Refuse Container-Loader Installation Manual (G2)

Transcription

1 Part # Refuse Container-Loader Installation Manual (G2) Generation 2 Installation Rev IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA Tel: FAX: Website: Copyright 2010 Iowa Mold Tooling Co., Inc. All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa Mold Tooling Co., Inc. Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company. Printed on 1 December, 2010

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3 i Contents Revisions... ii Chassis Assessment 3 Hoist Dimensions...4 Parts 5 Parts Introduction...5 Upfit Package, Shipout ( )...5 Hydraulic Kit, Shipout ( )...7 Electrical Kit, Shipout ( )...8 Pneumatic Kit, Shipout ( )...8 Installation Steps 9 Install Pressure and Return Lines...10 Install Chassis Harness...11 Re-Terminating Cable...15 Strobe Light Installation...16 Install the Crane Mode Switch...18 Install the Hydraulic Valve Panel...19 Hose Installation...21 Pressure & Return Hose Connection to Tubing...24 Hose Clamps & Mud Guard...25 Control Box Installation...26 Air Line Connection...27 Fittings on Secondary Air Tank...28 Container Locking Mechanism...29 Marking Frame for the Lift Cylinders...29 Hoist-Container Brackets...30 Bracket Template...32 Power Connector Bracket...33 Body-Container Bracket...34 Tarper Arm Modification...35 Assembly Drawings 36 Installation Drawing ( )...36 Wiring Diagram ( )...41 Hydraulic System ( )...42

4 ii Contents Revisions DATE LOCATION DESCRIPTION

5 3 C HAPTER 1 Chassis Assessment Before beginning an IMT Refuse Container with Loader installation, assess the chassis for the following: 1 Roll-off hoist must have inside rail / outside rail design OR outside rail design. 2 Hoist must be a recent model year. (2007 or newer to be verified.) 3 The hoist must meet the dimensional requirements shown in Hoist Dimensions (on page 4). 4 Use the supplied Bracket Template drawing to locate the hole pattern for the bracket. See Bracket Template (on page 32) for reference information. Use the full-size bracket template. 5 The hydraulic requirements include: a) Hydraulic Flow: Minimum 28 gpm. Most cable hoist systems run at 35 gpm or more. b) Hydraulic Pressure: 2900 psi (Operating system pressure when in crane mode. In hoist mode, the hydraulic pressure is 1850 psi.) c) Pressure line: 1.00" d) Return line: 1.25" e) All fittings JIC Unapproved Chassis The Refuse Container with Loader product cannot be installed on a compressed natural gas chassis. If your chassis will require repairs or equipment modification, contact the IMT Inside Sales Administrator for approval before performing repairs or modifications.

6 4 Refuse Container-Loader Installation Manual (G2) Part # Hoist Dimensions Dimension A: Outside of rails 35-1/2 36-1/4 Dimension B: From centerline of nose wheel stop to centerline of bracket 38 Dimension C: From outside of bracket to outside of opposite bracket 46-15/16 Dimension D: Roller depth 3-5/8 Additional requirements: Hoist rail length should be sufficient for a 22 container. Hoist must have a nose wheel stop. Flip-up stops will not work.

7 5 C HAPTER 2 Parts In This Chapter Parts Introduction...5 Upfit Package, Shipout ( )...5 Hydraulic Kit, Shipout ( )...6 Electrical Kit, Shipout ( )...7 Pneumatic Kit, Shipout ( )...8 Parts Introduction With your Refuse Container with Loader, you will receive a large upfit package ( ) which includes several smaller kits. The upfit package and the smaller kits are marked with part numbers. Use the parts lists for the kits, as well as the photos and drawings, to identify the appropriate installation parts prior to beginning the installation steps. Upfit Package, Shipout ( ) PARTS LIST PART # DESCRIPTION QUANTITY CONTROL BOX-BAGSTER G WELDMENT-BRKT LATCH BODY BAGSTER G WELDMENT-BRKT LATCH CHASSISIS BAGSTER G GUIDE-BODY BAGSTER G2 RH GUIDE-BODY BAGSTER G2 LH EXTENSION-TARPER ARM BAGSTER PLUNGER-LATCH BAGSTER G GUARD-CYLINDER BAGSTER G PLATE-BAGSTER HYDRAULIC MOUNT G SPACER PLATE-CYLINDER MOUNT BAGSTER G GUARD-FENDER BAGSTER SHIM-BAGSTER CLAMP MOUNT 10GA SHIM-BAGSTER CLAMP MOUNT SHIM-BAGSTER CLAMP MOUNT BRACKET-HARNESS MOUNTING BAGSTER G CLAMP-TUBE 1.00 W/WELD PLATE CLAMP-TUBE 1.25 W/WELD PLATE 5

