Dover HEIL LIBERTY TP1L-SM-0520 Service Manual
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Dover HEIL LIBERTY TP1L-SM-0520 Service Manual

Continuous-pack automated side loader
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CONTINUOUS-PACK AUTOMATED SIDE LOADER
SERVICE MANUAL
ISSUED MAY 2020
TP1L-SM-0520
© 2020 Heil Environmental
.

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Summary of Contents for Dover HEIL LIBERTY TP1L-SM-0520

  • Page 1 CONTINUOUS-PACK AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED MAY 2020 TP1L-SM-0520 © 2020 Heil Environmental...
  • Page 2 WARNING IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE IMPORTANT SAFETY NOTICE Proper service and repair are important to the safe, reliable operation of Heil Co.’s products.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Introduction ......................................4 Service/Parts Assistance ......................................5 Recommended Spare Parts ......................................6 Electronic Parts Catalog (EPC) ......................................8 Hazard Symbols and Definitions ......................................11 Lock-Out/Tag-Out Procedures ......................................15 Storing Refuse in Container ......................................16 Maintenance/Lubrication Information ......................................16 Winch Gear Oil ......................................16 Grease Lubrication Recommendation ......................................16 Oil Can Lubricant Recommendation ......................................16...
  • Page 4 TABLE OF CONTENTS Body Props ......................................66 Tailgate Support Props ......................................67 Pressure Adjustment Procedures ......................................68 Lift Control Valve for Liberty with Tandem Pump Setup ......................................70 Body-Up Limit Switch ......................................71 Tailgate Unlatch Limit Switch (N.C.) ......................................72 Packer Reversing Limit Switch (N.C.) ......................................72 Welding and Electronic Devices / Electrical Lubricants ......................................73 Maintenance and Adjustment...
  • Page 5 TABLE OF CONTENTS 701-9244-003 - 2018 Liberty/Rapid Rail Add-On Control Panel Schematic ......................................108 701-9244-100 - 2018 Liberty/2018 Autocar (RP170) Chassis Electrical Schematic ......................................109 701-9244-102 - 2018 Liberty/Mack LR/MRU Chassis Electrical Schematic ......................................110 701-9244-107 - 2018 Liberty/International Chassis Electrical Schematic ......................................111 701-8776-001 - Lift Arm Up and In Flow Diagram ......................................112 701-8776-002 - Lift Arm Release Flow Diagram...
  • Page 6 NOTES Issued May 2020 Copyright 2020, Heil Environmental Printed in the U.S.A.
  • Page 7 CONTINUOUS-PACK AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED MAY 2020 TP1L-SM-0520 Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A.
  • Page 8 NOTES Issued May 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.

  • Page 9: General Information

    General Information SECTION 1 GENERAL INFORMATION Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. General Information...

  • Page 10: Introduction

    General Information INTRODUCTION The following sections are a guide for maintenance and service of the Heil unit. The sections cover preventive maintenance, adjustment, and troubleshooting hints. Before performing maintenance, check the work area carefully to find all the hazards present and make sure all necessary safeguards or safety devices are used to protect all persons and equipment involved.

  • Page 11: Service/Parts Assistance

    General Information SERVICE/PARTS ASSISTANCE Assistance in troubleshooting repair and service is available by contacting the authorized Heil Dealer in your area. Parts are available at your Heil Dealer or through Heil. Heil personnel are trained to give prompt, professional assistance. ALWAYS give the unit serial number in all correspondence relating to the equipment.

  • Page 12: Recommended Spare Parts

    General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION BODY AND TAILGATE ASSEMBLIES 022-3996 SEAL, TUBING, 1-14", TAILGATE 019-1095 SPRING, 1" OD X 6" 003-4438 SPH BRG-QUAD LUB LOW LOADER AND GRABBER ASSEMBLIES 062-0805 ASSEMBLY, GRABBER, ROLLER, 4” 062-0804 ASSEMBLY, ROLLER, TRI-CUFF 062-0712 ROLLER, GRABBER, 4”...
  • Page 13 General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION 063-0123 SWITCH, PROXIMITY, NO, SOURCING, 30MM 063-0115 SWITCH, PRESSURE, W/CONNECTOR, PACKARD 069-0032 KIT, MICRO RELAY 108-5031 WHISKER SWITCH CONTROLS 031-6254 JOYSTICK, PNEUMATIC, 3 PUSH BUTTONS 075-0953-012 SWITCH, ELECTRICAL, FILTER, RETURN LINE 108-2280 RUBBER BOOT, 4000 108-6422 SWITCH TOGGLE...

