists To order a replacement manual or safety warning decals, contact one of the regional McNeilus Factory Service/Parts locations. Recycler Soft-Stop System 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

5 FOREWORD Branch/Factory Service/Parts Locations Contact your McNeilus Factory Service/Parts location to order parts, 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 CA Los Angeles CA Stockton CT Hartford FL Lakeland GA Atlanta (Service) (Parts) IL Chicago IN Fort Wayne MN Dodge Center NC Greensboro NV Las Vegas OH Cincinnati OH Columbus (Service) PA Philadelphia (Service) (Parts) TX Dallas TX Houston UT Salt Lake City WA Tacoma WI Oshkosh Canada Ontario and Western Provinces Quebec and Maritime Provinces Phone Corporate Headquarters Contact McNeilus Street Smart Parts and Service directly at our corporate headquarters at the following address, phone numbers and website address: McNeilus Street Smart Parts and Service 9 Airport Road North P.O. Box 70 Dodge Center, MN Telephone: (507) Toll Free: (888) (888) MTM-PART Fax: (507) Website: Patents Pending The Recycler Soft-Stop System has many new and innovative designs for the industry. Several patents have been applied for by McNeilus Street Smart Parts and Service and are PATENT PENDING. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 2 Recycler Soft-Stop System

6 SAFETY Important Safety Information Read and understand this entire manual before operating, repairing or adjusting your Recycler Soft-Stop System. Those who use and maintain this equipment must be thoroughly trained and familiar with the product. If incorrectly used or maintained, this equipment can cause severe injury or death. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed during installation or while performing Daily Checks or Scheduled PM on this equipment. If you are not familiar with the OSHA LOCKOUT/TAGOUT procedures or any other safety requirements, please contact McNeilus Street Smart Parts and Service. Always keep this manual in a location where it is readily available for persons who operate or maintain the product. Additional copies of this manual are available from McNeilus Street Smart Parts and Service. Please contact your McNeilus Factory Service/Parts location to order parts, 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 and danger, caution and warning decals on this unit. Such individuals should not be allowed to operate this equipment until they thoroughly understand all of these materials. Failure to do so may result in serious injury or death. Recycler Soft-Stop System 3 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

7 LOCKOUT/TAGOUT Procedure SAFETY NOTICE LOCKOUT/TAGOUT procedures must be followed when working on this equipment including, but not limited to, cylinders being changed or maintained. Failure to heed these instructions/warnings may result in serious personal injury or death. Before entering Packer body, or climbing on or getting under truck to perform any work, read and follow OSHA Regulations concerning entry and working in CONFINED SPACE OSHA AND LOCKOUT/TAGOUT OSHA Follow OSHA Regulations while performing any work to the Packer. Follow all safety instructions in this McNeilus Street Smart Parts and Service Recycler Soft-Stop System manual and the OEM manuals for Packer. 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 (McNeilus part number ). Lockout supplies are available from McNeilus Street Smart Parts and Service. Call (507) for assistance. SAFETY 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 4 Recycler Soft-Stop System

8 SAFETY Safety Notices Safety notices are one of the primary ways to call your attention to potential hazards. THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS. BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. The following safety notices are used throughout this manual. The signal words of DANGER, WARNING, CAUTION and SAFTETY NOTICE have specific meanings to alert you to the relative level of hazard. Take the safety warnings seriously. If you do not understand them or have questions about them, call McNeilus Street Smart Parts and Service. A hazard that will result in death or serious personal injury. A hazard which may result in death or serious personal injury. A hazard which may result in personal injury or damage to property or equipment. SAFETY NOTICE Procedures that must be performed for safe operation and/or maintenance. Recycler Soft-Stop System 5 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

9 SAFETY Product Safety Information Read, understand and follow the safety guidelines and heed dangers and warnings listed below and contained in this manual as well as on the Recycler Soft-Stop System and Packer itself to promote reliable operation and prevent serious personal injury. Contact McNeilus Street Smart Parts and Service if you require assistance or have questions. Safety Immediately replace safety decals if damaged, unreadable or missing. Contact McNeilus Street Smart Parts and Service for no-charge replacement decals when required. Failure to replace decals may result in serious personal injury or death. The Packer must not be modified in any way without authorization from McNeilus Truck and Manufacturing, Inc. Modifications may not comply with safety standards, including ANSI safety standards, and may result in serious personal injury or death. Operation Never attempt to clear a jammed Packer or container lift, enter a body or open an access door unless power is shut down, LOCKOUT/TAGOUT procedures have been complied with, and the employee is authorized, trained and competent to perform such activities. Failure to comply may result in serious personal injury or death. Wear the proper protective clothing when operating or maintaining the Packer. Hard hats, safety glasses, gloves and safety shoes should be worn. Reflective clothing is recommended for drivers and employees while operating during darkness. Serious injury or death will result without proper protective gear. All owners and supervisors should make sure all drivers, operators and maintenance personnel have read and thoroughly understand the decals affixed to this Packer as well as the safety information and instructions in the McNeilus Operator Manual. Owners and Supervisors must comply with ANSI Z245. Regulations. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 6 Recycler Soft-Stop System

10 SAFETY Never walk or stand behind Packer while it is backing up. Failure to heed these instructions/warnings may result in serious personal injury or death. Never operate the hydraulic system if a leak is present. Serious injury or death may result. Always keep hands and feet and other parts of your body clear of revolving or moving parts. Failure to comply may cause serious injury or death. Be sure everyone is clear of the area around the Packer before operating the Packer. Remain attentive at all times when operating the controls. Watch the mirrors for activity. Never back up the Packer unless and until you are completely sure it is safe. Use a spotter/observer and/or get out and check yourself, if necessary, to ensure it is safe to do so. Thoroughly understand the controls before operating the Packer. Failure to heed this warning may result in serious personal injury or death. Before opening the tailgate, be sure you have adequate clearance above the tailgate to prevent contact with buildings, electrical lines and any other overhead obstructions. Failure to comply may cause damage to the vehicle and serious personal injury or death. Recycler Soft-Stop System 7 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

