.

PO Box 790 – 200 Ladish Rd.

Cynthiana, KY 41031
800-331-0136
 WARNING
All applicable OSHA regulations must be understood and
observed when operating or before performing any service
or maintenance on the E-Z Pack product.

REFERENCED: Public Law 91-596, December, 1970, 84 Statute 1593 (including

among others, but not limited to the following), Section 5.
(a) Each employer -
(1) shall furnish to each of his employees employment and a place of employment which
are free from recognized hazards that are causing or are likely to cause death or serious
physical harm to his employees;
(2) shall comply with occupational safety and health standards promulgated under this
Act.
(b) Each employee shall comply with occupational safety and health standards and all
rules, regulations, and orders issued pursuant to this Act which are applicable to his own
actions and conduct.

Proper service and repair are important to the safe, reliable operation of E-Z Pack
products. Operational and servicing procedures recommended by E-Z Pack are in this
manual and are effective for proper use of this product. Some of these operations may
require the use of tools or blocking devices specifically designed for the purpose. Special
tools should be used when and as recommended. It is important to note that warnings
against the use of specific operations or methods that can damage the product or render it
unsafe are stated in this manual. It is also important to understand these warnings are not
exhaustive. E-Z Pack can not possibly know, evaluate, and advise the service trade of all
conceivable ways in which operation or service might be performed or of the possible
hazardous consequences of each method. Accordingly, anyone who uses operational
procedures, service procedures, or tools whether recommended by E-Z Pack or not must
first satisfy himself thoroughly that neither his safety nor the product safety will be
jeopardized by the methods he shall select.

(PL-0538D 11/03)
=2=
IMPORTANT SAFETY NOTICE

This E-Z Pack® Front Loader conforms to the American National Standard for Refuse
Collecting and Compacting Equipment – Safety Requirements Per ANSI Z245.1-1992

It is essential that everyone associated in any way with the E-Z Pack Front Loader
thoroughly understand and apply the contents of this American National Standard.

It should be noted that this standard is regularly reviewed and updated. It is the owner’s
responsibility to obtain updated copies of this ANSI standard for reference.

New copies of this standard can be obtained by contacting:

WASTEC - Waste Equipment Manufacturers Association 4301 Connecticut Avenue, NW

Suite 300 Washington DC 20008

Any person reconstructing or modifying this front loader must do so in accordance with
sections 4.3 and 5.2 of ANSI Z245.1-1992 or subsequent updates to such standard.

LOCKOUT / TAGOUT REQUIREMENTS

A LOCKOUT / TAGOUT PROCEDURE FOR THIS FRONT LOADER HAS BEEN

ESTABLISHED AND MUST BE FOLLOWED.

See detailed Lockout / Tagout procedures on page 4 of this manual.

If you are unfamiliar with the OSHA Lockout procedure or any safety requirements, please contact
either your E-Z Pack distributor or E-Z Pack direct.

200 Ladish Rd. P.O. Box 790 Cynthiana, KY 41031

=3=
LOCKOUT / TAGOUT PROCEDURE

IT IS THE EMPLOYER’S RESPONSIBILITY TO ESTABLISH AND APPLY A

“LOCKOUT / TAGOUT PROCEDURE” FOR ANY INSPECTION, REPAIRS, OR
MAINTENANCE BEING DONE ON AN E-Z PACK MOBILE UNIT. LISTED
BELOW IS OUR SUGGESTED PROCEDURE. THIS PROCEDURE IS NOT
INTENDED TO REPLACE ANY “LOCKOUT / TAGOUT PROCEDURES” THAT
YOU ARE CURRENTLY USING. IT IS ONLY TO BE USED AS A SUGGESTED
GUIDELINE.

LOCKOUT / TAGOUT PROCEDURE

. • Move the unit to firm level surface.

. • Position all components in travel position.
. • Set the parking brake. Make sure the brakes are working properly and
holding the vehicle as required.
. • If packer unit has a power switch, switch to “OFF” position.
. • Shift into “Neutral” (or Park if provided) if equipped with an automatic
transmission. If equipped with a manual transmission, put the unit in gear.

. • Shut off the engine.

.• Remove the ignition key and place in your pocket.