8 6 Refuse Container-Loader Installation Manual (G2) Part # PARTS LIST PART # DESCRIPTION QUANTITY CLAMP-TUBE 1.50 W/WELD PLATE CLAMP-TUBE 1.75 W/WELD PLATE TUBE ASSEMBLY-HYD 1.00X CHASSIS PRESS TUBE ASSEMBLY-HYD 1.25X CHASSIS RETURN TUBE ASSEMBLY-HYD 1.00X PRESS EXTEND A/R TUBE ASSEMBLY-HYD 1.25X RETURN EXTEND A/R TUBE ASSEMBLY-HYD 1.25 O.D. X 9.38 X TUBE ASSEMBLY-HYD 1.25 O.D. X 5.00 X CAP SCR.31-18X.75 HH GR5 Z NUT HEX NYLOC ZINC WASHER-FLAT.31 W ANSI B27.2 Z CLAMP-LOOP.75 CUSHIONED CLAMP-LOOP 1.00 CUSHIONED QUICK DISCONNECT-16 SOCKET-FEMALE QUICK DISCONNECT-20 SOCKET-FEMALE CLAMP-LOOP.50 CUSHIONED VALVE-ASSEMBLY-P.FLOW CNTRL 28 GPM CYLINDER-AIR BIMBA 2.00B 3.00S DBL ACT VALVE-SELECTOR 2POS 60GPM VALVE-RELIEF 60 GPM 2900PSI CAP-QUICK DISCONNECT -16 SOCKET CAP-QUICK DISCONNECT -20 SOCKET HARNESS-BAGSTER CHASSISIS G KIT-ELECTRICAL BAGSTER INSTALL G KIT-HYD BAGSTER SHIPOUT G KIT-HARDWARE BAGSTER CLAMP G KIT-HARDWARE BAGSTER TARPER G KIT-HARDWARE BAGSTER HYD PLATE G KIT-PNEUMATICS BAGSTER G DECAL KIT-BAGSTER, SHIPOUT DRAWING-BAGSTER INSTALL G DRAWING-BAGSTER CONTROL WIRING DIAGRAMS G DRAWING-HYD. & PNEUMATIC SYSTEM BAGSTER G DRAWING-BAGSTER DECAL INSTALLATION G2 1 Additional parts lists for the shaded parts follow.

9 Chapter 2 Parts 7 Hydraulic Kit, Shipout ( ) PARTS LIST PART # DESCRIPTION QUANTITY HOSE-AAJ 1.00 X (16-16) 100R HOSE-FF 1.00 X (16-16) 100R HOSE-FF 1.00 X (16-16) 100R HOSE-FJ 1.00 X (16-16) 100R HOSE-FJ 1.25 X (20-20) 100R HOSE-FF 1.25 X (20-20) 100R HOSE-FJ 1.25 X 18.5 (20-20) 100R ADPTR-MPT/HEX/MPT NIPPLE-DISC.25FPT STL HNV-14-M ADPTR-M STR/M JIC ADPTR-M STR/M JIC ADPTR-M JIC/M JIC ADPTR-M JIC/M JIC ELBOW-M STR/90/M JIC UNION-M STR/M STR SWVL ADPTR-M STR/M JIC ELBOW-M JIC/90/M JIC TEE-MALE JIC TUBE TEE-MSTR THD RUN CAP-DUST FOR

10 8 Refuse Container-Loader Installation Manual (G2) Part # Electrical Kit, Shipout ( ) PARTS LIST PART # DESCRIPTION QUANTITY BRACKET-LIGHT 4" RND GROMMET-RUBBER TAIL LIGHT LIGHT-STROBE SMART AMBER 4in LH # LIGHT-STROBE SMART AMBER 4in RH # LIGHT-STROBE SMART AMBER 4in LH # LIGHT-STROBE SMART AMBER 4in RH # CONN-PKRD WEATHERPACK 3 CAV FEMALE/TOWER CONN-PKRD WEATHERPACK 6 CAV FEMALE/TOWER CABLE SEAL-PKRD WP/MP GA BLUE PLUG-PKRD WEATHERPACK/METRIPACK PLUG CABLE SEAL-PKRD WP/MP 14 GA GREY TERM-PKRD WEATHERPACK 12GA FEMALE TERM-PKRD WEATHERPACK 14-16GA FEMALE DWG-BAGSTER CONTROL WIRING DIAGRAMS G2 1 Pneumatic Kit, Shipout ( ) PARTS LIST PART # DESCRIPTION QUANTITY TUBE-PUSHLOC.38 AIR (CS) ADPTR-MPT/HEX/MPT BRS REDUCER BUSH-BRS PUSH LOC- FTG ELBOW.38 DOT X.25 MPT PUSH LOC- FTG ELBOW.38 DOT X.12 MPT PUSH LOC- FTG.38 DOT X.12 MPT PUSH LOC- UNION TEE.38 DOT VALVE-BALL VALVE-PRESS PROTECTION.25in #