11 Maintenance SAFETY LOCKOUT/TAGOUT procedures must be followed when working on this equipment, including, but not limited to, cylinders being changed or maintained. Failure to heed these instructions/warnings will result in serious personal injury or death. Hydraulic systems operate under high pressure. Only qualified, experienced people properly trained in hydraulic system maintenance should attempt repairs or troubleshoot hydraulic systems. Use the proper tools and equipment when servicing the hydraulic system. Failure to comply may cause serious injury or death. Never wear watches, rings or jewelry while working with electrical and mechanical equipment. These items can be hazardous and may cause serious and painful injuries or death if they come into contact with electrical wires, moving parts or hydraulic equipment. When working on the Packer, the wheels must be blocked, the parking brake on, LOCKOUT/TAGOUT procedures in effect and the key out of the chassis ignition. Failure to do so may result in serious personal injury or death. All hydraulic pressure must be relieved from the hydraulic system prior to removing any components from the system. To relieve the hydraulic pressure from the hydraulic system, turn the chassis engine OFF and operate the Packer controls with the key in the ON position. This will allow the spools to shift and relieve the hydraulic pressure. Failure to comply may result in serious injury or death. Anytime the tailgate is raised in the shop, the tailgate must be supported to prevent it from lowering unexpectedly. Never allow anyone to work around or enter the tailgate area unless the tailgate is raised! Failure to follow this procedure may result in serious injury or death. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 8 Recycler Soft-Stop System

12 SAFETY Hydraulics The hydraulic cylinders can be holding a function in a certain position when the engine is OFF. An example of this would be a function being held in the lift or partial lift position by the cylinders. If a hydraulic line is removed or the hydraulic circuits or controls are being worked on, gravity may allow the function being held in position to drop. All workers and personnel must remain clear of these areas when working on or operating the McNeilus equipment. Block and secure all applicable devices and functions before beginning work or operation. Failure to comply with this may result in serious injury or death. 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. Disconnect battery before welding on body. Failure to do so might result in personal injury or damage to property or equipment. Hydraulic hoses, fittings, tubes and pipes must be inspected on a daily basis for leaks, cuts, abrasions, damage, aging, improper clearance and along the frame for hidden damage. If you find any with these adverse conditions or damage, they must be replaced before the Packer is returned to service! In any event, all hydraulic hoses must be replaced every three years or 7500 hours. Failure to properly inspect and maintain your Packer may result in serious personal injury or death. Recycler Soft-Stop System 9 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

13 SAFETY Hydraulic systems are hot. DO NOT TOUCH! Serious personal injury or death may result from hot oil. When you have completed working on the hydraulic systems, thoroughly clean any spilled oil from the equipment. Do not spill any hydraulic fluid on the ground. Clean any hydraulic fluid from your skin as soon as you have completed your maintenance and repairs. Dispose of used oil and filters as required by law. Correct hoses, fittings and adapters with the correct SAE rating must be used when replacing hoses to prevent possible serious injury or death. Always replace hoses, fittings, and adapters with replacements that have a proper, suitable working pressure rating. Replacement hoses must be of the correct length and must comply with the hose manufacturer s installation guidelines and recommendations. Consult hose and fitting manufacturers for correct specifications. Hydraulic hoses have the SAE ratings marked on the hose to assist in selecting the correct hose. Replacement hydraulic hose and fitting components must be supplied by the same manufacturer to prevent serious injury. As an example: Brand A hose and brand B fitting will not normally be compatible. Any hydraulic tubing that is replaced must conform to SAE J065 specifications. If incorrect hydraulic tubing is installed, the hydraulic system may fail and serious injury or death may result. Damage or leaking tubing must be replaced before the Packer is returned to service. Never heat hydraulic tubes or pipes. The carbon content of the steel in the tubes or pipes is such that if heated for bending, and either water or air quenched, the tubes or pipes may lose their ductility and thereby be subject to failure under high pressure or hydraulic shock conditions. Serious injury or death may result. Damaged or leaking tubes or pipes must be replaced before the Packer is returned to service. Increasing hydraulic pressure beyond the recommendations may result in serious damage to the Packer or serious personal injury or death and may void the Packer Warranty. Hydraulic components can be heavy. Use caution while lifting these components. Serious personal injury or death may be avoided with proper handling of the components. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 0 Recycler Soft-Stop System

14 SAFETY Do not steam clean or pressure wash hydraulic hoses or components. Failure to comply may result in serious injury or death. Steam cleaning, using extremely hot water or pressure washing may damage the hoses and components and shorten the life or cause failure of the components. Many hose coverings are available. Choose the hose manufacturer s covering which is most resistant to acid wash. Failure to comply may result in serious injury or death. Some hose coverings may retain acid wash and cause premature failure of the hose. Allow no twist when installing hoses. Remember that 7 of twist per foot decreases hose life by 95%. When installing hydraulic hose, use a wrench to hold the hose in its natural position before tightening the fittings. Failure to comply may result in serious injury or death. When performing hydraulic test procedures, use the proper hydraulic gauges. Installing an incorrect test gauge could result in serious injury or death if the gauge fails. Use properly rated hydraulic hoses with adequate length to allow the test gauge to be used far enough away from moving parts and functions. Anticipate a 4% hose shrinkage factor when determining hose length. When a hose pressurizes, it expands and becomes shorter. Hose style shrinkage rates vary among different size and brand hoses. Allowing 4% will prevent the hose from tugging on the fittings when the hose is pressurized. Failure to comply may result in serious injury or death. Example: a 50" hose would have to be 4% longer or 52" total length. Recycler Soft-Stop System 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