.o Multiple Lockout: If more than one person is working on or around the vehicle,
the key must be controlled by the supervisor, who must ensure all personnel are safely
clear before replacing the key.
. • Chock all drive wheels.
. • Switch the main battery disconnect to the “OFF” position.
. • Place a tagout locking device on the main battery disconnect
. • Place an “OUT OF SERVICE” sign on the steering wheel(s). This warns
others that the unit is being worked on and not to start the engine.
. • Block any system that could move by inertia with an easily visible safety
prop. (Open tailgate, lifted body, open hopper cover, elevated arms, etc.)

.• Disconnect the following items if any type of welding is required:
a. o Electronic Transmission (ECU)
b. o Electronic Engine (ECU)
c. o Battery
d. o E-Z Pack Controls (ECU)

1. Refer to manual for location of E-Z Pack harnesses to be

disconnected
FRONT LOADER DECAL LOCATIONS (BODY FRONT & CAB FRONT)

DECALS SHOWN ARE ENGINEERING DRAWINGS.

THEY ARE NOT TO SCALE AND ARE NOT SHOWN IN COLOR.

FRONT LOADER DECAL LOCATIONS (BODY FRONT STREETSIDE

CORNER)
=7=
 DECALS SHOWN ARE ENGINEERING DRAWINGS.
THEY ARE NOT TO SCALE AND ARE NOT SHOWN IN COLOR.
RECYCLER, FRONT & SIDE LOADER DECAL LOCATIONS (REAR VIEW OF
TAILGATE)
 DECALS SHOWN ARE ENGINEERING DRAWINGS.
THEY ARE NOT TO SCALE AND ARE NOT SHOWN IN COLOR.
 (PL-1543A)

READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE ATTEMPTING TO

OPERATE THIS FRONT LOADER.

DO NOT LEAVE THIS VEHICLE UNATTENDED UNLESS ENGINE IS SHUT OFF

AND IGNITION KEY IS REMOVED.

BE CERTAIN OPERATIONAL AREA IS CLEAR OF ALL PERSONNEL BEFORE OPERATING

ANY CONTROLS.

Your unit will have one of the following pump installations to power your Hercules Front Loader.

CRANK SHAFT - DRY VALVE PUMP OPERATION:

This is a continuous running power system controlled by an electric-air system and operated by a switch
(Figure OM-1, Item A) in the cab. After air pressure has been built up, the switch is used to control the
dry valve allowing oil flow to the pump, which supplies hydraulic power to the unit. When in operation a
cab mounted light (Figure OM-2, Item 1) will lite. DO NOT travel with the dry valve engaged and light
“ON”.

POWER TAKE-OFF DRIVEN PUMP OPERATION:

To engage the Power Take-Off on a standard transmission, shift into neutral, disengage clutch and move
control to shift Power Take-Off into gear. Engage clutch and Power Take-Off is in operation. (It may be
necessary to let out the clutch momentarily for proper alignment so the gear may slide into position).

To engage the Power Take-Off on an automatic transmission, apply brake, shift into any one of the
drive positions (this will stop transmission gears from turning). Shift Power Take-Off into gear,
and then shift transmission into neutral. This will start transmission gears turning, and in turn, put
Power Take-Off into operation.
NOTE: THIS UNIT IS WIRED SO THAT:
1) all functions will be disabled when the side door is not completely closed.
2) When the tailgate is opened, labeled (GATE OPEN) pilot lights will lite. When the tailgate is being
opened
the light (Figure OM-2, Item 2) will lite. . Also an alarm (Figure OM-1, Item B) will sound until the
tailgate is completely closed.

3) When the lift arm assembly is moved from the travel or dump position, a labeled (UNSAFE TRAVEL)
pilot light (Figure OM-2, Item 4) will lite and alarm will sound. Light will stay on and sound will continue
until arm assembly is moved into the travel/dump position.

NOTE: UNIT CANNOT BE DRIVEN SAFELY UNTIL ALARM HAS STOPPED, ALL LIGHTS ARE
OFF AND CONTAINER FORKS ARE STOWED INSIDE THE HOPPER AREA.
 Figure OM-1

OPTIONAL THROTTLE ADVANCE:

If optional throttle advance is installed it is necessary to operate the switch (Figure OM-1, Item C) to
activate this operation. Light (Figure OM-2, Item 4) will light until throttle advance is turned off.