11 9 C HAPTER 3 Installation Steps In This Chapter Install Pressure and Return Lines...10 Install Chassis Harness...11 Re-Terminating Cable...15 Strobe Light Installation...16 Install the Crane Mode Switch...18 Install the Hydraulic Valve Panel...19 Hose Installation...21 Pressure & Return Hose Connection to Tubing...24 Hose Clamps & Mud Guard...25 Control Box Installation...26 Air Line Connection...27 Fittings on Secondary Air Tank...28 Container Locking Mechanism...29

12 10 Refuse Container-Loader Installation Manual (G2) Part # Install Pressure and Return Lines In the Upfit Kit , locate: Long pressure tube assembly (1" x 216") (Qty 1) Long return tube assembly (1.25" x 220") (Qty 1) " (pressure) clamp with weld plate (Qty 5) " (return) clamps with weld plates (Qty 5) With the hoist down, locate a place at the rear of the chassis to place the pressure and return lines on the chassis frame. Avoid locating the large tube under the frame in the area marked as it could get pinched. Raise the hoist, then position the tubing along the chassis. Weld the clamp mounting plates to the cross members as shown. Use four clamps for each line. Return (large) Pressure (small) lines Avoid this area. Tube may get pinched here. Clamp mounting plates welded to cross members

13 Chapter 3 Installation Steps 11 Install Chassis Harness In the Upfit Kit , locate the following: Harness - green cable which is 40' long Cap Screw - 5/16-18 x 3/4" (bag of 30 included with kit) Nut - 5/16-18 (bag of 30 included with kit) Clamp - Loop 3/4" cushioned (15 included with kit) Clamp - Loop 1" cushioned (10 included with kit. Install green power cable through the chassis, then loop at the hoist pivot. Weld on 5/16 x ¾ bolts every 18. Weld the head of the bolt to the frame, with the threaded part sticking up. The clamp will fit over the bolt and the nut will secure it in place. Using rubber coated clamps and 5/16 nuts, fasten the cable all the way to the front of the hoist. Clamps for green electrical wire View of electrical cable clamped on lower hoist

14 12 Refuse Container-Loader Installation Manual (G2) Part # The green electrical cable is routed down the lower hoist, then wraps to the upper hoist. This view is at the back of the hoist where the cable wraps up. Clamp the wire to the inside of the front of the hoist. The cable may be too long, and may need to be shortened before it is terminated.

15 Clamp chassis harness to the inside of the front of the hoist. Chapter 3 Installation Steps 13

16 14 Refuse Container-Loader Installation Manual (G2) Part # Cable clamped on inside of front of hoist. Clamp cable to the outside of the front of the hoist as shown. Note: This photo shows the green electrical wire connecting to the bracket on the body. This bracket will be installed in the step, Installing Power Connector Bracket (on page 32). See the Wiring Diagram ( ) (on page 41) for details on the electrical connections for the harness.

17 Chapter 3 Installation Steps 15 Re-Terminating Cable The power connector end of the green cable is designed for the longest hoist models (24' long). If the green electrical cable is too long for your hoist, you may shorten the cable and re-terminate the end. 1 Loosen the slotted screw on the cable clamp connector near the inlet end. 2 Remove the two Phillips head screws on the sides of the connector cover. 3 Push the cable towards the connector cover. 4 Cut back the green jacket 1-3/8" from the end of the cable. 5 Strip the wire insulation back 3/8". 6 Install wires per the chart. Note that the cavity labels will not match the wire colors. CAVITY NUMBER WIRE COLOR GAUGE PRINT LABEL 1 WHITE RED 10 CRANE POWER 2 BLUE YELLOW 12 ENGINE STOP 3 GREEN BROWN 12 CRANE SWITCH 4 BLACK BLUE 10 CRANE GROUND 5 RED GREEN 12 SPARE 1 6 BROWN BLACK 12 SPARE 2 7 WHITE 8 SPARE 3 Cut back green jacket 1-3/8" from connector. Push cable this direction out the end as far as you need. Cut off excess cable. Slotted screw on cable clamp connector Phillips head screws (both sides) Strip wire insulation back 3/8" before terminating.

18 16 Refuse Container-Loader Installation Manual (G2) Part # Strobe Light Installation In the electrical kit , locate the following: Strobe light LH # Strobe light RH # Strobe light LH # Strobe light LH # " light bracket (Qty 2) " round grommets for lights (Qty 4) To install the rear strobe lights on the chassis, drill 4.5" diameter holes in the rear light boxes on center with the existing lamps. Rear view of chassis without strobe lights installed. Rear view of chassis with right rear strobe light installed.

19 Chapter 3 Installation Steps 17 To install the front strobe lights, position above the bumper or in the guard as shown. The front installation is always "best fit" based on the chassis. Use the brackets if needed. Front strobe lights Connect the green wiring harness to the strobe lights. Use additional parts as needed from the electrical kit to wire the harness to the lights. Refer to drawing (on page 41). NOTE: The wiring harness is labeled for each location - left rear, right rear, left front, right front. The strobe lights are labeled 1, 2, 3, and 4. Match up the wires and strobe lights as follows: Wiring Harness Label Strobe Light Number Right Rear 1 Left Rear 2 Right Front 3 Left Front 4 The master light, located at the right rear of the vehicle, includes a computer which controls the other three lights.

