(removed in Step 9)

Hopper
Assembly

Orient elbow against bracket if
bracket looks like bracket shown

Figure 6

5

12.
Install top bracket assembly to hopper support using hardware removed in Step 6. Final tighten mounting
hardware to 9 ft lbs. See Figure 7.
13.
Make sure the water add tube is against bracket stop, or if not equipped with bracket stop the tube is
pointed toward the center of the drum opening. Adjust tube position as required.
14.

Reconnect water supply hose to barb fitting and secure with hose clamp, See Figure 7.

Screws and
Lock Washers

Hose
Hose Clamp

Figure 7

15.
Remove hose bead fitting and ball valve from the manifold drain, see Figure 8. Set ball valve and bead
fitting aside for reinstallation later.

Ball Valve

Bead Fitting
Figure 8

6

16.
Remove 90° elbow and straight fitting from manifold, see Figure 9. Set straight fitting and 90° elbow aside
for reinstallation later.

Straight Fitting

90° Elbow

Figure 9

17.
Remove jam nuts securing valve handles and remove handles from the manifold assembly, see Figure
10. Set handles and jam nuts aside for reinstallation later.
18.
Remove the small brass caps from the two valve extensions, see Figure 10. Set brass caps aside for
reinstallation later.

Brass Cap

Handle
Jam Nut
Figure 10

7

19.

Disconnect the manifold pressure switch from the vehicle harness connector, see Figure 11.

20.

Install plug jumper (A000V757) into vehicle harness where switch connector was removed, see Figure 11.

Pressure Switch
Plug Jumper
(A000V757)

Vehicle Harness
Connector

Pressure Switch Connector
Figure 11

21.

Loosen hose clamps and disconnect the four water lines from manifold, see Figure 12.

Hose

Hose
Hose Clamp

Figure 12

8

22.

Clamp the manifold coolant lines before disconnecting hoses from manifold to prevent coolant loss.

23.

Squeeze and slide hose clamps away from the ends of coolant hoses, see Figure 13.

24.

Disconnect coolant hoses from manifold, see Figure 13.

Hose Clamp

Coolant Hose
Figure 13

25.
Remove screws and nuts securing manifold to frame rail and discard, see Figure 14. Remove manifold
from mounting location.

Mounting Screws
and Nuts

Figure 14

9

NOTE

Apply pipe sealant to all threaded
connections.
26.

Remove highlighted fittings from old manifold, see Figure 15.

27.

Install fittings removed in Step 26 into new manifold assembly, see Figure 15.

New Manifold
Assembly

Old Manifold
Assembly
Figure 15

28.

Orient the top and end fittings per Figure 16.

40°
50°

Top View

End View
Figure 16

10

150°

29.
Install new manifold assembly to frame rail. Place spacer (A000V232) between manifold and frame rail,
secure manifold to frame rail with 0.25-20 x 1.25” screws (A000A503). See Figure 17. Final tighten screws to 60
in. lbs.

Frame Rail
Spacer
Manifold
Assembly

Figure 17

30.
Locate the auxiliary air manifold on the right-hand side of the cab rear crossmember. Replace 90° fitting
in lower right-hand port with T-fitting (A000D602). Install air line from the removed 90° fitting into bottom of the
installed T-fitting. See Figure 18.
31.

Install air hose (A000V234) to T-fitting installed in Step 30.

32.

Connect other end of air hose (A000V234) to air valve (A000A433).

33.

Mark air valve mounting hole location on crossmember.

34.

Drill a 0.34” hole in crossmember to mount the air valve.

35.
Secure air valve to crossmember with 0.31-18 x 0.88 in. screw (A000A520) and flanged lock nut
(A000A689).

Air Valve

Air Hose

(A000A433)

(A000V234)

Aux Air Manifold

T-Fitting
(A000D602)

Crossmember
Manifold Assembly

Figure 18

11

36.

Connect one end of air hose (A000V233) to air valve installed in Step 35, see Figure 19.

37.

Connect other end of air hose (A000V233) to manifold assembly valve 90° elbow, see Figure 19.

38.

Zip tie air hose to existing lines or hoses, see Figure 19.

Zip Tie

Air Hose

Air Valve

(A000V233)

90° Elbow

Figure 19

39.
Reconnect water supply hose, water add hose, front and top hoses, and coolant lines to manifold. See
Figure 20. Secure hose connections with hose clamps.
40.

Remove clamps from coolant lines installed in Step 22.

Water Add Hose

Top Hose

Coolant Hoses
Water Supply

Front Hose

Figure 20

NOTE

Apply pipe sealant to all threaded
connections.
41.

Reinstall straight fitting and 90° elbow removed from old manifold in Step 16. See Figure 21.

Straight Fitting

90° Elbow
Figure 21

12

42.

Install ball valve removed in Step 15 to T-fitting of drain assembly. See Figure 22.

Drain
Assembly

Ball Valve

(removed in Step 15)

Figure 22

43.

Connect drain assembly to 90° elbow installed in Step 41. Orient drain assembly as shown in Figure 23.

Figure 23

13

44.
Install hose (A000V756) with hose clamps (A000H803) between the drain assembly T-fitting and
manifold. See Figure 24.

Hose Clamp
Hose

(A000H803)

(A000V756)

Hose Clamp
(A000H803)

Figure 24

45.

Reinstall brass caps, handles and jam nuts removed in Steps 17 and 18, see Figure 25.

Brass Cap
Handle

Jam Nut
Figure 25

14

46.

Locate existing water add harness connector in vertical hopper support, see Figure 26.

47.
Cut zip ties securing the water add harness to vertical hopper support. Replace zip ties as needed to
secure existing hoses/lines to vertical hopper support.
48.

Connect end of jumper harness (A000V410) to water add harness.

49.
Route water add harness with jumper harness along superstructure horizontal support and through
pedestal to the water add manifold. Secure harness to the water add hose with zip ties as needed.

Harness Connector

Zip Ties
Jumper Harness
Routing

Figure 26

50.

Connect jumper harness to air valve (A000A433) connector, See Figure 27.

Air Valve Connector
Figure 27

15

51.

Clean area on frame rail and install label (A000V451), see Figure 28.

Label

(A000V451)

Figure 28

52.

Remove lockout/tagout.

Reimbursement of Costs:
Affected units shall be repaired using the customer’s own qualified service technicians - at no cost to the owner.
The repairs will take approximately 3.5 hours to complete and Oshkosh Corporation will reimburse 4 hours labor.

Labor Reimbursement:
In order to receive credit, claims are to be submitted through the normal warranty claim system. Claims must be
received within 30 days of the repair. Claims must include the McNeilus serial number of the truck, the customer
asset number, and the number of this bulletin.

Parts Reimbursement:
Parts and ground shipping will be reimbursed to the customer. Parts necessary for this repair must be ordered
from McNeilus Parts at 888-686-7278.
Claims are to be submitted through the normal warranty claim system. Claims must be received within 30 days
of the repair. Claims must include the McNeilus serial number of the truck, the customer asset number, and this
bulletin’s number.

Contacts:
If you have questions or need further information, please contact a McNeilus National Service Representative at
888-686-7278.

Continuous Improvement:

The change included in this document is part of the
McNeilus Continuous Improvement Process.
McNeilus’s quality policy is providing customer satisfaction
through innovative products, dedicated service, and a
constant focus on continuous improvement.
16

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