  • Page 14: Electronic Parts Catalog (Epc)

    General Information ELECTRONIC PARTS CATALOG (EPC) The Parts Central EPC includes electronic versions of the Heil Parts Manuals, specific to a Customer’s truck configuration and options. After registering and logging in, the user can search by Keyword(s) or Part Number and/or Heil Body Serial Number to quickly identify a spare part or browse a custom parts catalog.
  • Page 15 General Information Search by Part Keyword(s) or Part Number in Body Serial Number After login, you will land on the User Dashboard. At the top right of the Dashboard, there will be two search fields, as shown in the image below. You can search by Keyword(s) or Part Number within a specific Heil Body Serial Number.
  • Page 16 General Information Search by Body Serial Number If you want to view an entire parts catalog for a particular Heil unit, you can search by only the Heil Body Serial Number, leaving the Keyword(s) / Part Number field blank. The search result will then be the Body Serial Number-specific parts catalog with familiar catalog sections that you can browse.

  • Page 17: Hazard Symbols And Definitions

    General Information PRECAUTIONARY STATEMENTS Listed below are the definitions for the various levels of hazards. It is important that the operators of this equipment and people who service units read and understand all warnings as they relate to this equipment operation. DANGER –...
  • Page 18 General Information DANGER The packer and crusher panels are dangerous. They can cause death or serious injury if a person is inside the hopper. Make sure no one is inside the hopper before you begin a packer or crusher function. Put the unit in the Lock-Out/Tag-Out mode if it is necessary to enter the hopper area.
  • Page 19 General Information WARNING Clear all people of the area before you lift a refuse container. Make sure the refuse is secure in the refuse container before you lift the container. Loose refuse can fall and cause death or serious injury. WARNING The hydraulic fluid can be under pressure and can spray while you open the connection.
  • Page 20 General Information NOTICE Grabbing a refuse container with too much pressure can damage the container. The container can become unusable. Use enough pressure with the grabber to raise the container with the lift arm and not damage the container. NOTICE Always use your employer’s Lock-Out/Tag-Out procedures.

  • Page 21: Lock-Out/Tag-Out Procedures

    General Information LOCK-OUT/TAG-OUT PROCEDURES NOTICE Always use your employer’s Lock-Out/Tag-Out procedures. If your employer does not have Lock-Out/Tag-Out procedures, use the procedures that follow. Contact your supervisor or Heil Technical Service if you have any questions about Lock- Out/Tag-Out procedures. Watch the Service Shack Video online at www.Heil.com/Heil-Service-Shack by selecting Lock-Out/Tag-Out.

  • Page 22: Storing Refuse In Container

    General Information STORING REFUSE IN THE BODY Heil does not recommend storing refuse in the body overnight. The different types of debris and corrosive elements usually collected can cause severe corrosion inside the body decreasing the life of your body. This corrosion can affect unloading and decrease the structural life of the body.

  • Page 23: Standard Torque Data For Nuts And Bolts

    General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS The following recommended torque data is for use as a general guideline. Recommended torque, in foot pounds, for all Standard Application nuts and bolts provided in the following table. NOTICE Torque specifications on a drawing override torque values in the Standard Torque Data for Nuts and Bolts Table. All thread surfaces are clean and lubricated with SAE-30 engine oil.
  • Page 24 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock) Grade (ft-lbs)
  • Page 25 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock) Grade (ft-lbs)
  • Page 26 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock) Grade (ft-lbs)

  • Page 27: Bolt Type Identification Chart

    General Information BOLT TYPE IDENTIFICATION CHART S.A.E. Bolt Head Description Type Grade Marking** No radial lines. 1 or 2 Low or medium carbon steel not heat treated. NOT USED, replace with same grade bolt. Three radial lines. Quenched and tempered medium carbon steel. Six radial lines.

  • Page 28: Torque For Hydraulic Tubes And Fittings

    General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS FLAT FACE ORFS FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1/4" 21 ft-lbs. 250 in-lbs. 3/8" 33.5 ft-lbs. 400 in-lbs. 1/2" 50 ft-lbs. 600 in-lbs. 5/8" 50 ft-lbs.
  • Page 29 General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) 37 DEGREE FLARE (JIC) FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1/8" 6.5 ft-lbs. 80 in-lbs. 3/16" 9 ft-lbs. 110 in-lbs. 1/4" 12.5 ft-lbs. 150 in-lbs. 5/16"...
  • Page 30 General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) FROM SAE J2593 TABLE 7 (STEEL) SET WRENCH TO BOSS (ORB) NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 3/16" 9 ft-lbs. 110 in-lbs. 1/4" 16.5 ft-lbs. 200 in-lbs. 5/16" 21 ft-lbs.
  • Page 31 General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) Figure 4. Torque for Hydraulic Tubes and Fittings SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 61) SET WRENCH TO NOMINAL TUBE BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT- LBS] LBS [IN-LBS] 1/2"...
  • Page 32 General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 62) SET WRENCH TO NOMINAL BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT-LBS [IN- TUBE OD LBS] LBS] 1/2" 5/16-18 x 1.25 17 ft-lbs. 200 in-lbs.