20 18 Refuse Container-Loader Installation Manual (G2) Part # Install the Crane Mode Switch Locate the green rocker switch and the switch rocker body, 12V. Install the switch in the cab on the Power Tower as shown. There may be a capped opening which you can use, or you may need to cut a hole in the Power Tower housing. Connect CP601 on the green wiring harness to the Crane Mode switch. Crane Mode Switch In the decal kit , locate the following: Height notice decal (Qty 1) PTO Mode decal (Qty 1) Install the Height Notice and PTO Mode decals on the dashboard. Most chassis will be set up to use the cruise control for elevated engine speed for PTO mode. Turn on the cruise control, push the Set control, then push Accelerate to raise the engine speed. The engine speed should go to approximately 1000 rpm. Using a permanent marker, write the PTO set speed on the decal. Do not exceed 1200 rpm. Height Notice, PTO Mode decals

21 Chapter 3 Installation Steps 19 Install the Hydraulic Valve Panel In the Upfit Kit , locate the following: Hydraulic valve mounting panel (Qty 1). This panel comes pre-assembled with fittings, valves, and hardware. Install the hydraulic valve panel on the tarper stow legs. A B Drill (4) 13/32" diameter holes in the tarper stow legs, in the positions shown by Dimensions A and B, and install the preassembled hydraulic valve panel. Dimension A - The distance between the upper and lower hole, dimension A, is 4.5" for both sides. Dimension B - The distance from the bottom of the leg, is 22.50" on the right side and 27.5" on the left side. See Installation Drawing ( ) (on page 36) for details.

22 20 Refuse Container-Loader Installation Manual (G2) Part # This photo shows the hydraulic panel from the front. Note that newer panels have the pneumatic control box mounting formed into the panel on this side.

23 Chapter 3 Installation Steps 21 Hose Installation Locate the following in Hydraulic Kit : " x 23" Hose " x 18.5" Hose " x 19" Hose " x 43" Hose " x 36" Hose Tee Install hoses and fittings as shown. PRESSURE HOSES ARE 1" HOSE 1" X 43" ( ) HOSE 1" X 23" ( ) T PORT Pump pressure hose. Remove from hoist valve and add 1" x 43" hose to extend. Connect to inlet port on valve assembly. P PORT Hoses when viewed looking from rear of chassis toward cab. HOSE 1" X 19" ( ) (Pressure line to rear coupling) HOSE 1.25" X 36" ( ) TEE ( ) RETURN HOSES ARE 1.25"

24 22 Refuse Container-Loader Installation Manual (G2) Part # SELECTOR VALVE RELIEF VALVE HOSE 1" X 23" ( ) (Connected to pump pressure hose.) HOSE 1.25" X 18.5" ( ) (Return line) HOSE 1" X 19" ( ) (Pressure line to rear coupling) TEE ( ) Side view with passenger side of cab on the right. Same hoses shown in both views.

25 Chapter 3 Installation Steps 23 1" x 23" hose ( ) which connects to pump pressure hose. Disconnect pump press. hose from hoist valve, add 1" x 23" hose, connect to inlet port on valve assembly. SELECTOR VALVE HOSE 1.25" x 18.5" To return line tee RELIEF VALVE 3/8" TUBING ( ) Connect to Retract air line tee HOSE 1" x 23" Pressure line to rear coupling HOSE 1" X 43" To hoist valve inlet P port 3/8" TUBING ( ) Connect to Extend air line tee Hoist inlet P port. May be 1" or 1.25". If 1.25", use an adapter to reduce to 1". View of hydraulics behind hoist control levers See the Hydraulic System ( ) (on page 41) for additional details and schematics on the hydraulic installation.

26 24 Refuse Container-Loader Installation Manual (G2) Part # Pressure & Return Hose Connection to Tubing In the Hydraulic Kit, locate the following: " x 32.5" pressure hose assembly " x 24" return hose assembly 1.25" x 24" return hose assembly 1" x 32.5" pressure hose assembly Connect quick coupling hoses to the ends of the pressure and return lines installed earlier. See the Hydraulic System ( ) (on page 41) for additional details and schematics on the hydraulic installation.

27 Chapter 3 Installation Steps 25 Hose Clamps & Mud Guard In the upfit kit, locate: mud guard " tube clamp with weld plate (Qty 1) " tube clamp with weld plate (Qty 1) Weld on clamp mounting plates. Locate as desired. Install quick couplings and rubber boots on hoses. Weld on mud guard. Modify as required to fit chassis.