15 SAFETY This Page Intentionally Left Blank 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 2 Recycler Soft-Stop System

16 Packing List Recycler Soft-Stop System PACKING LIST The Recycler Soft-Stop System is shipped complete as a kit. The kit includes all components required for installation. Components in the kit include Control Box, Proximity Switches, Harnesses, Air Supply Assembly, Air Actuator Kit, Tools and Supplies. Single Bucket Refer to the following Packing List for a complete list of all parts required for installation and included in kit. ITEM Description Qty. MTM Part No. Soft-Stop Kit, Single Bucket Recycler Control Box 4276 Power Stub Harness Proximity Switch Bracket, Proximity Switch Target, Proximity Switch Washers Air Supply Assembly, includes Air Regulator, Water Separator, Fittings and Mounting Bracket Air Actuator Kit, VA20, includes Red Spring Seal Kit, VA20 Spool 3760 Air Line Kit Dielectric Grease Deutsch Extraction Tool, Green 2HB290 Wide-Tip Adjustment Bit, /6" W x -/8" L Loctite Grade 262 Red Loctite Grade 609 Green Air Gauge Kit 3787 Recycler Soft-Stop System 3 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

17 Dual Bucket PACKING LIST Refer to the following Packing List for a complete list of all parts required for installation and included in kit. ITEM Description Qty. MTM Part No. Soft-Stop Kit, Dual Bucket Recycler Control Box 4277 Power Stub Harness Proximity Switch Brackets, Proximity Switch Targets, Proximity Switches Washers Air Supply Assembly, includes Air Regulator, Water Separator, Fittings and Mounting Bracket Air Actuator Kits, VA20, includes Red Spring Seal Kit, VA20 Spool Air Line Kit Dielectric Grease Deutsch Extraction Tool, Green 2HB290 Wide-Tip Adjustment Bit, /6" W x -/8" L Loctite Grade 262 Red Loctite Grade 609 Green Air Gauge Kit /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 4 Recycler Soft-Stop System

18 LOCKOUT/TAGOUT Procedures Recycler Soft-Stop System SYSTEM INSTALLATION Installation of the Recycler Soft-Stop System must be performed by skilled service personnel. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed when performing installation or maintenance on this equipment. If you are unfamiliar with the OSHA LOCKOUT/TAGOUT procedures or any other safety requirements, please contact McNeilus Street Smart Parts and Service. Installation Guidelines SAFETY NOTICE Before entering Packer body, or climbing on or getting under truck to perform any work, read and follow OSHA Regulations concerning entry and working in CONFINED SPACE OSHA and LOCKOUT/ TAGOUT OSHA Follow OSHA Regulations while performing any work to the Packer. Follow all safety instructions in your Recycler Soft-Stop System manual and your OEM 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. Failure to do so may result in serious personal injury or death. Before installing the Recycler Soft-Stop System, the Packer body must be empty and the chassis parked on a smooth and level surface. The Recycler Soft-Stop System is designed for use with McNeilus Compacting Recycler units. Most units have been updated per Technical Service Bulletin RCYC-TSB-00 to add a 2-speed option for improved operating functionality. This update decreased the bucket cycle time to 0 seconds. This manual describes how to install the Recycler Soft-Stop System for both units with or without the update installed. The 2-speed option is disabled and not used when the Recycler Soft-Stop System is installed. Additional parts are included in the kit to accommodate installation on units that do not have the update installed. This manual covers the installation of the Recycler Soft-Stop System for both the single and dual bucket Recycler units. Instructions are for the installation on the curb side which is standard for both systems. Repeat the instructions for installation on the street side on dual bucket Recycler units. Recycler Soft-Stop System 5 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

19 Mounting Control Box SYSTEM INSTALLATION The control boxes for the single (Figure, ) and dual bucket (Figure, 2) Soft-Stop kits are different. The control box for the dual bucket Soft-Stop kit is larger than the control box used with the single bucket Soft-Stop kit. The control boxes are shipped assembled complete and ready for installation. Several connections must be made after mounting the control box. Both control boxes have a harness connection for 2V power. 2 Figure The control box for the single bucket Soft-Stop kit has a connection for one () proximity switch and air line connections for only the curb side bucket functions (raise and lower). The control box for the dual bucket Soft-Stop kit has connections for two (2) proximity switches and air line connections for both the curb and street side bucket functions (raise and lower). 2 Figure 2 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 6 Recycler Soft-Stop System

20 SYSTEM INSTALLATION Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Determine the mounting location for the control box (Figure 2, ). The control box must be located near the VA20 control valve (Figure 2, 2) that controls the buckets. On the McNeilus Recycler, the VA20 control valve is located on the curb side of the front head of the Packer body. Securely mount the control box. Orientate the control box so that the connectors on the box are accessible. Be sure the cover can be easily opened for service and there is adequate clearance for removal of the VA20 valve spools. IMPORTANT The control box must be located as close as possible to the VA20 control valve assembly while providing adequate clearance for removal of the VA20 valve spools and allowing the cover to be easily opened. If the control box is located too far away from the VA20 control valve, the Recycler Soft-Stop System will not operate properly. Connecting Control Box Power The control box is supplied with an external 2-pin Weatherpak ready for input power. A power stub harness is provided to interface with the Packer harness at the MAC solenoid valve stack connection to provide a 2V power source to the Soft-Stop control box DEUTSCH Figure 3 Locate the 2-pin DT06 Deutsch connector (Figure 3, ) for the MAC solenoid valve stack (Figure 3, 2). The MAC solenoid stack is located above the VA20 control valve. 5 Recycler Soft-Stop System 7 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

