Summary of Contents for Dover HEIL POWERTRAK COMMERCIAL
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WARNING Failure to follow all instructions and safety precautions in this manual, in the Service Manual, in other manufacturers' manuals and on the safety decals attached to the product could result in serious injury or death to operators or bystanders and/or damage to property. DO NOT operate this vehicle before you READ and UNDERSTAND this Operation Manual, the Service Manual ®...
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READ THIS MANUAL! EVERY PERSON who will OPERATE, MAINTAIN, REPAIR, OR OTHERWISE WORK with the Heil unit MUST READ AND UNDERSTAND this entire Operator’s Manual before starting the engine or activating any switches or controls. MAKE SURE to read the Service Manual for the unit BEFORE you do any maintenance or repair procedures.
TABLE OF CONTENTS Introduction Section Preview ........................................4 How to Use This Manual ........................................5 To the Owner ........................................6 To the Operator ........................................7 To the Operator (Continued) ........................................8 To the Mechanic (Continued) ........................................9 Warranty Claims and Inquiries ........................................10 Customer Service and Repair Parts Contact Information ........................................11 Models ........................................12...
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TABLE OF CONTENTS In-Cab Display and Controls Section Preview ........................................60 Controls / In-Cab Display ........................................61 Home Screen ........................................62 Home Screen (Continued) ......................................63 Home Screen (Continued) ......................................64 Home Screen (Continued) ......................................65 Home Screen (Continued) ......................................66 Home Screen (Continued) ......................................67 Counter Screen ........................................68 Diagnostic, Maintenance, and Option Configuration Screens ........................................69...
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TABLE OF CONTENTS Body Daily Checklist ........................................88 Refuse Vehicle Daily Inspection ........................................90 Daily Checks and Inspections ........................................91 Before Going on Route Section Preview ........................................102 Battery Disconnect Switch / Daily Checklist ........................................103 Before Starting a Route / Warming up the Hydraulic Oil ........................................104 Check the Hydraulic Oil Level ........................................105...
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TABLE OF CONTENTS Loading Refuse with an Arm Mechanism (Continued) ......................................126 Loading Refuse with an Arm Mechanism (Continued) ......................................127 Loading Refuse with a Roll Bar Mechanism ........................................128 Loading Refuse with a Roll Bar Mechanism (Continued) ......................................129 Loading Refuse with a Roll Bar Mechanism (Continued) ......................................130 Loading Refuse with a Roll Bar Mechanism (Continued) ......................................131...
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TABLE OF CONTENTS Compressed Natural Gas (CNG) Option Important Safety Information ........................................158 Important Safety Information (Continued) ......................................159 Important Safety Information (Continued) ......................................160 Properties of Natural Gas / Signs of a Fuel Leak ........................................161 CNG Fuel System Functions and Components ........................................162 CNG Fuel System Components (Continued) ......................................163 CNG Fuel System Components (Continued)
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TABLE OF CONTENTS CNG Fuel System Troubleshooting (Continued) ......................................185 CNG Fuel System Troubleshooting (Continued) ......................................186 CNG Front of Body / Top of Body Decal Placement ........................................187 ........................................188 ......................................189 ......................................190 ......................................191 ......................................192 ......................................193 ......................................194 ......................................195 ......................................196 ......................................197 Index ..................................199 Issued July 2020 Copyright 2020, Heil Environmental Table of Contents Printed in the U.S.A.
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® POWERTRAK COMMERCIAL ® POWERTRAK COMMERCIAL HIGH-COMPACTION REAR LOADER OPERATION MANUAL ISSUED JULY 2020 TP1PTC-OM-0720 Issued July 2020 Copyright 2020, Heil Environmental Printed in the U.S.A.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: The responsibilities of the owner, the operator, and the mechanic Warranty information Telephone numbers and website URL for parts, technical support, warranty claims, training and manuals Identifying the different models Identifying the left (street side) of the unit The unit serial plate Various parts of the unit...
® POWERTRAK COMMERCIAL HOW TO USE THIS MANUAL Terminology Product Variance This manual uses terminology that is defined in the This manual may cover options not included on your unit. Glossary which is in Section 1, Introduction. Also, the location and appearance of the controls on your unit may be different than those shown in this manual.
® POWERTRAK COMMERCIAL You must make sure that repairs are made that may TO THE OWNER affect the safe operation of the unit before it is made This manual is designed to help ensure safe, efficient and available for operation. proper operation of The Heil Co.