28 26 Refuse Container-Loader Installation Manual (G2) Part # Control Box Installation In the Upfit Kit, locate the control box. In the Pneumatic Kit, locate: /8" air tube Push-loc tee Inlet - from air tank Coil is not polarity sensitive push-loc tees Install the control box on the driver's side of the panel behind the cab, using the hardware which was pre-installed on the hydraulic panel. To extend side of air cylinders To retract side of air cylinders Install the control box. Connect the 3/8" air lines from the fittings in the control box to the air tank (see "Fittings on Secondary Air Tank" on page 28) and to the extend and retract sides of the air cylinders. For the cylinders, add the push-loc tee to the air line just below the control box as shown, then route the air lines to the extend and retract sides of the air cylinders on both sides of the vehicle. NOTE: All fittings and air lines must be DOT approved.

29 Chapter 3 Installation Steps 27 Air Line Connection Route the 3/8" air line across the chassis for the passenger side air cylinder. Use cushioned clamps to secure. Use cushioned clamps (3/4" or 1") to secure air lines in place. See the Hydraulic System ( ) (on page 41) for additional details and schematics on the pneumatic installation.

30 28 Refuse Container-Loader Installation Manual (G2) Part # Fittings on Secondary Air Tank In the Pneumatic Kit, locate the valves and fittings. Secondary chassis air supply tank 3/8" air line to control box Minimum pressure valve Ball valve NOTE: Do not install fittings on a bottom port. Locate and use a port near the top of the air tank. All fittings and air lines must be DOT approved. See the Hydraulic System ( ) (on page 41) for additional details and schematics on the pneumatic installation.

31 Chapter 3 Installation Steps 29 Container Locking Mechanism Marking Frame for the Lift Cylinders Raise the hoist to the full extension. Using a white marker, mark the frame side even with the top of the two hoist lift cylinders. This line will be used to locate the locking cylinders. The cylinders and mounting brackets must not extend into the area behind the line. White line parallel to hoist Mark with hoist at full extension for standard and reverse-mounted cylinders.

32 30 Refuse Container-Loader Installation Manual (G2) Part # Hoist-Container Brackets Use the paper Bracket Template (supplied) to position the cylinder mounting brackets. Make sure the cylinder will not extend past the white line which indicates the position of the hoist, so there will be no interference between the hoist and the cylinders. See drawing sheet 2 (Installation Drawing ( ) (on page 36)) for complete details. NOTE: The cylinder mounting bracket may be reversed if it fits better in the opposite direction on the chassis. Latch Body Bracket Weldment

33 Chapter 3 Installation Steps 31 CYLINDER MOUNTING BRACKET WELDMENT BRACKET LATCH, BODY WELDMENT BRACKET LATCH, BODY.03" GAP BETWEEN HOLE IN UPPER PLATE AND TOP OF PLUNGER SHIMS (AS NEEDED) C C CENTER LOWER BRACKET AROUND UPPER BRACKET FOR PROPER ENGAGEMENT. VERIFY ENGAGEMENT BEFORE WELDING PUSH LOCK FITTING TO HOIST TUBES, INCLUDING SHIMS AIR CYLINDER PLUNGER 5/8 CAPSCREW, NUT WASHERS. 4 PLACES. DRILL 0.88" HOLES AS NEEDED. USE WIDEST SPREAD POSSIBLE. Install pinch point decals, , on both sides of cylinder mounting and on the container pocket.

34 32 Refuse Container-Loader Installation Manual (G2) Part # Bracket Template NOTE: This is a scaled example of the bracket template. The actual size is 23.5" wide, and the template must be actual size to be used.

35 Chapter 3 Installation Steps 33 Power Connector Bracket In the Upfit Kit , locate: Power connector bracket Power connector bracket Install the bracket at the front of the hoist. See drawing sheet 2 (Installation Drawing ( ) (on page 36)) for complete details. CONTAINER WELDMENT UPPER HOIST 0.13" 0.13" CHASSIS FRAME Bracket Position at the front of the hoist Once installed, attach the end of the green power cable to this bracket. This is where the crane power cable plugs in to power the crane.

36 34 Refuse Container-Loader Installation Manual (G2) Part # Body-Container Bracket Pocket on container. Bracket and pocket shown in the open position. Bracket to lock the upper hoist to the container. Right side ; Left side Locate and weld on the body bracket which fits into the pocket on the container, using the container for a placement guide. Position the bracket so the slot is centered around the lower edge of the bracket on the container. See drawing sheet 2 (Installation Drawing ( ) (on page 36)) for complete details. CONTAINER WELDMENT 0.38 UPPER HOIST CHASSIS FRAME BRACKET, BODY TYP BOTH SIDES BRACKET, BODY POSITION CONTAINER RESTRAINT BRACKET ON HOIST TO BE CENTERED AROUND POCKET ON CONTAINER. Install pinch point decals, , on both sides of cylinder mounting and on the container pocket.