21 SYSTEM INSTALLATION Disconnect the Deutsch connector for the MAC solenoid stack from the harness connection. Use the green Deutsch removal tool (Figure 3, 3) provided in the kit to remove pins "" and "2" from the mating Packer harness connector mounted in the bracket. Pin "" (Figure 3, 4) corresponds with the white wire (Pump Power). Pin "2" (Figure 3, 5) corresponds with the black wire (Ground). Before removing pins "" and "2" from the 2-pin Deutsch connector of the Packer harness, verify the wire colors used for each pin location. If the wire colors are different, label each wire to identify the pin location it is removed from. Before removing pins "" and "2" from the 2-pin Deutsch connector of the Packer harness, verify the wire colors used for each pin location. If the wire colors are different, label each wire to identify the pin location it is removed from. Failure to heed this warning may result in personal injury or damage to property or equipment. Installation of Power Stub Harness Insert pins in Packer harness 2-pin Deutsch plug for MAC solenoid stack White Pin 2 Black DT04-2P DT06-2S Pin 2 Deutsch 2-pin Connectors 2 Pins removed from Packer Harness 2-pin Deutsch plug for MAC solenoid stack A B Weatherpak 2-pin Female connector Figure 4 Identify pin of the power stub harness with white wire. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 8 Recycler Soft-Stop System

22 SYSTEM INSTALLATION Insert pin for white wire of power stub harness into location of the Deutsch connector where the white wire from the Packer harness was previously removed. Identify pin of the power stub harness with black wire. Insert pin for black wire of power stub harness into location 2 of the Deutsch connector where the black wire from the Packer harness was previously removed. Next identify the DT04-2P Deutsch male connector on the power stub harness. Inserted in the connector is a DT06-2S Deutsch female connector. Remove the DT06-2S Deutsch female connector. Identify the Packer harness wires removed from pins "" and "2" of the Deutsch connector. Identify the white wire removed from pin location of the Packer harness connector. Insert the white wire into location 2 of the DT06-2S Deutsch female connector. Identify the black wire removed from pin location 2 of the Packer harness connector. Insert the black wire into location of the DT06-2S Deutsch female connector. Install the locking wedge into the Deutsch connector. Reconnect the DT06-2S connector into the DT04-2S connector of the power stub harness. Apply dielectric grease to the pins before making connection. Power Stub Harness Test After installing power stub harness, it must be checked to verify that it has been installed correctly. Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON without starting the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Do not start and run chassis engine when performing the following procedures. Follow the previous procedure when performing power stub harness test. Failure to heed this warning may result in personal injury or damage to property or equipment. Recycler Soft-Stop System 9 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

23 SYSTEM INSTALLATION Using a multimeter, check for polarity across pins "" and "2" of the Packer harness Deutsch connector. Verify that pin location "" has 2V DC. Use pin location "2" for the ground. If the polarity across pins "" and "2" of the Packer harness Deutsch connector can not be verified, return to previous section Installation of Power Stub Harness on page 8 and repeat steps. If the correct polarity is confirmed on pins "" and "2", the remaining installation can be completed. Before the remaining installation can be completed, the polarity across pins "" and "2" of the Packer harness Deutsch connector must be verified. Failure to heed this warning may result in personal injury or damage to property or equipment. Reconnect the Deutsch connector for the MAC solenoid stack with the harness connection. Apply dielectric grease to the pins before making connection. Check the LED lights in the MAC solenoid stack to confirm their operation is normal. Connection of Control Box Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. On the power stub harness there is a remaining 2-pin Weatherpak female connector. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 20 Recycler Soft-Stop System

24 SYSTEM INSTALLATION Figure 5 Connect the 2-pin Weatherpak male connector (Figure 5, ) on control box to the 2-pin Weatherpak female connector on the power stub harness. Apply dielectric grease to the pins before making connection. Route and fasten the power cord so that it is secure and will not be damaged during operation. Connecting Proximity Switch(es) For the Recycler Soft-Stop System to function properly, the position of the bucket function must be known. To provide this information, a proximity switch is mounted to indicate when the bucket is located in the dump position or curved section of track. Installation of Proximity Switch(es) Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON and start the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Lower the bucket(s) to the down or HOME position. Apply LOCKOUT/TAGOUT procedure to the Recycler. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Remove the top door lifting lug cover (one with McNeilus logo) to gain access to the lifting lugs (Figure 6, ). Recycler Soft-Stop System 2 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

25 SYSTEM INSTALLATION Figure 6 Standard on all Recycler units is a proximity switch (Figure 6, 2) mounted to sense when the bucket is in the down or HOME position. The Packer function is interlocked and will only operate when this proximity switch is targeted. A second proximity switch (Figure 6, 3) is mounted on Recycler units with the 2-speed option update installed. When the proximity switch is targeted, the 2-speed option is activated and idles the chassis engine throttle. The 2-speed option is disabled and not used when the Recycler Soft-Stop System is installed. Remove the second proximity switch(es) (Figure 6, 3) used for the 2-speed option. A proximity switch bracket (Figure 6, 4) is provided for use on Recycler units that have not been updated with the 2-speed option. Center the proximity switch bracket under the lifting lugs and bolt bracket to provide mounting of the proximity switch(es) required for the Recycler Soft-Stop System. 4 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 22 Recycler Soft-Stop System

26 SYSTEM INSTALLATION 2-/4" 2-/4" Figure 7 Temporarily install the proximity switch(es) (Figure 7, ) provided with the Recycler Soft-Stop System kit. Position the edges of the proximity switches 2-/4" from the outside edge of the bracket. 3-/2" /4 /2 - Figure 8 The proximity switch targets (Figure 8, ) will already be welded onto the lifting lugs on Recycler units with the 2-speed option update installed. Proximity switch targets are provided for use on Recycler units that have not been updated with the 2-speed option. Weld on proximity switch target(s) to the face of the top door lifting lug. Position the edge of the proximity switch target 3-/2" from the bottom edge of top door lifting lug. Weld using a /4" weld /2" long on " centers. Recycler Soft-Stop System 23 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