  • Page 33: Cold Weather Warmup Procedure

    General Information COLD WEATHER WARMUP PROCEDURE When ambient air temperature is cold (below 0 degrees F), it is necessary to warm up the unit’s hydraulic oil before you start your daily route operation, check the oil level, or adjust hydraulic pressure settings. The hydraulic oil is sufficiently warmed when the temperature is between 120°...

  • Page 34: Proximity Switch Troubleshooting

    General Information PROXIMITY SWITCH TROUBLESHOOTING When one or more of a unit’s functions do not operate properly and there are proximity switches in the circuits of the unit for these functions, refer to the following table as a guide to find the problem(s). NOTICE Heil proximity switches have a Light Emitting Diode (LED) on the switch to indicate that the switch is sensing metal.
  • Page 35 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. General Information...
  • Page 36 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Issued May 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.
  • Page 37 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. General Information...

  • Page 38: Safety Decals On The Unit

    General Information DECALS ON THE UNIT Make sure you can read all hazard and instruction decals. Clean decals if you cannot read the words. See for directions on cleaning decals. Replace any decal that is damaged, missing, or is not readable. When you replace a part that has a decal, make sure a new decal is installed on the new part.
  • Page 39 General Information DECAL CARE (CONTINUED) Figure 5. Recommended Technique Figure 6. Incorrect Technique Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. General Information...

  • Page 40: Hydraulic Symbols

    General Information HYDRAULIC SYMBOLS Issued May 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.
  • Page 41 General Information HYDRAULIC SYMBOLS (CONTINUED) Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. General Information...

  • Page 42: Electrical Symbols

    General Information ELECTRICAL SYMBOLS Issued May 2020 Copyright 2020, Heil Environmental General Information Printed in the U.S.A.
  • Page 43 Pumps SECTION 2 PUMPS Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Pumps...

  • Page 44: Hydraulic Pump Control

    Pumps HYDRAULIC PUMP CONTROL The pump system consists of a tandem hydraulic pump driven by either a transmission mounted PTO or engine crank shift (front mount pump). There can be up to three control solenoids in this system Pump #1 (Lift Pump), Pump #2 (Body Pump) and Hot Shift PTO (if equipped).

  • Page 45: Tandem O.i.g.a.i. Pump

    Pumps TANDEM O.I.G.A.I. PUMP Front Loaders, Rear Loaders, Recycle 2000, and Liberty Figure 7. Tandem O.I.G.A.I. Pump This is the Hydraulic Controls Operate-In-Gear-At-Idle (OIGAI) System. The pump section (pump 1) closest to the input shaft operates the lift and shuts off first. The pump section (pump 2) farthest from the input shaft operates the packer and stays on at higher RPMs.

  • Page 46: Tandem Vane Pump O.i.g.a.i. Hydraulic System Troubleshooting

    Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING The Operate-in-Gear-at-Idle (OIGAI) system is designed to perform the loading operations at standard idle speed. It is comprised of two major components, the monoblock tandem vane pump and attached unloader valve assembly. On the OIGAI REL systems the P1 closest to the pump input shaft while the P2 farthest from the input shaft supplies flow to the complete hydraulic systems.
  • Page 47 Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING (CONTINUED) NOTICE If flow is present check the main relief valves for proper adjustment and operation. Figure 9. Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Pumps...
  • Page 48 NOTES Issued May 2020 Copyright 2020, Heil Environmental Lift Arm Printed in the U.S.A.

  • Page 49: Lift Arm

    Lift Arm SECTION 3 LIFT ARM Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Lift Arm...

  • Page 50: Nomenclature

    Lift Arm NOMENCLATURE Figure 10. Lift Arm Nomenclature Issued May 2020 Copyright 2020, Heil Environmental Lift Arm Printed in the U.S.A.

  • Page 51: Specifications

    Lift Arm SPECIFICATIONS NOTICE All pressures are +/- 100 PSI at operating temperature. See Lift Control Valve Pressure Adjustments and Relief Valve Adjustment pages for valve adjustment procedures. A. Hydraulic Cylinders Lift and Reach ..........................3.1" Bore X 16" Stroke Grab ..............................

  • Page 52: Python Lift Lubrication Guide

    Lift Arm PYTHON LIFT LUBRICATION GUIDE Clean fittings before applying grease and always pump enough grease into joint to remove the old grease. Wipe off excess grease. Lubricate moveable mechanical parts without fittings every 60 days with non-detergent engine oil. NOTICE If a grease zerk is missing or damaged, replace as necessary.

  • Page 53: Preventive Maintenance Guide

    Lift Arm LIFT ARM PREVENTIVE MAINTENANCE CHART Maintenance performed on a regular schedule is preventive maintenance. Normal maintenance intervals are based on an 8-hour day and average operating conditions. Severe use or adverse conditions make it necessary to do this maintenance more frequently.