Figure OM-2
OPERATION AND OPERATING CONTROLS:

Before operating unit turn on all lights that are required. (See Figure OM-3, Item D).

Open hopper door (Figure OM-3, Item E). Note: When hopper is opened the light (Figure OM-4, Item G)
will be off. When hopper is closed the light will be lite.
STANDARD - SINGLE JOYSTICK CONTROL:

The single joystick (Figure OM-5) controls the action of the lift arms and container forks. Pushing the lever
forward, away from the driver/operator will lower the lift arms, while pulling it towards the driver/operator
will raise the lift arms. Moving the lever to the left will pivot the container forks forward to the down,
container pick-up position. When moved to the right, container forks will tilt back to the up-stowed
position or (if lift arms are fully raised) the container dumping position. The “UNSAFE TRAVEL” light
will remain on until the lift arms are moved into the travel/dump position, or under 13' 6". (See Figure OM-
2, Item 4).

Figure OM-5

OPTIONAL DUAL LEVER CONTROLS:

The lever to the left controls the action of the lift arms, See Figure OM-5. Pushing the lever forward, away
from the driver/operator will lower the lift arms, while pulling it towards the driver/operator will raise the
lift arms. The other lever controls the container forks. When pushed forward away from driver/operator the
container forks will tilt down to the container pick-up position and when pulled towards the driver/operator
will tilt back to the up-stowed position or (if lift arms are fully raised) the container dumping position. The
“UNSAFE TRAVEL” light will remain on until the lift arms are moved into the travel/dump position. (See
Figure OM-2, Item 4). DO NOT GO UNDER RAISED LIFT ARMS
UNLESS THEY HAVE BEEN SECURELY PROPPED OR CHAINED TO PREVENT
ACCIDENTAL LOWERING. LIFT ARMS DROP BY GRAVITY WHEN THE LIFT ARM
CONTROL IS ACTIVATED TO LOWER POSITION AND PUMP IS NOT ENGAGED. =18=

When front loader has moved forward enough to engage the container without it falling off of container
forks, raise container about a foot or so to permit backing up of the front loader as far as needed to clear
well behind container and/or overhead obstructions which might interfere with dumping of the container.

Before lifting container to dumping position, make sure hopper door is open. Check light (Figure
OM-4, Item G) to make sure that it is off.

Tilt forks up slightly to cause container to slide toward truck and come to rest against fork assembly. Be
careful not to tilt container too much while attempting to bring the container to rest against fork assembly,
or top edge of container may damage cab, (larger capacity containers in particular)> Having accomplished
the above, tilt forks back to more level position and proceed to raise lift arms. At this point, do not attempt
to tilt container forks until container is in dumping position

Figure OM-6
When container is in dump position, tilt container forks so that container is 50 to 55 degrees (from vertical),
see Figure OM-6. If you attempt to dump the container and get no response from the controls, check to see
if packing panel is completely to front of body. Your unit is equipped with a dump limit control and the
container dumping is automatically prevented unless the packing panel is fully forward. This feature
prevents dumping of the container behind the packing panel where the refuse could only be removed by
hand. So remember, make sure that the packing panel is fully forward before dumping container. Tilt
container forks back and forth a couple of times to remove all of the refuse out of the container.
If hopper area of body has refuse in it, and this is preventing complete dumping of container, it 3will be
necessary to pack the load, thereby clearing the hopper area. NOTE: TILT FORKS UNTIL
CONTAINER IS ROTATED OUT OF HOPPER AREA BEFORE ATTEMPTING TO OPERATE
THE PACKING PANEL.

The switch (Figure OM-7, Item F) permits automatic or manual operation of the packing panel. For
automatic cycling push the top of this switch to “AUTO-PACK”. Packing panel is activated by pressing
and holding for approx. 2 seconds, the green “START” button (Figure OM-7, Item G). Panel will make one
complete cycle and stop. Auto-cycle operation can be stopped at any time by pushing the red “STOP”
button (Figure OM-7, Item H).