27 Connection of Proximity Switch(es) SYSTEM INSTALLATION Locate the proximity switch harness(es). The harness(es) have a 3-pin Weatherpak connector. Route the harness(es) down the front of the body to the control box. Fasten the harness(es) every 2" so that it is secure and will not be damaged during operation. 2 Figure 9 Connect the 3-pin Weatherpack male connector end for the proximity switch on the curb side to the corresponding 3-pin Weatherpak female connector (Figure 8, ) on control box labeled "Curb Side Proximity Switch". Apply dielectric grease to the pins before making connection. If installing on a dual bucket Recycler, connect the 3-pin Weatherpack male connector end for the proximity switch on the street side to the corresponding 3-pin Weatherpak female connector (Figure 8, 2) on control box labeled "Street Side Proximity Switch". Proximity Switch(es) Adjustment Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON and start the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 24 Recycler Soft-Stop System

28 SYSTEM INSTALLATION 2 Figure 0 Raise the curb side bucket until the top roller (Figure 0, ) of the bucket is aligned " below the seam (Figure 0, 2) at the top of the track where the curved section starts. Apply LOCKOUT/TAGOUT procedure to the Recycler. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Adjust the proximity switch on the curb side. If installing on a dual bucket Recycler, the proximity switch for the street side must also be adjusted. Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON and start the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Lower the curb side bucket to the down or HOME position. Raise the street side bucket until the top roller (Figure 0, ) of the bucket is aligned " below the seam (Figure 0, 2) at the top of the track where the curved section starts. Apply LOCKOUT/TAGOUT procedure to the Recycler. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Adjust the proximity switch on the street side. Recycler Soft-Stop System 25 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

29 Connection of Air Lines SYSTEM INSTALLATION The Recycler buckets are controlled by a VA20 control valve mounted at the front of the body on the curb side. Each of the valve sections of the valve assembly is controlled by an air actuator. The air actuators are controlled from the MAC air solenoid stack. 3 2 Figure The Recycler Soft-Stop System meters the air control of the bucket functions for the Recycler. The valve section for the curb side bucket function is identified as the third valve section from the inlet section (Figure, ) on a single bucket Recycler or the fourth working section (Figure, 2) from the inlet section on a dual bucket Recycler. On a dual bucket Recycler the valve section for the street side bucket function is identified as the third valve section (Figure, 3) from the inlet section. The installation of the control box for the Recycler Soft-Stop System requires that air from the MAC air solenoid stack to the valve section for the bucket functions must be split and plumbed through the control box. To ensure reliable performance of the VA20 control valve, the centering spring on the spool(s) must be replaced with a red spring provided with the kit. When replacing the centering spring, the spool seals on both ends of the valve section must also be replaced. To effectively remove and replace the spool seals, the spool assembly must be removed. For this reason, the following procedure removes the spool assembly when replacing the centering spring. When the spool assembly is removed, oil will leak from the spool section. Use an oil pan to collect any oil that drains from the valve section. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 26 Recycler Soft-Stop System

30 SYSTEM INSTALLATION Replace the Air Actuator and Centering Spring Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON and start the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Lower the bucket(s) to the down or HOME position. Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Locate the VA20 valve assembly mounted at the front of the body on the curb side Figure 2 Clean all debris and dirt away from the top of VA20 valve assembly before disassembling. Locate the third section (Figure 2, ) away from the inlet section (Figure 2, 2) for the bucket function. The inlet section can be identified by the main relief and pressure gauge port. On Recycler units with dual buckets, the fourth section (Figure 2, 3) away from the inlet section must also be reworked. Disconnect air lines (Figure 2, 4) from air actuator fittings. Recycler Soft-Stop System 27 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

31 SYSTEM INSTALLATION Figure 3 Loosen two (2) capscrews and remove air actuator. Air actuator must be moved to the side to slide the actuator rod (Figure 3, ) out of the stripper bolt. Remove air actuator from valve section. All parts removed will be replaced with a new style air actuator. 2 Figure 4 Hydraulic oil will leak from the valve section body when the spool assembly is removed. Place a container under the valve section to collect the hydraulic oil while the spool assembly is removed. Pull the spool assembly (Figure 4, ) up and out of valve section body. Lift the retainer plate (Figure 4, 2) under the centering spring assembly when removing the spool assembly. After removing spool assembly, slide the retainer plate off the spool assembly and discard. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 28 Recycler Soft-Stop System

32 Replace Spool Centering Spring Recycler Soft-Stop System SYSTEM INSTALLATION Figure 5 Clamp the spool assembly (Figure 5, ) in a vise with the centering spring assembly (Figure 5, 2) away from the vise. IMPORTANT When clamping spool assembly in vise, make certain not to damage machine surfaces of spool. Only clamp using the opposite end of the centering spring assembly. Using the wide-tip adjustment bit (Figure 5, 3) provided in the kit, remove the stripper bolt (Figure 5, 4) securing the centering spring assembly. When removing the stripper bolt, be sure to collect all of the components from the spring assembly for use during reassembly Figure 6 Discard the spring (Figure 6, 4) removed during disassembly. Reassemble the centering spring assembly using the red spring (Figure 6, 6) supplied with kit. Reassemble the centering spring assembly in the order illustrated in (Figure 6). Recycler Soft-Stop System 29 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