  • Page 54: Check Lift And Torque Mount Base Bolts

    Lift Arm CHECK LIFT AND TORQUE MOUNT BASE BOLTS When the Lift Base Mounting bolts weld is cracked, you must replace the bolts and nuts. The goal of this torque method is to achieve a 59,000lb clamp load consistently. A torque multiplier is not accurate enough at the values required. This method (torque/turn) is accurate and repeatable.
  • Page 55 Lift Arm CHECK LIFT AND TORQUE MOUNT BASE BOLTS (CONTINUED) Figure 13. Lift Mount Bolt 7. Use a wrench and extension handle to turn the nut's marked corner to the second mark at the center of the fourth nut flat. It is critical that the head of the bolt is held in place and not allowed to rotate further. Brace the wrench handle as necessary.

  • Page 56: Universal Belt And Tri-Cuff Grabber Adjustments

    Lift Arm UNIVERSAL BELT AND TRI-CUFF GRABBER ADJUSTMENTS A. 60-90 Gallon Belt Grabbers Adjust the grabber belt length so the distance between the roller on the inner arm and the outside roller is 30” (+/- 1”). See illustration below. NOTICE The grabber belt holes on the inside end of the belt are farther apart to make longer adjustments.
  • Page 57 Lift Arm UNIVERSAL BELT AND TRI-CUFF GRABBER ADJUSTMENTS (CONTINUED) B. 90-300 Gallon Belt Grabbers Adjust the grabber belt length so the distance between the inner arm and the outside roller is approximate 30” (+/- 1”) to obtain a firm grip for smaller containers. The total overall length of the grabber belt must be set to obtain a firm grip for larger containers.
  • Page 58 Lift Arm UNIVERSAL BELT AND TRI-CUFF GRABBER ADJUSTMENTS (CONTINUED) C. 30-110 Gallon Tri-Cuff Belt Grabbers Adjust the grabber belt length so the distance between the roller on the inner arm and the outside roller is 30” (+/- 1”). See illustration below. NOTICE The grabber belt holes on the inside end of the belt are farther apart to make longer adjustments.

  • Page 59: Lift-Stowed And Grabbers Open Proximity Switches

    Lift Arm LIFT-STOWED AND GRABBERS OPEN PROXIMITY SWITCHES Adjust the proximity switches to deactivate if grabber or arms are extended outside the width of the vehicle. You will need a 15/16" wrench. The grabbers open proximity switch should be adjusted so that it is activated when the grabbers are fully open.

  • Page 60: Lift Control Valve

    Lift Arm LIFT CONTROL VALVE Some key areas are shown below on the standard lift control valve. The Python Lift uses a precision-machined parallel control valve that does not have interchangeable spools. Each spool is matched to the individual bore. See Lift Control Valve Pressure Adjustments Figure 20.

  • Page 61: Lift Control Valve Pressure Adjustments

    Lift Arm LIFT CONTROL VALVE PRESSURE ADJUSTMENTS The lift control valve has adjustable hydraulic pressure settings that should be checked twice yearly (1000 hrs). All lift valve pressure adjustments are made with the engine running at idle. In general, hydraulic pressures are normally increased by turning the pressure adjusting screw clockwise.
  • Page 62 Lift Arm LIFT CONTROL VALVE PRESSURE ADJUSTMENTS (CONTINUED) B. Checking and Making Adjustments 1. Connect a 0-5000 psi pressure gauge to the gauge port on the inlet of the valve. See the image below. Figure 21. Inlet Section Pressure Gauge Port Figure 22.
  • Page 63 Lift Arm LIFT CONTROL VALVE PRESSURE ADJUSTMENTS (CONTINUED) B. Checking and Making Adjustments (Continued) 2. To check the main relief on the lift valve, dead head any function that has a higher set point - like lift retract or lift raise, and hold that function while monitoring the pressure gauge.

  • Page 64: Remove Grabber Beam Assembly

    Lift Arm REMOVE GRABBER BEAM ASSEMBLY The grabber beam connects the grabber gears and grabbers to the lift arm. If the beam is damaged, you must replace the grabber beam. You need the following tools to replace the grabber beam. A.
  • Page 65 Lift Arm REMOVE GRABBER BEAM ASSEMBLY (CONTINUED) 5. To make the pin easier to remove, insert a different bolt with a washer into the bolt hole. Inserting this bolt makes it easier to remove the pin. DO NOT use the original bolt. 6.

  • Page 66: Relief Valve Adjustment

    Lift Arm RELIEF VALVE ADJUSTMENT Follow these steps to set the main relief valve. A. Tools Required Quantity Tool Personal protective equipment Pressure gauge (0-5000) 1-1/2" Wrench 15/16" Wrench 7/16" Wrench 1/8" Wrench 1/2" Hex Wrench Wire cutters Slotted Screwdriver Replacement seal B.

  • Page 67: Lift And Weld Cracks Decision Tree

    Lift Arm LIFT AND WELD CRACKS DECISION TREE Use this decision tree to help you decide whether to repair a crack or to replace the entire lift arm. Follow these welding requirements for repairing the lift arm. 1. All material shall be free from paint, soil, grease, dirt, and any other non-metal contamination. 2.

