Dover HEIL PT 1100 G Service Manual
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Dover HEIL PT 1100 G Service Manual

Dover HEIL PT 1100 G Service Manual

High-performance rear loader
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PT 1100 G
HIGH-PERFORMANCE REAR LOADER
SERVICE MANUAL
ISSUED AUGUST 2023
TP1PT11G-SM-0823
© 2023 Heil Environmental
.

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  • Page 1 PT 1100 G HIGH-PERFORMANCE REAR LOADER SERVICE MANUAL ISSUED AUGUST 2023 TP1PT11G-SM-0823 © 2023 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 ......................................4 Precautionary Statements ......................................5 Lock-Out/Tag-Out Procedures ......................................7 Electronic Parts Catalog (EPC) ......................................8 Storing Refuse in Container ......................................11 Maintenance/Lubrication Information ......................................11 Grease Lubrication Recommendation ......................................11 Oil Lubricant Recommendation ......................................11 Hydraulic Oil Specifications ......................................11 Cold Weather Warm-Up Procedure ......................................12...
  • Page 4 TABLE OF CONTENTS Schematics Tailgate Harness 263-1772 ......................................56 Body Harness 263-1773 ......................................57 Tailgate Mechanical Harness 263-1788 ......................................58 Solenoid Valve Assembly 031-6572 ......................................59 Blade Down Slide In Circuit ......................................60 Blade Up Slide Out Circuit ......................................61 Slide In Circuit ......................................62 Slide Out Circuit ......................................63 Electrical Schematic 701-9141 ......................................64...
  • Page 5 PT 1100 G HIGH-PERFORMANCE REAR LOADER SERVICE MANUAL ISSUED AUGUST 2023 TP1PT11G-SM-0823 Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A.
  • Page 6 NOTES Issued August 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 7: General Information

    General Information SECTION 1 GENERAL INFORMATION Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. General Information...

  • Page 8: 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 9: Precautionary Statements

    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 10 General Information DANGER Contact of the unit with overhead electric lines is dangerous. Death or serious injury can occur. Make sure there is adequate overhead clearance before you raise the container. If the unit does make contact with overhead electric lines do not touch any metal in the cab.

  • Page 11: 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. Put the unit in a Lock-Out/Tag-Out mode: BEFORE you enter the unit’s body BEFORE you do maintenance, repair or cleaning procedures on the unit.

  • Page 12: 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 13 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 14 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 15: 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 16: 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 17: Proximity Switch Troubleshooting 2

    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 18 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Issued August 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 19: 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 20 General Information DECAL CARE (CONTINUED) Figure 2. Recommended Technique Figure 3. Incorrect Technique Issued August 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 21: Hydraulic Symbols

    General Information HYDRAULIC SYMBOLS Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. General Information...
  • Page 22 General Information HYDRAULIC SYMBOLS (CONTINUED) Issued August 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 23: Electrical Symbols

    General Information ELECTRICAL SYMBOLS Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. General Information...
  • Page 24 NOTES Issued August 2023 Copyright 2023, Heil Environmental Pump Printed in the U.S.A.
  • Page 25 Pump SECTION 2 PUMP Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Pump...

  • Page 26: Hydraulic Pump Control

    Pump HYDRAULIC DRIVE CONTROL There are multiple hydraulic drive configurations available on the 2020 Rear End Loader. Each achieves the same goal utilizing different mechanisms and modes of operation. A. Clutch Shift PTO Listed in the display as Cab Controller Output, OUT02 p16 – PTO Sol. Not equipped Applies to Constant Drive PTO or Crankshaft Driven Front Mount Pumps.
  • Page 27 Pump HYDRAULIC DRIVE CONTROL (CONTINUED) C. Tandem Vane Pump Applies to Operate at Idle, PTO or Crankshaft driven Tandem Pumps. Listed in the display as Cab Controller Output, OUT03 p15 – Pump 1 Sol. And OUT04 p14 – Pump 2 Sol. Clutch Shift PTO Driven Option Config Clutch Shift PTO, W/Pump Manifold: [ON]...

  • Page 28: Underbody Valve Hydraulic Flow

    Pump UNDERBODY VALVE HYDRAULIC FLOW The underbody valve is located on the street side, beneath the body. The diagram below, viewed looking up at the underbody, shows the hydraulic oil flow to the valve from the pump and from the valve to the various body and tailgate cylinders.

  • Page 29: Body And Tailgate

    Body and Tailgate SECTION 3 BODY AND TAILGATE Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Body and Tailgate...

  • Page 30: Specifications

    Body and Tailgate SPECIFICATIONS A. Body Hydraulic Oil Tank ..............................107 L Hydraulic Oil System Capacity ..........................137 L Hydraulic In-Tank Oil Filter ..........................3-Micron Hydraulic Cylinders: Ejector cylinder; 001-7098 ..................EJECTOR CYLINDER. KIT, 20 YD (15 Cu. M) 001-7099 ..................EJECTOR CYLINDER. KIT, 23 YD (18 Cu. M) 001-7100 ..................