33 SYSTEM INSTALLATION The spacer tube (Figure 6, 3) is inserted inside the red spring (Figure 6, 6) with spring retainers (Figure 6, 2) on each end of the spring. Slide the stripper bolt (Figure 6, ) through the spring retainers for installation. Figure 7 Thoroughly clean the threads of the stripper bolt (Figure 7, ) and inside spool (Figure 6, 5). Apply two to three (2-3) drops of Loctite Grade 262 Red (Figure 7, ) to threads of stripper bolt before installation. IMPORTANT Apply two to three (2-3) drops of Loctite Grade 262 Red (Figure 7, ) to threads of stripper bolt before installation. Do not over-apply Loctite, as it will result in a weaker seal. Using the wide-tip adjustment bit (Figure 5, 3) provided in the kit, install the centering spring assembly to the spool. Torque the stripper bolt to 5 ft-lb (80 in-lb). Inspect to make sure the spring retainers on each end of the spring are free and rotate independent of the spool. IMPORTANT Inspect to make sure the spring retainers on each end of the spring are free and rotate independent of the spool. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 30 Recycler Soft-Stop System

34 Replace Spool Seals Recycler Soft-Stop System SYSTEM INSTALLATION When installing the Recycler Soft-Stop System on units that have previously been in service, the spool seals must be replaced before installing the spool subassembly. This will ensure reliable operation after the repair is completed Figure 8 First, replace the spool seal and backup ring in the bottom of the valve section in the Recycler valve assembly. Remove the two (2) screws (Figure 8, ) and retainer plate (Figure 8, 2). Remove the old seal and backup ring. Install the seal (Figure 8, 4) first followed by the backup ring (Figure 8, 3). Reinstall the retainer plate and two (2) screws. Next, remove the old seal and backup ring from the top of the valve section. Install the seal (Figure 8, 5) first followed by the backup ring (Figure 8, 6). Recycler Soft-Stop System 3 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

35 SYSTEM INSTALLATION Installation of Air Actuator The air actuator kit (Figure 9, ) is included with the Recycler Soft-Stop System Figure 9 Remove the nuts (Figure 9, 2) from the cap screws to disassemble the kit. Nuts will not be used and can be discarded Figure 20 Slide the retainer plate (Figure 9, 7) (Figure 20, ) over the spool assembly (Figure 20, 2). Align the curved end with slot (Figure 20, 3) on the retainer plate up to fit around relief valve port (Figure 20, 4). Insert spool assembly with retainer plate into valve section. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 32 Recycler Soft-Stop System

36 SYSTEM INSTALLATION Install spacer (Figure 9, 6) and spacer plate (Figure 9, 5) over centering spring assembly of spool assembly. Install both with the curved side up for clearance with the relief valve port. The air actuator (Figure 9, 3) also has a curved side. Install the air actuator with the curved side up for clearance with the relief valve port. To attach the air actuator, slide the actuator rod into the slot of the stripper bolt. The spool assembly can be pushed up to provide better access when attaching air actuator. Figure 2 Apply two to three (2-3) drops of Loctite Grade 609 Green to the threads of the two (2) cap screws (Figure 9, 4). IMPORTANT Do not over-apply Loctite Grade 609 Green, as it will result in a weaker seal. Install the cap screws through the air actuator assembly and torque to 2 ft-lb (44 in-lb). IMPORTANT Do not over-tighten cap screws. On Recycler units with dual buckets, repeat the previous steps to rework the fourth working section (Figure 2, 3) from the inlet section. Recycler Soft-Stop System 33 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

37 Connecting Air Lines SYSTEM INSTALLATION 5 EXH 5 AIR ACTUATOR UP 4 EXH 4 AIR MANIFOLD VALVE UP AIR ACTUATOR 2 AIR ACTUATOR DOWN VALVE DOWN Figure Figure 23 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 34 Recycler Soft-Stop System

38 SYSTEM INSTALLATION The simplest and most reliable method to reconnect the air control lines previously removed from the air actuator is to have someone assist with the operation of the bucket control located beside the bucket on each side. Remove LOCKOUT/TAGOUT and turn battery switch ON. Turn the chassis ignition ON without starting the chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Do not start and run chassis engine when performing the following procedures. Follow the previous procedure when performing power stub harness test. Failure to heed this warning may result in personal injury or damage to property or equipment. Move the curb side bucket control DOWN and identify which air line expels air. Connect the identified air line to the "CAN DOWN FROM VALVE" (Figure 23, ) port on the control box. After connecting air line, air should expel from the connection labeled "CAN DOWN CYL PORT " (Figure 23, 2). Blue and black air lines are provided with the kit. Use the air line color that corresponds with the color of air line installed previously in the "CAN DOWN FROM VALVE" port. Install the air line into the "CAN DOWN CYL PORT " port on control box. Connect the opposite end of the air line in the air actuator fitting located at "Port 2" (Figure 23, 3). "Port 2" is located away from the curved side (Figure 23, 4) of the air actuator. Move the curb side bucket control UP and identify the other air line that expels air. Connect the identified air line to the "CAN UP FROM VALVE" (Figure 23, 5) port on the control box. After connecting air line, air should expel from the connection labeled "CAN UP CYL PORT 2" (Figure 23, 6). Install the remaining air line into the "CAN UP CYL PORT 2" port on the control box. Connect the opposite end of the air line in the air actuator fitting located at "Port " (Figure 23, 7). "Port " is located near the curved side (Figure 23, 4) of the air actuator. On Recycler units with dual buckets, proceed with the following steps to install the air lines from the street side bucket control to the fourth valve section from the inlet section. Recycler Soft-Stop System 35 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