  • Page 68: Lift Pneumatic Installation With Autolift Function

    Lift Arm LIFT CONTROL PNEUMATIC INSTALLATION WITH AUTOLIFT FUNCTION Use the following illustration to troubleshoot the Autolift function. Issued May 2020 Copyright 2020, Heil Environmental Lift Arm Printed in the U.S.A.

  • Page 69: Body And Tailgate

    Body and Tailgate SECTION 4 BODY AND TAILGATE Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Body and Tailgate...

  • Page 70: Nomenclature

    Body and Tailgate NOMENCLATURE The following picture shows the major components and their typical location on the unit. Figure 26. Body Nomenclature Issued May 2020 Copyright 2020, Heil Environmental Body and Tailgate Printed in the U.S.A.

  • Page 71: Specifications

    Body and Tailgate SPECIFICATIONS NOTICE All pressures are +/- 100 PSI at operating temperature. See Lift Control Valve Pressure Adjustments and Relief Valve Adjustment pages for valve adjustment procedures. Valve Pressure Settings: Loader Main Systems ............................2300 PSI Loader In/Out Cross-Port Relief ....................... 2500/1250 PSI Body Main Relief Valve .............................

  • Page 72: Body Props

    Body and Tailgate BODY PROPS The factory-supplied body props are located on both sides under the body and forward of the rear wheels. Refer the figure below. Follow these steps to lower the body props. Figure 27. Factory Body Props Issued May 2020 Copyright 2020, Heil Environmental Body and Tailgate...

  • Page 73: Tailgate Support Props

    Body and Tailgate TAILGATE SUPPORT PROPS Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Body and Tailgate...

  • Page 74: Pressure Adjustment Procedures

    Body and Tailgate PRESSURE ADJUSTMENT PROCEDURES CAUTION Prior to making any adjustments to the packer circuit, the body must be properly blocked with body props and in the elevated position. CAUTION Prior to making any adjustments to the body main relief valve, block wheels of the unit and set the parking brake. NOTICE Hydraulic pressure above 2400 PSI will cause excessive pin wear and reduced linkage life.
  • Page 75 Body and Tailgate RELIEF VALVE ADJUSTMENT This page contains the steps to making an adjustment to the relief valve. A. Tools Required 1. 1-1/8” open end wrench 2. Ratchet with screwdriver attachment 3. 0-3000 PSI glycerin filled pressure gauge B. Before Making Adjustments 1.

  • Page 76: Lift Control Valve For Liberty With Tandem Pump Setup

    Body and Tailgate LIFT CONTROL VALVE FOR LIBERTY WITH TANDEM PUMP SETUP This hydraulic system is used with a tandem pump set up. The system is activated by energizing pump solenoid “A”. This solenoid is normally open and blocks (closes) the unloader system pressure when it is energized. Pump solenoid “B” is mounted directly on the hydraulic pump.

  • Page 77: Body-Up Limit Switch

    Body and Tailgate BODY-UP LIMIT SWITCH The Body-Up Limit Switch is a non-adjustable normally closed (N.C.) switch and is located on the left body prop bracket with the striker located on the body above the switch. This limit switch turns on an alarm when the body is raised off the chassis.

  • Page 78: Tailgate Unlatch Limit Switch (N.c.)

    Body and Tailgate TAILGATE UNLATCH LIMIT SWITCH (N.C.) The Tailgate Unlatch Limit Switch (N.C.) is non-adjustable and mounted on the tailgate with the striker mounted on the tailgate hinge. It is activated by breaking contact with the striker. When the tailgate latch is released, causing the striker to move, this switch interrupts an electrical circuit causing an alarm to sound, warning the operator that the tailgate is not fully closed and latched.

  • Page 79: Welding And Electronic Devices / Electrical Lubricants

    Body and Tailgate WELDING AND ELECTRONIC DEVICES / ELECTRICAL LUBRICANTS proximity switches complete the following procedures. WARNING Never weld on a compressed natural gas vehicle unless the compressed natural gas fuel system has been purged with inert gas. See Service Manual Section 1. Disconnect all battery connections.
  • Page 80 NOTES Issued May 2020 Copyright 2020, Heil Environmental Maintenance and Adjustment Printed in the U.S.A.

  • Page 81: Maintenance And Adjustment

    Maintenance and Adjustment SECTION 5 MAINTENANCE AND ADJUSTMENT Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Maintenance and Adjustment...

  • Page 82: Body Daily Checklist

    Maintenance and Adjustment BODY DAILY CHECKLIST Make sure you perform a daily check of the unit. Refer to the Operator’s Manual for the Daily Checklist. Many checks in the Daily Checklist are maintenance related, such as checking tire pressures and hoses for wear and damage. DAILY CHECKLIST MAINTENANCE ITEMS Item Required Action...