The manual operation of the packing panel is controlled by the switch (Figure OM-7, Item F). To
activate manual operation push the bottom of this switch to “MANUAL”. Pressure at the top of the
switch (Figure OM-7, Item J “EXTEND”) will extend the packing panel towards the tailgate while
pressing the bottom (RETRACT) will retract the packing panel towards the front of the body.
Once container has been emptied, TILT FORKS UNTIL CONTAINER IS ROTATED OUT OF HOPPER
AREA AND CLEAR OF BODY before lowering container to ground. Back away from container while
observing position of container forks, otherwise forks may not clear container forks brackets and the
container will be dragged from its residing place. Once disengaged from container, back front loader away
from container sufficiently to permit retracting of container forks to the full up position and raising of lift
arms to full travel position. Before leaving site make sure hopper door is closed and hopper door closed
light (Figure OM-4, Item 6) is lite. Also the packing panel should be in the retracted (forward) position,
with the pump disengaged, before moving vehicle.
When packing, the packing panel will move thru the hopper, packing the refuse into the body chamber. As
additional loads from the hopper are packed, the refuse forces the earlier loads to the back of the body
chamber resulting in a solidly compacted load. When material starts to fall back into the hopper area and
you can no longer pack it out of the way in automatic cooperation, switch to manual and run the packing
panel manually to break the load and clear the hopper. Continue operation in automatic mode until material
can no longer be packed out of the hopper area. The body must be unloaded at this time.

UNLOADING:

At unloading site, move lock pin keepers to release pins, remove tailgate lock pins (one each side) see
Figure M-8. The tailgate can now be opened.

Figure OM-8
To open tailgate move rocker switch (OM-9, Item K) to open position. NOTE: This switch is a locked
switch and to move the switch the tab on top of the switch must be moved down and held while the switch
is being held to open or close the tailgate. When the tailgate is opened, labeled pilot lights will lite. When
the tailgate is being opened the light (Figure OM-2, Item 2) will lite, when the gate is full open the light
(Figure OM-2, Item 3) will lite. Also an alarm (Figure OM-9, Item L) will sound until the tailgate is
completely closed.

To eject load, move rocker switch (Figure OM-9, Item F) to “MANUAL”. Manually hold switch (Figure
OM-9, Item J) in the “EXTEND” position, which will cause the packing panel to fully eject the load. If
there is a pile of refuse at rear of body, pull truck ahead so that it will not be gathered between the closing
tailgate and rear of body.
Lower tailgate by moving rocker switch (OM-9, Item K) to “CLOSE” position. This switch is a locked
switch and to move the switch the tab on top of the switch must be moved down and held while the switch
is being held to close the tailgate. Continue holding this switch until tailgate is completely closed and fully
locked decals are lined up (both sides) Pilot lights (Figure 2, Items 2 and 3) will go out.

Reinstall lock pins (one each side) and move pin keepers (both sides) to hold pins in place, see Figure OM-8.

DO NOT GO UNDER A RAISED BODY OR TAILGATE UNLESS IT HAS BEEN SECURELY

PROPPED OR CHAINED TO PREVENT ACCIDENTAL LOWERING. TAILGATE WILL DROP
BY GRAVITY WHEN ITS CONTROL SWITCH IS ACTIVATED TO LOWER POSITION AND
PUMP IS NOT ENGAGED

Before leaving unloading site, make certain that;

1) The packing panel is to the front of the body. Never travel with the packing cylinders extended, even

partially, as this can cause undue shock on the cylinders which may result in accelerated cylinder wear or

permanent damage.

2) All lights are OFF on the indicator light cluster, except the System On and Hopper Closed which will be

ON.

3) Lift arms and fork assembly are in travel position.

4) Tailgate is properly closed and locked. Tailgate lock pins (one each side) are installed.

5) If applicable P.T.O. and/or pump is disengaged.

SIDE ACCESS DOOR:

The side access door is not intended to be used for loading. This door is provided to allow access to
interior of body when maintenance and/or repairs are performed. As a precautionary measure, however,
driver/operator should open side access door and observe that no one has entered the front loader body in
his absence, before dumping containers or moving the packing panel. NOTE: THIS UNIT IS WIRED SO
THAT ALL FUNCTIONS WILL BE DISABLED WHEN THE SIDE DOOR IS NOT COMPLETELY
CLOSED.

MAINTENANCE
(PL-1524)

NOTICE: DO NOT ALLOW MATERIAL TO ACCUMULATE FORWARD OF PACKING

PANEL. MATERIAL BUILDUP CAN RESULT IN DAMAGE TO YOUR EQUIPMENT.