39 SYSTEM INSTALLATION Move the street side bucket control DOWN and identify which air line expels air. Connect the identified air line to the "CAN DOWN FROM VALVE" (Figure 23, 8) port on the control box. After connecting air line, air should expel from the connection labeled "CAN DOWN CYL PORT " (Figure 23, 9). Blue and black air lines are provided with the kit. Use the air line color that corresponds with the color of air line installed previously in the "CAN DOWN FROM VALVE" port. Install the air line into the "CAN DOWN CYL PORT " port on control box. Connect the opposite end of the air line in the air actuator fitting located at "Port 2" (Figure 23, 3). "Port 2" is located away from the curved side (Figure 23, 4) of the air actuator. Move the curb side bucket control UP and identify the other air line that expels air. Connect the identified air line to the "CAN UP FROM VALVE" (Figure 23, 0) port on the control box. After connecting air line, air should expel from the connection labeled "CAN UP CYL PORT 2" (Figure 23, ). Install the remaining air line into the "CAN UP CYL PORT 2" port on the control box. Connect the opposite end of the air line in the air actuator fitting located at "Port " (Figure 23, 7). "Port " is located near the curved side (Figure 23, 4) of the air actuator. On Recycler units with dual buckets, proceed with the following steps to install the additional air lines. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 36 Recycler Soft-Stop System

40 SYSTEM INSTALLATION Installation of Regulator/Water Separator The Recycler air system must be clean and properly maintained for the Recycler Soft-Stop System to provide repeatable operation. The air supply for the bucket control valves is controlled from the MAC valve bank (Figure 24, ). An air supply assembly (Figure 24, 2) is provided for installation between the air filter (Figure 24, 3) and MAC valve stack on the Recycler. The air supply assembly includes a water separator (Figure 24, 4) and air regulator (Figure 24, 5). The air regulator is preset to limit the air supply pressure to the Soft-Stop System between psi Figure 24 Apply LOCKOUT/TAGOUT procedure to the Packer. Observe all conditions of the Safety Notice concerning LOCKOUT/TAGOUT Procedures on page 5. Determine the mounting location for the air supply assembly. The air supply assembly must be located near the air filter for the Packer air controls. The air filter is usually located near the MAC solenoid valve stack. Securely mount the air supply assembly. Orientate the assembly so that the connectors are accessible. IMPORTANT Mount the air supply assembly as close as possible to the air filter for the Recycler air controls. Identify the air line (Figure 24, 6) between the air filter and MAC solenoid valve stack. The air filter should have an arrow (Figure 24, 7) on the air filter to identify the direction of air flow. Split the identified air line. Recycler Soft-Stop System 37 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

41 SYSTEM INSTALLATION Make connection between air filter outlet (Figure 24, 8) and the "IN" port (Figure 24, 9) on the water separator. Make a second connection between the air regulator outlet (Figure 24, 0) and the MAC solenoid valve stack. Start-Up Procedure System is now ready to start up. Before starting the vehicle, make certain that the hydraulic reservoir level is checked and hydraulic oil is added if necessary. Before starting the chassis engine, the hydraulic reservoir must be checked and oil added if necessary. Failure to heed this warning may result in personal injury or damage to property or equipment. Remove LOCKOUT/TAGOUT and turn battery switch ON. Start chassis engine. Turn E-STOP and Lockout Toggle switches ON. Turn PUMP rocker switch on cab control box ON. Warm up the hydraulics to normal operating temperature by cycling each of the Recycler functions several times. Observe and inspect for any air leaks or deficiencies during operation. Correct all identified air leaks or deficiencies before placing into service. 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 38 Recycler Soft-Stop System

42 PREVENTIVE MAINTENANCE Design The Recycler Soft-Stop System is designed to provide exceptional performance and value while requiring a mininum amount of maintenance. Performing Preventive Maintenance will provide prolonged life of the Soft-Stop system, help prevent expensive downtime and minimize the potential for problems arising on the route. Maintenance Intervals NOTE If the Packer is operated more hours per day or double shifted, the maintenance interval must be adjusted accordingly. LOCKOUT/TAGOUT Procedures All maintenance procedures must be performed by skilled service personnel. Safety and safe working procedures must be followed at all times. OSHA LOCKOUT/TAGOUT procedures must be followed when performing maintenance on this equipment. If you are unfamiliar with the OSHA LOCKOUT/TAGOUT procedures or any other safety requirements, please contact McNeilus Street Smart Parts and Service. SAFETY NOTICE Before entering Packer body, or climbing or getting under truck to perform any work, read and follow OSHA Regulations concerning entry and working in CONFINED SPACE OSHA and LOCKOUT/ TAGOUT OSHA Follow OSHA Regulations while performing any work to the Packer. Follow all safety instructions in your Recycler Soft-Stop System manual and your OEM 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. Failure to do so can result in serious personal injury or death. Recycler Soft-Stop System 39 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

43 PREVENTIVE MAINTENANCE Daily (0 Hours) Inspection and Check Daily (0 Hours), before placing the Recycler Soft-Stop System in service, a thorough and complete inspection for damage, loose hardware and oil leaks is required. Cycle the Recycler bucket several times before leaving the yard to verify the Soft-Stop system is operating properly. Repair as necessary any deficiencies found during the inspection and check Figure 25 Packer Coalescing Filter Daily (0 Hours) Drain the standard coalescing filter (Figure 25, ) for the Packer air system. Locate the drain fitting (Figure 25, 2) on the bottom of the coalescing filter. Drain the filter by turning the drain fitting counterclockwise. Turn the drain fitting clockwise after all moisture and contaminants have drained from the canister. Semi-Annual (250 Hours) The filter element is the only maintenance item and must be changed semi-annually. Replace the filter element with McNeilus part number /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 40 Recycler Soft-Stop System

44 Water Separator Daily (0 Hours) Recycler Soft-Stop System PREVENTIVE MAINTENANCE Drain the water separator (Figure 25, 3) installed for the Recycler Soft-Stop System. Locate the drain fitting (Figure 25, 4) on the bottom of the coalescing filter. Drain the filter by turning the drain fitting counterclockwise. Turn the drain fitting clockwise after all moisture and contaminants have drained from the canister. Semi-Annual (250 Hours) The filter element is the only maintenance item and must be changed semi-annually. Replace the filter element with McNeilus part number Recycler Soft-Stop System 4 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