  • Page 31: Product Nomenclature

    Body and Tailgate PRODUCT NOMENCLATURE The figures below show the major body and tailgate components. Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Body and Tailgate...

  • Page 32: Tailgate Support Props

    Body and Tailgate TAILGATE SUPPORT PROPS Two support props are on the unit and must be used whenever the tailgate is opened for service or maintenance. Both props must be used. DANGER Do not walk under or go between the body and the tailgate when the tailgate is in motion, while you prop the tailgate or while the tailgate is propped.
  • Page 33 Body and Tailgate TAILGATE SUPPORT PROPS (CONTINUED) CAUTION Do not proceed to lower the tailgate until both props are in place. 4. Slowly LOWER tailgate until props mate with the tailgate Stop. Figure 6. Tailgate Lowered onto Both Streetside and Curbside Props 5.
  • Page 34 NOTES Issued August 2023 Copyright 2023, Heil Environmental Maintenance and Adjustment Printed in the U.S.A.

  • Page 35: Maintenance And Adjustment

    Maintenance and Adjustment SECTION 4 MAINTENANCE AND ADJUSTMENT Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Maintenance and Adjustment...

  • Page 36: 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 37: 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 38 Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE cause damage to the pump shaft. Greasing is NOT required on wet spline PTOs such as the Chelsea 890/897 series. Lubricate as shown on Body Lube Grease Fittings Chart.

  • Page 39: Pto Inspection And Preventive Maintenance

    Maintenance and Adjustment PTO INSPECTION AND PREVENTIVE MAINTENANCE Due to normal torsional vibrations of transmission mounted Power Take-Offs (PTOs), it is important that Service Technicians include the PTO/transmission interface in their standard inspection and maintenance schedules. If a PTO Inspection and Preventive Maintenance schedule is not followed, it is possible that the PTO mounting screws can come loose, resulting in transmission fluid leaks between the PTO and transmission and potential damage to the PTO or drive train 1.

  • Page 40: Packer/Ejector Cylinder Preventive Maintenance

    Maintenance and Adjustment PACKER/EJECTOR CYLINDER PREVENTIVE MAINTENANCE It is critical to follow the guidelines of the Body Preventive Maintenance Chart and Body Lubrication Guide found in this section of this Service Manual and the Body Lubrication Guide decal on the unit. Failure to follow stated routine preventive maintenance can lead to premature cylinder failure that is not covered by your warranty.

  • Page 41: Lubrication Guide

    Maintenance and Adjustment LUBRICATION GUIDE Use No. 1 pressure gun grease. Clean fittings before applying grease and always pump enough grease into joint to remove the old grease. Wipe off excess grease. For slide surfaces, use cloth or brush to coat. Lubricate moveable mechanical parts without fittings every 60 days with non-detergent engine oil.

  • Page 42: Cold Weather Warmup Procedure

    Maintenance and Adjustment COLD WEATHER WARMUP PROCEDURE When ambient air temperature is cold (below 0 degrees F) 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 –...

  • Page 43: 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 44: Drain And Clean The Hydraulic Oil Tank

    Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK Change the hydraulic oil at least annually or every 2000 hours of operating time, whichever comes first. 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 45: 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 46: Hydraulic Valves

    Maintenance and Adjustment HYDRAULIC VALVES This body air controlled valve is located under the front street side of the body. It controls the ejector panel, tailgate raise/ lower and tailgate lock/unlock functions. See the Operation Manual for operational information. Figure 10. Body Valve Figure 11.

  • Page 47: Tailgate Valve

    Maintenance and Adjustment TAILGATE VALVE (MANUAL CONTROL UNITS ONLY) The tailgate valve controls the packing mechanism through the complete cycle. With this control, the position of the blade and slide and their respective cylinders can be positioned as desired. Refer to the Operation Manual for operational instructions.

  • Page 48: Pressure Adjustment Settings

    Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS A. Unit Preparation Follow these unit preparation steps prior to making any pressure adjustments listed in this section. 1. Make sure area around unit is clear to enable arm and fork operation. 2. Place wheel chocks on both sides of driver side rear wheel. 3.
  • Page 49 Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS (CONTINUED) E. Underbody Valve This 2-lever, sectioned valve is located under the front left (street side) of the body. It controls the ejector panel and tailgate raise/lower functions. 1. Follow the procedure on the previous page for warming the hydraulic oil. 2.

  • Page 50: Slide Wear Strips

    Maintenance and Adjustment SLIDE WEAR STRIPS Slide wear strips on a standard model are bronze and should be greased weekly by applying a line of grease on the exposed portion of the wear bar when extended, both inside and outside. Refer to Body Lubrication Guide and Lubrication Guide Decal on the unit.