DRIVE LINE:
Grease the drive line at least twice a week during heavy usage (daily if live power). Use a standard grease
gun as used on other parts of the truck’s chassis. The intervals of lubrication may be reduced or increased
as usage merits.

Check mounting bolts on the pump and brackets as well as the center bearing hanger, universal joints, etc.
check set screws and wires on the joints to make sure that these are not working loose. The slip joint should
also be adequately lubricated and free from abrasive matter.

PUMP:
Properly installed and operated, this hydraulic pump will give years of service with very little, if any
maintenance or service repair required. There are a number of precautions which should be observed to
obtain the long life possible through proper card.
1) Universal joints should be snug on the shaft and properly locked to prevent vibration.
2) Power Take-Off should be disengaged so that pump will not be operated when truck is being driven.
3) Whenever servicing the hydraulic system, prevent dirt from getting into the system.
4) Be careful not to operate pump with insufficient oil in tank.
OIL SUPPLY TANK - CAPACITY 49 GALLONS:

The oil supply tank is the storage place of the life blood of the hydraulic system. Careful maintenance and
inspection at this point will materially increase the longevity of the unit and keep repairs to a minimum.
The tank for the hydraulic oil supply is located on the streetside chassis frame rail. Check oil supply daily,
making sure oil level is at mid-way point on the oil sight gauge (See Figure M-1). When checking, have the
unit setting level, oil at a normal operating temperature, all cylinders in the retracted position and the pump
not operating.

FIGURE M-1

We recommend that after the first 6 months of operation, the oil be drained and replaced. An annual oil
change thereafter will suffice in normal operations. KEEP YOUR OIL CLEAN!!!

OIL SAMPLING PROCEDURE:

The following are items and steps to be adhered to when taking an oil sample.

A. Operate the unit for no less than 15 min. To allow the oil to come up to temperature and circulate in the
tank.

B. Check the oil indicator lights on the control panel to be sure they are not on. NOTE: An indicator light
coming on momentarily does not indicate the need to change the filter. Only a sustained light for several
minutes, after the hydraulic oil is up to operating temperature, indicates filter maintenance.

=25=
The indicator pressure switch is set to activate at 43 PSI. The filter will not by-pass until a 50 PSI
differential is reached. This allows for a safety margin while the unit is out on the route operating so it
does not have to leave the route at first signs of indicator light on.

C. Have the proper equipment needed to take the oil sample. The oil sample analysis kit 2049699000 and
send to E-Z Pack, in the carton with the forms filled out properly. Be sure to use the oil
sample hand pump 5505950000 or your sample will not be valid.

NOTE: The tubing on the hand pump must be cleaned before each oil sample by pumping some of the
sample oil into a clean test container or replaced with new tubing.

D. Clean the area where you will insert the tubing into the hydraulic reservoir, normally at the plug on top
of the tank.

E. Insert the tube into the tank until it is approximately in the middle of the hydraulic fluid.

F. Draw oil into a standard container to flush the test equipment. Now draw the oil sample at this point
into the clean oil sample container.

G. Check the oil level with all the cylinders in their normal position.
Add make up oil if needed. This must be clean oil with an ISO of 15/12 is recommended. See following
oil specifications. This can be achieved by pumping the new oil through a 3 micron absolute, Beta 3=200,
filter while filling the reservoir.

H. Be sure to inspect the air breather filter for oil contamination. If oil is present in the breather the
breather (1072562000) must be replaced.

J. Return the oil sample to E-Z Pack in the carton with the forms properly filled out and all
the necessary notes.

OIL SPECIFICATIONS:

CODE 1657 RANDO OIL HD 32

Typical Characteristics: Appearance . …..Pale Brown, Pour Point -27.4 ᵒF Flash Point 428 ᵒF
API Gravity ………..32.6ᵒ Viscosity Index . ……… 99.0
Saybolt Viscosity at 100ᵒ F ……….157 SUS Saybolt Viscosity at 210ᵒ F ……….44.0 SUS
Kinematic Viscosity at 40ᵒ C (104ᵒF) …………. 30.4 cSt
Kinematic Viscosity at 100ᵒC (212ᵒF) ………….5.20 cSt
Neutralization No. . . . . . . . . . . . . 0.4