  • Page 83: Body Preventive Maintenance Chart

    Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART Preventive maintenance must be performed to ensure the safe and reliable operation of your unit. Use the chart below as a guideline for when essential items should checked and serviced. Severe use or adverse conditions may require more frequent maintenance.
  • Page 84 Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE Lubricate as shown on Body Lube Grease Fittings Chart. Inspect body undercoating and repair Body Undercoating as necessary. Tailgate Seal Integrity * Daily = 8 hrs. Weekly = 40 hrs. Monthly = 200 hrs. 6 Months = 1000 hrs. Yearly = 2000 hrs. Issued May 2020 Copyright 2020, Heil Environmental Maintenance and Adjustment...

  • Page 85: Body Lubrication Guide

    Maintenance and Adjustment BODY LUBRICATION GUIDE Clean fittings before applying grease and always pump enough grease into joint to remove the old grease. Wipe off excess grease. Lubricate moveable mechanical parts without fittings every 60 days with non-detergent engine oil. Figure 30.

  • Page 86: 10 Point Auto Lube

    Maintenance and Adjustment 10 POINT AUTO LUBE CAUTION If one of the hydraulic hoses breaks, all the grease in the reservoir will drain. If one of the nylon lines break, only grease stored in the individual injector will drain. A. Operation THE Heil Rapid Rail 10-Point Automatic Lube System is used to lubricate the packer mechanism.
  • Page 87 Maintenance and Adjustment 10 POINT AUTO LUBE (CONTINUED) C. Maintenance (a)How to Refill Lubrication Cylinder Raise the body and secure with body props. Tailgate must be closed and locked in position. Rotate the packer so that the lubrication cylinder is in a convenient access position, such as front street side. Turn ignition off To fill the reservoir, locate the grease fittings on the inside end and the ¼”...

  • Page 88: Preparing The Unit To Check The Oil Level

    Maintenance and Adjustment PREPARING THE UNIT TO CHECK THE OIL LEVEL Before checking the oil level or adding oil, make sure the unit is in the following position with all cylinders collapsed: Truck – on level ground Tailgate and Body – fully down and locked Packer Panel –...

  • Page 89: Check Oil Level

    Maintenance and Adjustment CHECK OIL LEVEL Check the hydraulic oil level (after warning up the oil) daily or every eight (8) hours, whichever comes first. Fill as necessary. Important: Contamination is a hydraulic system’s worst enemy. Do not let dirt enter the system. Use a clean rag and remove dirt or other contamination around any system component before you disconnect or remove it.

  • Page 90: Drain And Clean The Hydraulic Oil Tank

    Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK Change the hydraulic oil when the oil sample shows to change it. Remember that almost all hydraulic system malfunctions can be traced to dirt in the fluid. When working with the hydraulic system, the hands, tools, working area and parts must be as clean as possible.

  • Page 91: Purge The Hydraulic System

    Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK (CONTINUED) NOTICE Before filling the tank be sure the funnel is clean and 200 mesh (or finer) screen is used to strain the hydraulic oil. 13.Fill tank with recommended oil, checking the sight gauge as you fill. Refer to Hydraulic Oil Specifications 14.Check the entire system to make sure all connections are tight and no leaks are found.

  • Page 92: Packer/Body Valve

    Maintenance and Adjustment PACKER/BODY VALVE The packer valve is located between the chassis rails and controls the packer panel left and right movements, body raise/ lower and tailgate raise/lower functions. Issued May 2020 Copyright 2020, Heil Environmental Maintenance and Adjustment Printed in the U.S.A.

  • Page 93: Packer/Body Valve Troubleshooting

    Maintenance and Adjustment PACKER, TAILGATE, AND BODY VALVE TROUBLESHOOTING Packer doesn’t move Operate manual overrides on packer pilot valve. Packer now moves? – Check for electrical problems such as wiring, solenoid coil, and current from controller, or pressure switch failure. Packer doesn’t move? Operate tailgate.

  • Page 94: Cracked Weld Joints

    Maintenance and Adjustment REPAIRING CRACKED WELD JOINTS Repair all cracked weld joints immediately after finding cracked weld joints. If you are unsure of the proper repair procedure, call Heil Technical Services at 866-310-4345. OIL LUBRICANT RECOMMENDATION Use only non-detergent engine oil to lubricate all moveable mechanical parts not furnished with grease fittings. Apply sufficient oil to give good lubrication, but do not bathe parts in oil.

  • Page 95: Body Controller Hardware

    Body Controller Hardware SECTION 6 BODY CONTROLLER HARDWARE Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Body Controller Hardware...

  • Page 96: Body Controller

    Body Controller Hardware BODY CONTROLLER The Body Controller is mounted inside the street side hoist cylinder bracket. Mounted with the body controller are the relays that control the hoist raise/lower and tailgate raise/lower. LED COLOR STATUS DESCRIPTION No Supply Voltage Red/Green 1 Flash Initialization...