  • Page 51: Troubleshooting

    Maintenance and Adjustment TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY 1. Cylinder leaking or worn 1. Check cylinders. 2. Oil bypassing valve plunger 2. Replace valve. Load will not hold 3. Port relief valve not holding 3. Remove and clean. 1. Defective pump 1.

  • Page 52: Double Acting Telescopic Hydraulic Cylinder Disassembly And Assembly

    Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY Step 1 The cylinder is best serviced when mounted in the vertical position, for both disassembly and assembly. Also, it is best located where a hoist can be used directly overhead of the cylinder for removing the plungers if complete disassembly is required.
  • Page 53 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 3 - Head Nuts After the set screws have been loosened, tap head nut gently around its circumference and unscrew the head nut with a chain wrench, or an equivalent tool. Do not use a chisel, punch or weld any studs to the head nut to remove.
  • Page 54 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 5 – Packing To remove packing, pull the plunger up about one foot. Add tape to a clean area as shown in Figure 20. Push the plunger down past the packing then pull the plunger up. The packing will stick to the tape and be pulled out with the plunger.
  • Page 55 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 7 - Retainer Rings Using a tool shown in Figure 22, insert the hooked end into the retaining ring slot. Force the retaining ring out of the groove and lift ring out of plunger. Figure 21.
  • Page 56 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 9 – Second Retaining Ring and Plunger Stop Repeat Step 6 to remove second retaining ring. The plunger is now free to lift out. The plunger stop will come out with the plunger.
  • Page 57 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 10 - Setting Head Nuts Remove the small slug located opposite the set screw. Using an allen wrench (Figure 17), tighten the head-nut down until the hex wrench bottoms out on the top of the plunger. Remove the hex wrench and replace the slug. Install the set screw using a nylon slug to protect the threads.

  • Page 58: Clean And Inspect The Tailgate Seal

    Maintenance and Adjustment CLEAN AND INSPECT THE TAILGATE SEAL Periodically check the tailgate seal to make sure it mates properly with the body and inspect for possible wear, damage or leaking. Replace the seal as necessary. See the figure below. Figure 25.
  • Page 59 Schematics SECTION 4 SCHEMATICS Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Schematics...

  • Page 60: Schematics

    Schematics TAILGATE ELECTRONIC HARNESS - 263-1772 Issued August 2023 Copyright 2023, Heil Environmental Schematics Printed in the U.S.A.

  • Page 61: Body Harness 263-1773

    Schematics BODY HARNESS - 263-1773 Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Schematics...

  • Page 62: Tailgate Mechanical Harness 263-1788

    Schematics TAILGATE MECHANICAL HARNESS 263-1788 Issued August 2023 Copyright 2023, Heil Environmental Schematics Printed in the U.S.A.

  • Page 63: Solenoid Valve Assembly 031-6572

    Schematics SOLENOID VALVE ASSEMBLY 031-6572 Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Schematics...

  • Page 64: Blade Down Slide In Circuit

    Schematics BLADE DOWN SLIDE IN CIRCUIT Issued August 2023 Copyright 2023, Heil Environmental Schematics Printed in the U.S.A.

  • Page 65: Blade Up Slide Out Circuit

    Schematics BLADE UP SLIDE OUT CIRCUIT Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Schematics...

  • Page 66: Slide In Circuit

    Schematics SLIDE IN CIRCUIT Issued August 2023 Copyright 2023, Heil Environmental Schematics Printed in the U.S.A.

  • Page 67: Slide Out Circuit

    Schematics SLIDE OUT CIRCUIT Copyright 2023, Heil Environmental Issued August 2023 Printed in the U.S.A. Schematics...

  • Page 68: Electrical Schematic 701-9141

    108-8721-001 108-8721-001 108-8721-001 SCHEMATIC, ELECTRICAL 701-9141 REV: E RELEASE DATE: 06/16/14...

  • Page 69: Electrical Schematic 701-9141-001

    108-8721-001 108-8721-001 108-8721-001 SCHEMATIC, ELECTRICAL - MECHANICAL 701-9141-001 REV: E RELEASE DATE: 08/16/14...

  • Page 70: Hydraulic Schematic 701-9172

    TAILGATE TAILGATE EJECTOR RAISE LOCK LOWER PANEL UPPER PANEL PNEUMATIC ACTIVATION 1500 3900 2750 1OO lpm...

  • Page 71: Index

    INDEX hydraulic drive control hydraulic oil specifications hydraulic symbols hydraulic valves 263-1772 263-1773 263-1788 introduction 701-9141 lock-out/tag-out procedures 701-9141-001 lock-out tags 701-9172 lubrication guide blade down slide in circuit maintenance/lubrication information blade up slide out circuit body daily checklist body preventive maintenance chart notice caution oil lubrication recommendation...
  • Page 72 INDEX valve adjustment warm up the hydraulic oil warming up the hydraulic oil warning when to change oil filter element Issued August 2023 Printed in the U.S.A. Index Copyright 2023, Heil Environmental...
  • Page 73 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 74 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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