Rando Oils HD are light-colored, premium, anti-wear hydraulic oils blended from high quality paraffin
disillate stocks with excellent stability. There rust and oxidation inhibited and contain a specially selected
antifoamant which permits very rapid release of entrained air. This latter point is important since entrained
air will cause system sponginess, thus affecting the rapidity and accuracy of system response. They also
contain a very effective zinc-type antiwear agent that helps minimize wear in high-speed, high pressure
vane and gear pumps while meeting the lubrication requirements of axial piston pumps having bronze-on
steel metallurgy.

FILTER BREATHER CAPS:

Located on top of oil tank (See Figure M-1) are two (2) filter breather caps. These caps are for the ease of
replacing or adding oil and allows the free exchange of filtered air to and from the tank, as the level of oil
fluctuates. It is important that these caps be kept clean and in place. Before removing these caps make sure
the area is clean, as any foreign materials allowed into the oil supply can cause expensive down time and
repairs.

OIL FILTERS:

The elements in the high pressure and return filters should be replaced after the first fourteen(14) days of
operation, then serviced when the indicator light on the cab console comes on or at six month intervals.
Note: If oil filter lights are staying lit after the hydraulic oil is warm and you know that the unit does not
need service, the sending unit could be defective and need replacing. NOTICE: To keep from having a
mess with spilled oil - Before removing the filter bowl on the high pressure filter 1) Shut the pump off, 2)
Remove the pipe plug on the side of the filter (See Figure M-2) to siphon the oil from the filter bowl.
Replace plug before operating unit.

CYLINDERS:

A thin film of oil on the piston rod or sleeves as they extend is desirable, but a cylinder showing a steady
drip of oil indicates need of service. The piston rod or sleeves should be inspected occasionally for
scratches and nicks which can cause considerable damage to wiper rings, bearings and packing. Any marks
such as these should be smoothed out to prevent damage to the cylinder.
Cylinder pivot pins should be checked periodically for tightness and wear. See Lubrication Chart for
grease zerks and lubrication schedule.

PACKING PANEL AND TRACKS:

The packing panel rides on guide shoes in tracks on both sides of the body. It is important that these tracks
be kept clean and lubricated. Check these tracks daily, removing any accumulation of trash, apply by brush,
a good chassis lube (Standard Oil “GEAREP OG” or equal) to the full length of these tracks (both sides).

It is also important to replace the panel guide shoes when they become worn.

If using tools or equipment to remove restricting material, use all safety precautions and safety equipment
recommended by their manufacture.

INSPECTION:
In addition to aforementioned maintenance, a regular weekly schedule of service checks should be made
of the following.
1) Body Mounting Fasteners.
2) All Hydraulic Fittings and Connectors.
3) All Pivot Pins and Fasteners.
4) Electrical Connections and Components.
5) All Air Connections.
Checking and tightening bolts and nuts is a standard maintenance item. All mounting or load carrying bolts
need to be inspected weekly. Please note the correct torque for the bearing bolts shown in Figure M-3. Arm
bolts should be tack welded in place. If tacks are broken, replace bolt, torque to 235-285 ft. lbs. and tack.

HERCULES (EJECT) LUBRICATION CHART

(ALL POINTS TO BE LUBRICATED ONCE A WEEK)

1) TAILGATE HINGE PIVOTS (2 = 1 EACH SIDE)

2) TAILGATE LIFT CYLINDERS (1 FITTING ROD END - BOTH SIDES = TOTAL 2)
3) BODY PIVOT HINGES (1 FITTING EACH HINGE - BOTH SIDES = TOTAL 2)
4) ARM LIFT CYLINDER (1 FITTING EACH END - BOTH SIDES = TOTAL 4)
5) PACKING CYLINDERS - ROD END (3 FITTINGS - BOTH SIDES = TOTAL 6)
6) PACKING CYLINDERS - BASE END (2 FITTINGS - BOTH SIDES = TOTAL 4)
7) FRONT DRIVE OR PTO DRIVE (3)
8) FORK BOX PIVOTS (1 FITTING EACH SIDE - BOTH SIDES = TOTAL 2)
9) FORK DUMP CLINDER PIVTOS (1 FITTING EACH END - BOTH SIDES = TOTAL 4)
10) LOWER TORQUE TUBE PIVOTS (2 FITTINGS EACH SIDE = TOTAL 4)

APPLY A GOOD CHASSIS LUBE (STANDARD OIL “GEAREP OG” OR EQUAL) TO

THE FOLLOWING AREAS.