45 How To Use Recycler Soft-Stop System ILLUSTRATIONS and PARTS LISTS The pages are arranged with illustrations followed by the corresponding parts list ITEM Description Footnote Qty. MTM Part No. SSP Cart Tipper Assembly /2-3 UNC x.25 BHCS, ZP F Torque Arm Retainer Torque Arm Weldment 2 DBA 4 /4-28 UNF x 0.38 Set Screw Master Cylinder Assembly Master Cylinder Rod Assembly (Includes Items 2, 5, 6 and 9) 2 Rod End Mount NSS 6 Cam Roller, " OD NSS 9 Dowel Pin, 5/6" x -/4" NSS 7 F Quantity shown for single bucket kit Double quantity for dual bucket kit Figure. ITEM: Refers to callout and leader on corresponding illustration. 2. Description: Provides a description of item to identify size, type or application. The description is indented (Figure, 6) to indicate when the component is part of an assembly. 3. Footnote: A footnote is used when specific information is required for that item. A footnote is indicated by an F accompanied by a number such as F (Figure, 7). Additional sequential numbers are used when more than one footnote is used on the page. 4. Qty: Quantity of the part in the assembly. 5. MTM Part No.: The McNeilus part number to use when ordering replacement parts. When a component part is not available, an NSS is used to indicate that the part is Not Serviced Separately. When the application determines which part number is used, a DBA is used to indicate that the part is Determined By Application. Recycler Soft-Stop System 42 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

46 ILLUSTRATIONS and PARTS LISTS Control Box (Single Bucket) ITEM Description Footnote Qty. MTM Part No. Soft-Stop Control Box, Single Bucket Soft-Stop Control Box Enclosure F Air Manifold, Without Air Valves MAC Air Valve, 2 per Air Manifold Fuse, 5 Amp Footnote F Stubbed out with wiring harness assemblies Recycler Soft-Stop System 43 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

47 ILLUSTRATIONS and PARTS LISTS Control Box (Dual Bucket) ITEM Description Footnote Qty. MTM Part No. Soft-Stop Control Box, Dual Bucket Soft-Stop Control Box Enclosure F Air Manifold, Without Air Valves MAC Air Valve, 2 per Air Manifold Fuse, 5 Amp Footnote F Stubbed out with wiring harness assemblies 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 44 Recycler Soft-Stop System

48 Power Stub Harness Recycler Soft-Stop System ILLUSTRATIONS and PARTS LISTS ITEM Description Qty. MTM Part No. Power Stub Harness Bracket, Proximity Switch ITEM Description Qty. MTM Part No. Bracket, Proximity Switch(es) Recycler Soft-Stop System 45 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

49 Proximity Switch ILLUSTRATIONS and PARTS LISTS 2 ITEM Description Footnote Qty. MTM Part No. Proximity Switch F Washer F Footnote F Quantity shown for single bucket kit Double quantity for dual bucket kit Target, Proximity Switch ITEM Description Footnote Qty. MTM Part No. Target, Proximity Switch F Footnote F Quantity shown for single bucket kit Double quantity for dual bucket kit /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 46 Recycler Soft-Stop System

50 Air Actuator Kit Recycler Soft-Stop System ILLUSTRATIONS and PARTS LISTS ITEM Description Footnote Qty. MTM Part No. Kit, Air Actuator F Fitting, Air Lines Air Actuator NSS Seal Kit, Air Actuator Cap Screws 2 NSS 4 Plate, Spacer NSS 5 Spacer NSS 6 Retainer, Spacer NSS 7 Spring, VA20 Red Footnote F Quantity shown for single bucket kit Double quantity for dual bucket kit Recycler Soft-Stop System 47 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

51 Seal Kit, VA20 ILLUSTRATIONS and PARTS LISTS 2 ITEM Description Footnote Qty. MTM Part No. Seal Kit, VA20 Spool (Single Bucket) F 3760 Backup Ring 2 NSS 2 O-Ring Seal 2 NSS Footnote F Quantity shown for single bucket kit Double quantity for dual bucket kit Air Line Kit ITEM Description Footnote Qty. MTM Part No. Air Line Kit F Air Line, Blue NSS Air Line, Black NSS Footnote F Quantity shown for single bucket kit Double quantity for dual bucket kit /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 48 Recycler Soft-Stop System

52 Air Supply Assembly Recycler Soft-Stop System ILLUSTRATIONS and PARTS LISTS ITEM Description Qty. MTM Part No. Air Supply Assembly Water Separator Filter Element Air Regulator Fitting, Air Connection Nipple, /4" NPT x " Recycler Soft-Stop System 49 2/2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved.

53 Tools ILLUSTRATIONS and PARTS LISTS 2 3 Supplies ITEM Description Qty. MTM Part No. Air Gauge Kit, 0-50 psi Wide-Tip Adjustment Bit, /6" W x -/8" L Deutsch Extraction Tool, Green 2HB ITEM Description Qty. MTM Part No. Dielectric Grease Loctite Grade 262 Red Loctite Grade 609 Green /2009 McNeilus Truck and Manufacturing, Inc. All Rights Reserved. 50 Recycler Soft-Stop System

54 Visit or call to get quality replacement parts for ALL makes and models McNeilus Truck and Manufacturing Inc. McNeilus, the McNeilus logo are registered trademarks and Street Smart Parts and Service is a trademark of McNeilus Truck and Manufacturing Inc., Dodge Center, MN, USA. Oshkosh is a registered trademark of Oshkosh Corporation, Oshkosh WI, USA. All other designated trademarks are the property of their respective owners.