  • Page 97: Control Fuses

    Body Controller Hardware CONTROL FUSES Fuse holder is located under the dog house cover, in the cab to body harness, near the Connector D1. FUSE AMPERAGE CIRCUIT Body Controller Power (Pin10) Cab Controller Power (Pin10) Switch Banks System Power Input Auxiliary Control Lift Control Sensor Power Cab Controller Output Power 08-15 (Pin1)
  • Page 98 NOTES Issued May 2020 Copyright 2020, Heil Environmental Body Controller Software Printed in the U.S.A.

  • Page 99: Body Controller Software

    BODY CONTROLLER SOFTWARE SECTION 7 BODY CONTROLLER SOFTWARE Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Body Controller Software...

  • Page 100: Control Area Network (Can)

    BODY CONTROLLER SOFTWARE CONTROL AREA NETWORK (CAN) The control system for the 2018 Liberty has multiple components that communicate via messaging over Control Area Networks or CAN. a. Body Controller (32 I/O Cortex Control Module) b. Cab Controller (32 I/O Cortex Control Module) c.

  • Page 101: Body Controller Inputs

    BODY CONTROLLER SOFTWARE BODY CONTROLLER INPUTS INPUT PIN# DESCRIPTION IN00 PACKER PRESS SW IN01 SPARE IN02 GRABBER PRESS SW IN03 LIFT LOWERED PROX IN04 OIL TEMP IN05 HOPPER COVER PROX IN06 SIDE DOOR PROX IN07 TAILGATE CLOSED PROX IN08 BODY DOWN PROX IN09 PACKER PROX IN10...

  • Page 102: Cab Controller Inputs

    BODY CONTROLLER SOFTWARE CAB CONTROLLER INPUTS INPUT PIN# DESCRIPTION IN00 HOPPER COVER RAISE IN01 HOPPER COVER LOWER IN02 TRANS TEMP SIG IN03 SECONDARY CONTROL SIG IN04 TURN SIG IN05 SERVICE BRAKE IN06 SPARE IN07 NEUTRAL SIG IN08 SYSTEM POWER SW IN09 PUMP ENABLE PB IN10...

  • Page 103: Switch Bank Inputs

    BODY CONTROLLER SOFTWARE SWITCH BANK INPUTS DESCRIPTION PUMP ENABLE SW1 MANUAL PACK SW1 AUTO LIFT ENABLE SW1 STROBE ENABLE SW1 WORK LIGHT SW1 PACK RIGHT SW1 PACK LEFT SW1 BODY RAISE SW1 BODY LOWER PSW1 TG RAISE SW1 TG LOWER SW1 PUMP ENABLE SW2 MANUAL PACK SW2 AUTO LIFT ENABLE SW2...

  • Page 104: Chassis J1939 Vars

    BODY CONTROLLER SOFTWARE CHASSIS J1939 VARS VARIABLE LIST FUNCTIONALITY PARK BRAKE ON = PARK BRAKE SET SERVICE BRAKE ON = SERVICE BRAKE APPLIED FORWARD GEAR ON = TRANSMISSION IN FORWARD GEAR REVERSE GEAR ON = TRANSMISSION IN REVERSE GEAR NEUTRAL ON = TRANSMISSION IN NEUTRAL TRANS.

  • Page 105: Body Controller Outputs

    BODY CONTROLLER SOFTWARE BODY CONTROLLER OUTPUTS State of each output in brackets [ ]. All Outputs [ON] - Output is On. [OFF] - Output is Off. Diagnostic features outputs 00 thru 07 [Disabled] - Output is disabled by option set or spare. [Under Voltage on VBB] - Supply Voltage is too low.

  • Page 106: Cab Controller Outputs

    BODY CONTROLLER SOFTWARE CAB CONTROLLER OUTPUTS State of each output in brackets [ ]. All Outputs [ON] - Output is On. [OFF] - Output is Off. Diagnostic features outputs 00 thru 07 [Disabled] - Output is disabled by option set or spare. [Under Voltage on VBB] - Supply Voltage is too low.

  • Page 107: Password Protected Screens

    BODY CONTROLLER SOFTWARE PASSWORD PROTECTED SCREENS To access password protected screens press and hold the OK button for 3 seconds. This will switch the view to the password screen. Enter the password and press OK. Passwords for Protected Screens: Maintenance Screen: 4321 Option Settings Screen: 123412 Figure 42.

  • Page 108: Option Setting Screen

    BODY CONTROLLER SOFTWARE OPTION SETTING SCREEN Press the OK button to change option setting. Press the escape button to exit screen J1939 Baud Rate - 250/500 - Setting should match chassis baud rate. Does not require added hardware. Hot Shift PTO - On/Off - ON, Enables Hot shift PTO functionality and PTO Solenoid Output.