® POWERTRAK COMMERCIAL You must observe pertinent laws and regulations. TO THE OPERATOR Do not use drugs or alcohol while you operate the unit. DANGER You must read, study and understand all procedures Do not operate the unit or perform repair or maintenance and requirements of this Operation Manual before procedures on the unit until you read and understand all of you operate the unit for the first time.If you do not...
® POWERTRAK COMMERCIAL TO THE OPERATOR (CONTINUED) TO THE MECHANIC Always use your employer’s Lock-Out/Tag-Out WARNING procedures. If your employer does not have Lock- Out/Tag-Out procedures, use the Lock-Out/Tag-Out Do not operate the unit or perform repair or maintenance Procedure in this manual.
® POWERTRAK COMMERCIAL Always use your employer’s Lock-Out/Tag-Out TO THE MECHANIC (CONTINUED) procedures. If your employer does not have Lock- As the mechanic of the unit, you have several Out/Tag-Out procedures, use the Lock-Out/Tag-Out responsibilities: Procedure in this manual. Before you start the engine or operate the unit for the You must have a valid driver’s license if you operate first time: the unit on a public road.
® POWERTRAK COMMERCIAL WARRANTY CLAIMS AND INQUIRIES The HEIL ENVIRONMENTAL WARRANTY STATEMENT is printed on the inside, back cover of this manual. Should a failure occur that is covered by this warranty, contact the nearest Heil dealer for warranty repair unless otherwise authorized by Heil.
® POWERTRAK COMMERCIAL CONTACT INFORMATION Customer Care Phone: 866-275-4345 Technical Service Phone: 866-310-4345 Parts Central Phone: 800-528-5308 4301 Gault Avenue North Fort Payne, AL 35967 www.heil.com Issued July 2020 Copyright 2020, Heil Environmental Introduction Printed in the U.S.A.
® POWERTRAK COMMERCIAL MODELS ® The PowerTrak Commercial is a Rear End Loader (REL) and has one body model, the eject model. See the figure below. The blade and upper panel open the hopper for loading refuse into the hopper, sweep the refuse into the body and compacts the refuse.
® POWERTRAK COMMERCIAL SERIAL PLATE LOCATION You determine the sides of the unit by facing the direction of forward travel. The left side is the “streetside” and the right side is the “curbside”. The figure below shows the locations of the serial plates on the street side of the unit’s body and tailgate.
® POWERTRAK COMMERCIAL READING THE SERIAL PLATE NOTICE The serial plate is the “birth certificate” of the unit. See the The code for the year of manufacture is in accordance figure below. with FMVSS 115. See the following table. Year of Manufacture Year Code Year Year Code...
® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE The figure below shows the major components and their typical location on the unit. See the following pages for brief descriptions of each component shown below. 1. Slide Panel and Cylinder Location 2. Tailgate Assembly 3.
® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) DANGER Do not use an arm mechanism or roll bar as a riding step. Obey safety messages and use the riding step for when traveling on the unit. Serious injury or death may occur. Arm Mechanism –...
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) DANGER Do not use an arm mechanism or roll bar as a riding step. Obey safety messages and use the riding step for when traveling on the unit. Serious injury or death may occur. Comb Lift and Arm Mechanism options allow operators to lift compatible waste containers and empty them into the hopper.
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) WARNING BE CAREFUL at all times when you use the ladder rungs and grab handles. Maintain good balance with two feet and one hand, or one foot and two hands, firmly in place. Grab Handles – The grab handles are on the street and curb sides of the tailgate. You use the grab handles to help stabilize you when you use the riding step.
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) Hydraulic Pump – The unit’s hydraulic pump provides the hydraulic flow for the hydraulic system. It is located either in front of the unit’s engine or underneath the unit, powered by the transmission through a Power Take-Off (PTO). With a front-mount pump, the operator turns the pump ON and OFF as needed with the SYSTEM POWER switch located on the in-cab control panel.
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) DANGER Do not use an arm mechanism or roll bar as a riding step. Obey safety messages and use the riding step for when traveling on the unit. Serious injury or death may occur. Roll Bar –...
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) Slide/Blade Controls – The operator uses these controls to operate the slide assembly and the packer blade to open the hopper to load refuse and to move refuse from the hopper into the body. DANGER A tailgate in motion is dangerous.
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® POWERTRAK COMMERCIAL PRODUCT NOMENCLATURE (CONTINUED) Throttle Advance – There are two standard and an additional switch when there is a lifting option (winch, etc.) installed, The primary switch is in the cab and must be set to ON for the outside switch(es) to operate. The second standard switch is next to the tailgate and ejector panel controls at front, street side of the body.