37 Chapter 3 Installation Steps 35 Tarper Arm Modification Cut arms approximately 21" from the top of the lower arm. Use the supplied tarper arm extensions ( ). Locate, clamp, and drill (3) holes through both ends of the upper arms. Extensions may need to be shortened in some applications. Always use (6) bolts per extension assembly. Tarper arm modification Upper arm angle modification The tarper arms need to be modified to allow the horizontal arms to be parallel with the ground, thus extending the upper portion of the arms. When installing the tarper arm extensions, always use 6 bolts at the bottom and top of the extension assembly. You may have to modify the angle of the upper arm. Add reinforcement plates (shown) if the arm angle is modified. See drawing sheet 1 (Installation Drawing ( ) (on page 36)) for complete details.

38 36 Refuse Container-Loader Installation Manual (G2) Part # Assembly Drawings Installation Drawing ( ) TARPER ARM EXTENSION-See below. HYDRAULIC PLATE - See ,2,5 1 1,2, RETENTION BRACKETS & CLAMP ASSEMBLY See ,4 1 2,3 1 35,45(2),46 58 Cut original upper arm. Splice together with supplied C-channels. 3-bolts per end. Cut & reweld as necessary. Lower arm must be horizontal. TARPER ARM EXTENSION 2 NOTES (SEE REFERENCE NUMBER IN BOX): 1 STROBE LIGHTS ARE STAMPED WITH PART NUMBERS. SEE PARTS LIST FOR PROPER LOCATIONS. POSITION BRACKETS AS NECESSARY. 2 UPPER ARMS ARE STRETCHED AND LOWER JOINT ANGLE IS INCREASED TO ALLOW TARP TO REST IN ORIGINAL CRADLE, WHILE LOWER ARMS ARE HORIZONTAL.

39 Chapter 3 Assembly Drawings DRAWING CONTAINER WELDMENT UPPER HOIST 0.13" 0.13" TYP BOTH SIDES CHASSIS FRAME (SHIMS AS NEEDED) (AS NEEDED) C ,12, , C NOTES (SEE REFERENCE NUMBER IN BOX): 1 POSITION AT FRONT OF CONTAINER. 2 POSITION CONTAINER RESTRAINT BRACKET ON HOIST TO BE CENTERED AROUND POCKET ON CONTAINER " GAP BETWEEN HOLE IN UPPER PLATE AND TOP OF PLUNGER. 4 CENTER LOWER BRACKET AROUND UPPER BRACKET FOR PROPER ENGAGEMENT. VERIFY HOIST AND CONTAINER ENGAGEMENT BEFORE WELDING. CAUTION - EXCESSIVE WEAR IN COMPONENTS WILL CAUSE MISALIGNMENT. 5 TO HOIST TUBES, INCLUDING ANY SHIMS IF PRESENT. USE MULTIPLE PASSES IF NECESSARY. 6 MINIMUM 4 PLACES. USE WIDEST SPREAD POSSIBLE. DRILL 0.88" HOLES AS NECESSARY. TORQUE TO 160 FT-LB (22.1 KG-M). 7 ASSEMBLY TYPICAL FOR BOTH SIDES OF CHASSIS. CYLINDER MOUNTING PLATE MAY BE REVERSED.

40 38 Refuse Container-Loader Installation Manual (G2) Part # DRAWING (HYDRAULIC PLATE SUB-ASSEMBLY) 35,44(2) ,49(2), ,46(2) 1 35,45, ,56, NOTES (SEE REFERENCE NUMBER IN BOX): 26 1 FOR PLATE MOUNTING. 2 FOR ELECTRICAL BOX MOUNTING. 3 HYDRAULIC PLATE SUBASSEMBLY - ADD LOOSE HARDWARE TO KIT AS SHOWN. USE HARDWARE KIT

41 Chapter 3 Assembly Drawings DRAWING DRILL 13/32" THROUGH BOTH WALLS (4 PLACES) 1.25" 31.5" 4.5" 4.5" 27.5" 22.5" A HYD MOUNTING PLATE HOLE LOCATIONS ON BODY ASSEMBLY WELDED TO REAR BUMPER AS NECESSARY 21 DETAIL A PARTS LIST ITEM PART # DESCRIPTION DETAILS QUANTITY BRACKET-LIGHT 4" ROUND GROMMET-RUBBER TAIL LIGHT 4" LIGHT-STROBE SMART AMBER 4in LH # LIGHT-STROBE SMART AMBER 4in RH # LIGHT-STROBE SMART AMBER 4in RH # LIGHT-STROBE SMART AMBER 4in LH # CYLINDER-AIR 1.06B 1.00S REV SNGL WELDMENT-BRACKET LATCH BODY WELDMENT-BRACKET LATCH 2 CHASSIS PLUNGER-LATCH WASHER.62 FLAT ASTM F CAP SCREW.62-11X 2.50 HH GR8 Z NUT HEX ZINC NYLOK GR GUARD-CYLINDER WASHER.25 LOCK CAP SCREW.25-20X.50 HH GR5 Z CONTROL BOX 1