  • Page 109: Critical Faults

    BODY CONTROLLER SOFTWARE CRITICAL FAULTS Accessed from the Main screen by using the down directional arrow, this screen shows the status of all critical faults. Press escape button to exit. Figure 45. Critcal Faults Accessed from the Critical Faults screen by using the right directional arrow, this screen shows the status of all system faults.
  • Page 110 NOTES Issued May 2020 Copyright 2020, Heil Environmental Schematics Printed in the U.S.A.
  • Page 111 Schematics SECTION 9 SCHEMATICS Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Schematics...
  • Page 115 2/15/2018 Rev A2...
  • Page 116 REV -...
  • Page 117 REV -...
  • Page 118 Schematics LIFT ARM UP AND IN FLOW DIAGRAM - 701-8776-001 Issued May 2020 Copyright 2020, Heil Environmental Schematics Printed in the U.S.A.
  • Page 119 Schematics LIFT ARM RELEASE FLOW DIAGRAM - 701-8776-002 Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Schematics...
  • Page 120 Schematics LIFT ARM GRAB FLOW DIAGRAM - 701-8776-003 Issued May 2020 Copyright 2020, Heil Environmental Schematics Printed in the U.S.A.
  • Page 121 Schematics LIFT ARM REACH IN FLOW DIAGRAM - 701-8776-004 Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Schematics...
  • Page 122 Schematics LIFT ARM REACH OUT FLOW DIAGRAM - 701-8776-005 Issued May 2020 Copyright 2020, Heil Environmental Schematics Printed in the U.S.A.
  • Page 123 Schematics LIFT ARM DOWN FLOW DIAGRAM - 701-8776-006 Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Schematics...
  • Page 125 PACKER LEFT BODY CYLINDER TAILGATE CYLINDER PACKER CYLINDER LEGEND = PUMP PRESSURE = RETURN PRESSURE LOADER SOLENOID VALVE (BLOCKER) LOGIC VALVE RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-B...
  • Page 126 PACKER-RIGHT BODY CYLINDER TAILGATE CYLINDER PACKER CYLINDER LEGEND = PUMP PRESSURE = RETURN PRESSURE LOADER SOLENOID VALVE (BLOCKER) LOGIC VALVE RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-A...
  • Page 127 TG LOWER LEGEND TAILGATE CYLINDER PACKER CYLINDER BODY CYLINDER = PUMP PRESSURE = RETURN PRESSURE = METERED PRESSURE LOADER VALVE LOGIC VALVE SOLENOID (BLOCKER) RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-C...
  • Page 128 TG RAISE BODY CYLINDER TAILGATE CYLINDER PACKER CYLINDER LEGEND = PUMP PRESSURE = RETURN PRESSURE = METERED PRESSURE LOADER VALVE LOGIC VALVE SOLENOID (BLOCKER) RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-D...
  • Page 129 BODY RAISE TAILGATE CYLINDER PACKER CYLINDER LEGEND BODY CYLINDER = PUMP PRESSURE = RETURN PRESSURE = METERED PRESSURE LOADER VALVE LOGIC VALVE SOLENOID (BLOCKER) RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-E...
  • Page 130 BODY DOWN BODY CYLINDER TAILGATE CYLINDER PACKER CYLINDER LEGEND = PUMP PRESSURE = RETURN PRESSURE = METERED PRESSURE LOADER VALVE LOGIC VALVE SOLENOID (BLOCKER) RETURN FILTER ASSY BODY RAISE TAILGATE CYLINDER DRAIN PACKER STRAINER ASSY HYDRAULIC TANK 701-8394-F...
  • Page 131 Schematics Copyright 2020, Heil Environmental Issued May 2020 Printed in the U.S.A. Schematics...
  • Page 132 NOTES Issued May 2020 Copyright 2020, Heil Environmental Schematics Printed in the U.S.A.
  • Page 133 INDEX electrical symbols electronic controls lubricants Electronic Parts Catalog (EPC) 10 point auto lube registration and login search by body serial number search by part keyword in body serial number 701-8394-A 701-8394-B 701-8394-C flow diagram, lift arm down 701-8394-D flow diagram, lift arm grab 701-8394-E flow diagram, lift arm reach in 701-8394-F...
  • Page 134 INDEX nomenclature universal belt and tri-cuff grabber adjustments notice warming up the hydraulic oil oil lubricant recommendation warning oil lubrication recommendation welding and electronic devices option setting screen welding procedures when to change oil filter element winch gear oil packer reversing limit switch packer tailgate and body valve troubleshooting packer/body vlave password protected screens...
  • Page 135 HEIL ENVIRONMENTAL WARRANTY STATEMENT The Heil Co. d/b/a Heil Environmental ("Heil") warrants its solid waste collection equipment to be free from defects in material and workmanship under normal use for a period of one (1) year or 2000 hours of operation (whichever comes first) from the date of equipment In-Service or during the period of coverage offered by an extended warranty program, when proper service and maintenance as described in Heil Service Bulletins and Parts &...
  • Page 136 www.heil.com Customer Care: 866-ASK-HEIL (866-275-4345) Heil Environmental 4301 Gault Avenue North Fort Payne, AL 35967-9984 Parts Central: 800-528-5308 Technical Service: 866-310-4345 TechSupport@DoverESG.com...

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