® POWERTRAK COMMERCIAL GLOSSARY TERM DEFINITION accident An incident that results in unintended harm arm mechanism An option for Rear End Loaders (RELs), an assembly that uses arms that mate with a refuse container’s slots to lift, dump and lower a refuse container The refuse collection container blade The assembly that moves refuse into the body.
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® POWERTRAK COMMERCIAL GLOSSARY TERM DEFINITION hazard A potential source of harm hopper The loading chamber of the unit in front of the packer panel where you dump the refuse material illuminate Make a lamp shine light (the lamp is on) Command to move the slide assembly IN in-cab display display indicators, status, critical fault messaging and counter information and allows a qualified...
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® POWERTRAK COMMERCIAL GLOSSARY TERM DEFINITION The position of a switch or other control to start a function operator Any person who uses the unit and its equipment. One who controls the operation of various unit accessories and mechanisms, loads material, performs functions such as operating the loader, cart tipping and packing of wastes or recycled products, and who may also drive the unit along the route during the collection process.
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® POWERTRAK COMMERCIAL GLOSSARY TERM DEFINITION Revolutions Per Minute should The action is advised. side access door The optional side access door is located on the street side of the unit. This is the preferred access into the body. ALWAYS Lock-Out/Tag-Out the unit BEFORE entering the body.
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® POWERTRAK COMMERCIAL SECTION 2 SAFETY MESSAGES AND DECALS Issued July 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in the U.S.A.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: General safety precautions and safety precautions for the safe operation and maintenance of the unit The safety precautions for NOT towing another vehicle or machine Safety decals on the unit Issued July 2020 Copyright 2020, Heil Environmental Safety Messages and Decals...
® POWERTRAK COMMERCIAL PRECAUTIONARY STATEMENTS Read this entire manual and especially this safety section before you operate the vehicle. Failure to follow these important precautions could result in serious injury, death, or property damage. This safety alert symbol indicates important safety messages in this manual and on safety decals attached to the equipment.
® POWERTRAK COMMERCIAL DISENGAGE the PTO or PUSH the SYSTEM GENERAL SAFETY PRECAUTIONS POWER switch so the pump shuts off when you are not using the unit, when you are repairing the unit, DO NOT operate the unit under the influence of when you are working on the unit, or when traveling alcohol or drugs or when extremely tired or when you in the unit for longer than two minutes.
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® POWERTRAK COMMERCIAL BEFORE OPERATING THE EQUIPMENT DO NOT operate or service this machine until you are fully trained and have read and understand this entire manual. NEVER operate the unit UNLESS you are fully knowledgeable of all control functions. See the In-Cab Display and Controls of this manual.
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® POWERTRAK COMMERCIAL LOOK UP AND LIVE. MAKE SURE there is enough clearance between a lowered or raised container and overhead power lines. It is not necessary for the unit or container to touch the electric cable for the electricity to pass through the unit.
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® POWERTRAK COMMERCIAL Table 2. Overhead Clearances When Driving the Unit Voltage of Electric Line Minimum Clearance Above 750,000 to 1,000,000 20 feet (6.1 m) LOADING REFUSE INTO THE UNIT YOU MUST BE ATTENTIVE at all times when you load refuse and be ready to stop or reverse the function in use if necessary.
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® POWERTRAK COMMERCIAL DO NOT go under the chassis or enter the body area unless the unit is locked-out. To lock-out the unit, stop the engine, apply the brakes and make sure the brakes hold and work properly, chock all wheels, remove the keys from the cab, and place a lock-out tag on the steering wheel.
® POWERTRAK COMMERCIAL DECALS The following pages show the DANGER, WARNING and CAUTION decals and list the reflective safety materials that are on the vehicle. See the Parts and Service Manual for the location and part numbers of all decals on the unit. NOTICE Replace any decal with a new decal if the old decal is lost, destroyed, painted over or cannot be read.
® POWERTRAK COMMERCIAL CARE OF DECALS It is important that the decals are properly cleaned to make sure that they are readable and do not come off the unit. Use the following steps to clean the decals. General Instructions Wash the decals with a blend of mild car wash detergent and clean water. Rinse with clean water.
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® POWERTRAK COMMERCIAL PRESSURE WASHER TECHNIQUE Figure 40. Recommended Technique Figure 41. Incorrect Technique Issued July 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in the U.S.A.