42 40 Refuse Container-Loader Installation Manual (G2) Part # PARTS LIST ITEM PART # DESCRIPTION DETAILS QUANTITY PUSH LOCK FITTING ELBOW.38 DOT X.25 MPT PUSH LOCK FITTING.38 DOT X.25 MPT TUBE ASSEMBLY-HYDRAULIC 1.00 O.D. X CHASSIS 1 PRESSURE TUBE ASSEMBLY-HYDRAULIC 1.25 O.D. X CHASSIS 1 RETURN TUBE ASSEMBLY-HYDRAULIC 1.25 O.D. X 9.38 X TUBE ASSEMBLY-HYDRAULIC 1.25 O.D. X 5.00 X VALVE-ASSEMBLY-PRIORITY FLOW 28 GPM 1 CONTROL PLUG-PIPE SOC HEX STL ADAPTER M STR/M JIC ADAPTER M STR/M JIC ELBOW M JIC/90/M JIC TEE MALE JIC TUBE TEE MSTR THD RUN VALVE-SELECTOR 2 POSITION 60GPM VALVE-RELIEF 60 GPM PSI PUSH LOCK FITTING ELBOW.38 DOT X.12 MPT NUT HEX NYLOCK UNION M STR/M STR SWVL GUARD-FENDER SHIM-CLAMP MOUNT 10GA A/R SHIM-CLAMP MOUNT 0.19 A/R SHIM-CLAMP MOUNT 0.25 A/R SPACER PLATE-CYLINDER MOUNT A/R PLATE-HYDRAULIC MOUNT CAP SCREW.38-16X 2.75 HH GR WASHER.38 FLAT CAP SCREW.38-16X 3.50 HH GR5 Z CAP SCREW.38-16X 4.25 HH GR5 Z CAP SCREW.25-20X 1.00 HH GR5 Z WASHER.25 FLAT NUT HEX NYLOCK BRACKET-HARNESS MOUNTING GUIDE-BODY LEFT HAND GUIDE-BODY RIGHT HAND ADAPTER MPT/HEX/MPT NIPPLE-DISC.25FPT STL HNV-14-M CAP-DUST FOR EXTENSION-TARPER ARM ADAPTER M STR/M JIC REV A

43 Chapter 3 Assembly Drawings 41 Wiring Diagram ( ) CRANE WIRING CRANE PWR WIRE #2 CRANE GND WIRE #1 CRANE ON/OFF WIRE #3 TO WHITE WIRE TO PINK WIRE TO BLUE WIRE TO GREEN WIRE TO BROWN WIRE TO GRAY WIRE A B C A B C D E F CJ-302 CRANE PWR A CRANE GND B CRANE ON C N/C A ENG STOP B N/C C N/C D N/C E N/C F CJ-601 HR MTR CRANE PWR ON HR W4 W9 MTR CRANE GND ON W3 W8 G J W1 A B W2 C D W5 W6 W7 CP CRANE PWR 2 ENG STOP 3 CRANE ON 4 CRANE GND 5 N/C 6 N/C 7 N/C FRONT STROBE LIGHTS LF STRB GND 1 PTO SIGNAL 2 N/C 3 SYNC R 1 RF STRB GND 1 N/C 2 N/C 3 SYNC R 1 CJ-700 CRANE POWER 1 ENGINE STOP 2 CRANE SW 3 CRANE GND 4 N/C 5 N/C 6 N/C 7 CHASSIS GND W1 CRANE GROUND W2 W5 W6 W7 R R1 87a 87 D 85 G G G G B R2 87a P G A R3 87a REAR STROBE LIGHTS 1 LR STRB GND 2 PTO SIGNAL 3 N/C R 1 SYNC R 1 RR STRB GND 2 N/C 3 N/C 1 SYNC R CP-302 CP-102 CP-303 CP-103 CP-601 TO CHASSIS A BATTERY B PTO SWITCH C CRANE SWITCH D ENGINE STOP E AIR DUMP CIRCUIT F AIR DUMP CIRCUIT CRANE BODY HARNESS TO CONTROL BOX AIR SOLENOID PWR W3 AIR SOLENOID GND W CHASSIS HARNESS

44 42 Refuse Container-Loader Installation Manual (G2) Part # Hydraulic System ( ) HYDRAULIC LAYOUT P R T INSTALLED BY IMT TARPER MOTOR PUMP CRANE PRESSURE FILTER P 59 T CRANE V.B P T 7 60

45 Chapter 3 Assembly Drawings PNEUMATIC LAYOUT NOTES: 1 USE SECONDARY AIR SYSTEM WHEN POSSIBLE. 2 USE ONLY DOT-APPROVED AIR FITTINGS SUBASSEMBLY