A) WEAR SURFACES OF TAILGATE LOCKS (BOTH SIDES)

B) CHECK THE FULL LENGTH OF THESE TRACKS (BOTH SIDES) DAILY, REMOVING ANY
ACCUMULATION OF TRASH. WE RECOMMEND THAT YOU DAILY APPLY BY BRUSH THE
 ABOVE CHASSIS LUBE TO THE FULL LENGTH OF THESE TRACKS.
C) CHECK OIL SUPPLY DAILY, MAKING SURE OIL LEVEL IS AT MID-WAY POINT ON THE
OIL SIGHT GAUGE. WHEN CHECKING, HAVE UNIT SITTING LEVEL AND OIL AT A
NORMAL OPERATING TEMPERATURE WITH ALL CYLINDERS IN THE RETRACT POSITION
AND WITH PUMP NOT RUNNING.

APPLY OIL TO ALL LINKAGE AND FRICTION POINTS.

=29=
 SHIM INSTALLATION

1) To pivot the top of the arm out around axis “A-A”, install a shim @ position (1).
NOTE: 1/16" Shim = 3/4" Movement.
2) To pivot the top of the arm in, install a shim @ position (2).
3) To pivot the back of the arm in around axis “B-B”, install a shim @ position (3).
4) To pivot the back of the arm out, install a shim @ position (4).
NOTE: Arm bolts should be tack welded in place. If tacks are broken, replace bolt, torque
to 235-285 ft. Lbs. And tack. (4 Bolts, Both Sides).

=30=
 TAILGATE PROPPING INSTRUCTIONS
(PL-0955)

TO USE THE TAILGATE PROPS:

1). Set emergency brake and chock wheels.
2). Remove tailgate manual lock pins (both sides). Loosen optional turnbuckles if installed (both sides).

3). Raise tailgate approximately 4 feet.

4). Remove retainer pins and swing props into support position and reinstall retainer pins (both sides).

5). Lower tailgate in a slow controlled manner until the props rest in the prop receivers. Check that both
sides are seated. Shut-off engine.
6). To disengage props, raise tailgate and pin props in travel position. Power tailgate completely closed
until full locked decals are lined up.
7). Reinstall tailgate manual lock pins. (both sides). Relatch optional tailgate turnbuckles (both sides).
 SERVICE HOIST PROCEDURE
(PL-0954)

1). Set emergency brake and chock wheels.

2). Lower tailgate fully. Insert tailgate manual lock pins (one each side).

3). Remove 1/4" hose (Item A) from travel position quick disconnect and plug into tailgate system quick
disconnect (Item B). See figure SH-1.

4). Raise body, by closing the tailgate. Raise body to a height that the body props can be released (both
sides) to align with prop pockets (both sides).

5). Lower body, by opening the tailgate, until the props are resting properly in pockets (both sides).
When lowering body onto prop pockets, do so in a slow controlled manner. Shut-off engine.

6). To disengage props - start engine - close tailgate to raise body enough to secure props in travel
position. Lower body to frame by opening the tailgate.

7). Reinstall 1/4" hose to travel position (item a) and cap tailgate system. (Item b).
 FLOOR SERVICE HOIST PROCEDURE
(PL-1335)

BEFORE PERFORMING THESE PROCEDURES HAVE THE CHASSIS ON A PAVED LEVEL

SURFACE, WITH WHEELS CHOCKED AND PARKING BRAKE ON.

1). Unbolt spring mounting (both sides) and hose clamps at front of body.
NOTE: REMOVE EXHAUST STACK.

2). Lower tailgate fully. Insert tailgate manual lock pins (one each side).

3). Release body props (both sides).

4). Position service floor jack (2104958) under chassis, inline with the cylinder pivot brackets on the body.
5). Swing cylinders up into position and pin to the pivot pin brackets on the body. (Make certain that
cylinders are perpendicular to ground and chassis).