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® POWERTRAK COMMERCIAL ALTERNATIVE CLEANING PROCEDURE When normal cleaning procedures do not remove difficult debris from the decals, try the following: WARNING Isopropyl alcohol is flammable and is harmful to eyes and skin. Keep isopropyl alcohol away from heat or open sources of ignition.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about the proper Lock-Out/Tag-Out procedures. You MUST Lock-Out/Tag-Out a unit BEFORE: You enter the body Do maintenance or repair procedures. Issued July 2020 Copyright 2020, Heil Environmental Lock-Out/Tag-Out Procedure Printed in the U.S.A.
® POWERTRAK COMMERCIAL a. Move the switches of the hydraulic controls. This LOCK-OUT/TAG-OUT PROCEDURE relieves the pressure in the cylinders. b. Turn the ignition switch to OFF. NOTICE 6. When there are no in-cab controls, move the outside Always use your employer’s Lock-Out/Tag-Out control levers to relieve the pressure in the cylinders.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about the operation of the in-cab display controls and indicator messages, outside controls, switches and buttons. NOTICE The location and appearance of the controls may be different than those shown in this manual. Make sure you know the location of the controls and the how you operate the controls on your unit before you use the vehicle.
® POWERTRAK COMMERCIAL CONTROLS The unit’s standard controls are located on the In-Cab Display Screens 1. Home Screen standard controls in the cab enable the hydraulic pump and 2. Display Screen the throttle advance. The hydraulic controls are installed on the street side of the body (tailgate and ejector panel 3.
® POWERTRAK COMMERCIAL HOME SCREEN Use the image below to identify the locations of the display indicators, function buttons, directional arrow buttons, "esc" and "ok" buttons, message banner, and status LED. Issued July 2020 Copyright 2020, Heil Environmental In-Cab Display and Controls Printed in the U.S.A.
® POWERTRAK COMMERCIAL HOME SCREEN (CONTINUED) Function Buttons 3. F3 Function Button (Continued) Each button is assigned multiple functions which change by Inside Hopper – turns on tailgate hopper light. scrolling the DOWN directional arrow. Button Functions are Outside Hopper – turns on tailgate side light. listed below.
® POWERTRAK COMMERCIAL HOME SCREEN (CONTINUED) Display Indicators 4. Low Oil - (Optional) Included with Hydraulic Tank Monitoring. 1. System/PTO - Indicates PTO or System Status GREEN, “OIL OK” – Oil Level is Good On units with a Clutch Shift PTO: RED, “LOW OIL”...
® POWERTRAK COMMERCIAL HOME SCREEN (CONTINUED) Display Indicators (Continued) Status LED 9. Side Door - (Optional) Included with Side Door The Status LED on the bottom-right corner of the display indicates status of the display as described below. Pump Shutdown interlock, indicates Side Door Closed or Open.
® POWERTRAK COMMERCIAL HOME SCREEN (CONTINUED) Message Banner A. Critical Faults (Continued) The Message Banner displays important information about 5. “Pump Shutdown Pressed, Reset Street side Switch, the system status. Below are the potential messages that Restart System Enable.” Optional Pump Shutdown can be displayed.
® POWERTRAK COMMERCIAL HOME SCREEN (CONTINUED) Message Banner (Continued) D.Miscellaneous (Continued) C.Communication Failure – either intermittent or 4. Hydraulic Oil Life – remaining oil life is below 5% ongoing, between one or more controllers. Press (BLACK BANNER) ESC button to acknowledge. (RED BANNER) “Hyd.
® POWERTRAK COMMERCIAL COUNTER SCREEN A. Cycle Counts 1. Total Cycles are non-resettable counts, retained throughout the life of the unit controller. 2. Daily Cycles can be reset. Choose the count to be reset by scrolling down using the directional arrow. 3.
® POWERTRAK COMMERCIAL DIAGNOSTIC, MAINTENANCE, AND OPTION NOTES: CONFIGURATION SCREENS Additional screens allow a qualified and authorized Service Technician to see detailed system information and make configuration changes based on option configuration. ® Refer to the Heil PowerTrak Commercial Service Manual for more information on these screens.