46 44 Refuse Container-Loader Installation Manual (G2) Part # SCHEMATIC FILTER T HYDRAULIC RESERVOIR S P PRESS REL 2900 PSI (200 BAR) BALL VALVE T P HOIST VALVE SEL. VALVE P T P PRIORITY FLOW CONTROL 28 GPM (106 L/MIN) CRANE FILTER FLOW DIVIDER P T CRANE VALVE CHASSIS AIR TANK SOL AIR VALVE AIR CYL (2) TO ATMOSPHERE

47 Chapter 3 Assembly Drawings PARTS LIST ITEM PART # DESCRIPTION DETAILS KIT # QUANTITY KIT-HYDRAULIC SHIPOUT REF REF KIT-HYDRAULIC INSTALL REF REF 3. N/A EXISTING HOSE FROM PUMP (1" OR 1 1/4") REF REF ADAPTER M JIC/M JIC HOSE AAJ 1.00 X (16-16) 100R ADAPTER M BSPP/M JIC VALVE-RELIEF 60 GPM PSI N/A UNION M STR/M STR VALVE-SELECTOR 2POS 60GPM ADAPTER M STR/M JIC TUBE ASSEMBLY HYDRAULIC 1.25 O.D. X 5.00 X N/A ADAPTER M STR/M JIC PRIORITY FLOW CONTROL N/A HOSE FJ 1.25 X 18.5 (20-20) 100R HOSE FF 1.00 X (16-16) 100R ELBOW M JIC/90/M JIC TUBE ASSEMBLY-HYDRAULIC 1.00X CHASS PRESS N/A HOSE FJ 1.00 X (16-16) 100R ADAPTER M STR/M JIC & QUICK DISCONNECT 16 SOCKET-FEMALE N/A CAP-QUICK DISCONNECT 16 SOCKET N/A QUICK DISCONNECT 16 PLUG-MALE N/A CAP-QUICK DISCONNECT 16 PLUG N/A HOSE AAF 1.00 X (16-16) 100R TUBE ASSEMBLY-HYDRAULIC 1.00X CONT PRESS N/A HOSE AAJ 1.00 X (16-16) 100R ADAPTER M BSPP/M JIC HOSE FJ 1.00 X (16-16) 100R ELBOW FLANGE/M JIC N/A FLANGE KIT SAE 20 (METRIC BOLTS) N/A FLANGE KIT SAE 16 (METRIC BOLTS) HOSE BBEE 0.75X (12-16) R ADAPTER M BSPP/M FACE HOSE FF 1.00 X (16-16) 100R N/A EXISTING HYDRAULIC TUBING.. ON CONTAINER ELBOW FLANGE/M JIC HOSE FJ 1.00 X (16-16) 100R TEE SWIVEL NUT RUN JIC ADAPTER M JIC/F JIC ADAPTER M JIC/MM SW ADAPTER M JIC/F JIC HOSE AAJ 1.00 X (16-16) 100R4 2 1

48 46 Refuse Container-Loader Installation Manual (G2) Part # PARTS LIST ITEM PART # DESCRIPTION DETAILS KIT # QUANTITY TUBE ASSEMBLY-HYDRAULIC 1.25X CONT RETURN N/A HOSE AAF 1.25 X (20-20) 100R ELBOW M STR/90/M JIC CAP-QUICK DISCONNECT 20 PLUG N/A QUICK DISCONNECT 20 SOCKET-FEMALE N/A CAP-QUICK DISCONNECT 20 SOCKET N/A HOSE FJ 1.25 X (20-20) 100R TUBE ASSEMBLY-HYDRAULIC 1.25X CHASS RETURN N/A TEE MALE JIC TUBE TEE MASTER THREAD RUN TUBE ASSEMBLY HYDRAULIC 1.25 O.D. X 9.38 X N/A HOSE FF 1.25 X (20-20) 100R TUBE ASSEMBLY-HYDRAULIC 1.00X PRESS EXTEND N/A TUBE ASSEMBLY-HYDRAULIC 1.25X RETURN EXTEND N/A MANIFOLD ASY-FLOW DIVIDER N/A HOSE AAJ.38 X (6-6) 100R N/A EXISTING HYDRAULIC TUBING N/A REF ON CONTAINER KIT-PNEUMATICS N/A REF PUSH LOC- FITTING ELBOW.38 DOT X.12 MPT 62 6 REF PUSH LOC- UNION TEE.38 DOT PUSH LOC- FTG ELBOW.38 DOT X.25 MPT MUFFLER-AIR 1/8" NPT SINTERED BRONZE N/A 1 REF PUSH LOC- FTG.38 DOT X.25 MPT CYLINDER-AIR 2.00B 3.00S DBL ACT N/A ADAPTER MPT/HEX/MPT VALVE-PRESS PROTECTION.25in VALVE-BALL 0.25" TUBE-PUSHLOC.38 AIR (CS) 62 40' ADAPTER MPT/HEX/MPT BRS NIPPLE-DISC.25FPT STL HNV-14-M CAP-DUST FOR REDUCER BUSHING-BRASS REV B