6). Connect hoist cylinders extend hose into tailgate system quick disconnect (Item B) and connect rod
side of cylinders to quick disconnect on the tank (Item A)

7). Raise body, by closing the tailgate. Raise body to a height to allow props to align with prop pockets
(both sides).

8). Lower body by opening the tailgate, until the props are resting properly in pockets (both sides). When
lowering body onto prop pockets, do so in a slow, controlled manner. Shut-off ignition and remove keys.
9). To disengage props, start engine and pump system. Close tailgate to raise body enough to secure props
in travel position. Lower body to frame by opening the tailgate.

10). Disconnect hoses from quick disconnects (Items A & B) and un-pin service floor jack cylinders from
brackets on body. Remove service floor jack from area.

11). Reinstall spring mountings (both sides) and hose clamps at front of body. Reinstall exhaust stack.

=33=
 PROPER PROCEDURE FOR BLEEDING AIR PRESSURE FROM OPTIONALWASH-OUT
TANK
(PL-1344)

2) Open bleed air valve (Item B). This will relieve the air pressure in the tank. NOTE: Bleed off all
pressure before removing the fill cap (Item C). Check pressure gauge, (Item D) for a zero (0) reading
before removal of the fill cap.

3) Proceed to remove the fill cap (Item C) slowly. If any air pressure is trying to escape (a hissing sound)
around the cap, stop loosening and retighten the cap. Repeat steps 1 and 2 to release all pressure in tank.

DO NOT REMOVE THE FILL CAP (ITEM C) WITH PRESSURE IN TANK

AIR CONTROLS PICTORIAL
LAYOUT
CIRCUIT BOARD LIGHT OPERATION DEFINITION
CIRCUIT BOARD LIGHT OPERATION DEFINITION

AUTO PACK OPERATION:

-- Mode switch (SW2) must be in Auto Pack. -- Green Start Button (PB1) must be depressed and held
until packer extends off of packer position limit switch (PS3) N.C. contacts. --LED2 (GREEN) and
LED14 (GREEN) will be on and packer will extend. -- This condition will remain until the packer
reaches the pack point (LS1) or the packer extend pressure switch (PS3) closes. Either
condition will cause LED3 (GREEN) to lite. -- This will cause LED14 (green) to go
off and LED15 (GREEN) to come on. -- Once blade starts to retract LED3 will go
off, as blade continues to retract. --LED15 will remain on until packer retracts to the
home (fully retracted) position. LED2 & LED15 goes off.

CR4 RELAY (USED WITH THROTTLE ADVANCE OPTION):

-- Once Throttle advance Control Switch (SW4) is engaged & a function requiring throttle advance
are enabled, LED16 (RED) and LED7 (AMBER) will come on. -- Once transmission is placed in
neutral LED5 (GREEN) comes on, LED7 (AMBER) goes off and LED6 (GREEN) comes on.
*This sequence of operations displays that CR4 is working properly and has changed states.

CR6 RELAY.
--The following procedure will be accurate most of the time. But LED12, 13 & 18 may never lite. This
will depend on what type of signal is required by the engine to enable throttle advance. -- LED11
(GREEN) comes on with LED6 (GREEN) -- LED 18 (RED) and LED13 (AMBER) will always be on. (If
engine uses +12VDC for throttle advance). -- When LED11 (GREEN) comes on, LED12 (GREEN) comes
on. Led12 is the output to engine for throttle advance (if engine uses +12VDC for throttle advance).

CR5 RELAY (TRAPEZOIDAL LIGHT):

-- LED17 (RED) and LED10 (AMBER) will always be on, showing that relay has power and is off.
-- Once transmission is placed in reverse LED8 (GREEN) comes on (signal from transmission) --
This causes LED9 (GREEN) to come on & LED10 to go out, giving output to trapezoidal control
switch. (SW8).

AIR CONTROL VALVE:

Corresponding LED lights on the air control valve will light as a specific function is called for.

PL-1528-1
 CABLE, DIN CONNECTOR

( 2111833 )
CONTROL BOX WIRING

2-POSITION FORKS
( 2114427 )
 This Page
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 P.O. Box 790

200 Ladish Road

Cynthiana, KY 41031

(800) 331-0136

(859) 234-1100

FAX: (859) 234-0061