® POWERTRAK COMMERCIAL 1. PUSH the lever to the FULL DOWN position and STANDARD OUTSIDE CONTROLS RELEASE it to MOVE the blade UP. The standard outside controls for the unit are located on 2. PULL the lever to the FULL UP position and the front street side of the body and on the curb side of the RELEASE it to MOVE the blade DOWN.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS (CONTINUED) Figure 43. Blade Control Lever Issued July 2020 Copyright 2020, Heil Environmental In-Cab Display and Controls Printed in the U.S.A.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS (CONTINUED) Figure 44. Upper Panel Control Lever Issued July 2020 Copyright 2020, Heil Environmental In-Cab Display and Controls Printed in the U.S.A.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS (CONTINUED) Figure 45. Normal Loading Cycle Issued July 2020 Copyright 2020, Heil Environmental In-Cab Display and Controls Printed in the U.S.A.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS DANGER (CONTINUED) Stand clear when the ejector panel is in motion. Keep side access door closed when ejector panel is in motion. DANGER Failure to obey may result in severe injury or death. A tailgate in motion is dangerous. Serious injury or death may occur if a person is struck by a moving tailgate or NOTICE becomes trapped between the tailgate and the body.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS F. BUZZER Switch (CONTINUED) Without any options, this switch is located on curb side of the tailgate near the grab handle. This switch may be E. THROTTLE ADVANCE Switch located in different areas depending on optional container lifting devices.
® POWERTRAK COMMERCIAL STANDARD OUTSIDE CONTROLS (CONTINUED) G.HOPPER LIGHT Switch (Option) If equipped, use this switch to turn on the Hopper Light. See the figure to the right. Figure 48. Buzzer and Hopper Light Switch Location Issued July 2020 Copyright 2020, Heil Environmental In-Cab Display and Controls Printed in the U.S.A.
® POWERTRAK COMMERCIAL OPTIONAL OUTSIDE CONTROLS The optional outside controls include levers to operate the optional hydraulic equipments such as: Reeving mechanism Winch Arm mechanism Roll bar Cart tipper There are several combinations of optional equipment. The controls for optional equipment are usually located on the Figure 49.
® POWERTRAK COMMERCIAL OPTIONAL OUTSIDE CONTROLS 2. PULL the lever to the RAISE position and HOLD it (CONTINUED) there to MOVE the cylinder IN (RETRACT). 3. RELEASE the lever to stop a RAISE or LOWER operation at any time or when the cable hook is at DANGER the position you want.
® POWERTRAK COMMERCIAL OPTIONAL OUTSIDE CONTROLS D.ROLL BAR (CONTINUED) The optional roll bar mechanism consists of a lift arm on each side of the tailgate connected by a tube. You raise C.ARM MECHANISM and lower each arm with two cylinders. A single lever controls the two cylinders.
® POWERTRAK COMMERCIAL OPTIONAL OUTSIDE CONTROLS (CONTINUED) E. CART TIPPER One or two optional cart tippers can be installed on the unit. The control lever for a single cart tipper will be located on the curb side of the tailgate as shown in the figure to the right.
® POWERTRAK COMMERCIAL OPTIONAL OUTSIDE CONTROLS (CONTINUED) F. LATCH BAR ASSEMBLY You use the latch bar assembly to secure a refuse container BEFORE you raise or lower the container with a reeving mechanism, winch or roll bar. Refer to the figure on the right.
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® POWERTRAK COMMERCIAL SECTION 5 BODY AND TAILGATE PROPS Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Props Printed in the U.S.A.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: Using the body props Using the tailgate props Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Props Printed in the U.S.A.
® POWERTRAK COMMERCIAL PROPPING THE BODY Factory Tailgate Props YOU MUST USE BOTH of the two support props at the There are no body props as you cannot raise the body of rear of each unit whenever you open the tailgate for service the unit since the unit is an eject model and not a dump or maintenance.
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® POWERTRAK COMMERCIAL Issued July 2020 Copyright 2020, Heil Environmental Body and Tailgate Props Printed in the U.S.A.
® POWERTRAK COMMERCIAL DAILY CHECKLIST Make sure you perform a daily check of the unit. Make copies of the Refuse Vehicle Daily Inspection on the next several pages to have the Operator mark completed items before each route. Many checks in the Daily Checklist are maintenance related, such as checking tire pressures and hoses for wear and damage.
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® POWERTRAK COMMERCIAL DAILY CHECKLIST MAINTENANCE ITEMS Item Required Action Body structure has loose or missing hardware Tighten loose hardware Replace missing hardware Body structure has cracked weld joints Repair immediately Body mounting brackets have loose hardware, Tighten loose hardware damaged hardware or cracked welds Replace missing hardware Repair cracked welds...
® POWERTRAK COMMERCIAL DATE: __________/__________/__________ REFUSE VEHICLE DAILY INSPECTION UNIT NO. ____________________________ Enter one of the following codes in the Inspection Results Code column: Use a to indicate inspected and no repair, service or adjustment is necessary. Use an R to indicate repair, service or adjustment is necessary. Use an N to indicate vehicle not equipped.
® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE INSPECT PER APPLICABLE MANUFACTURER MANUAL Cab/Drive Wheels and Tires Tractor and Chassis Electrical Chassis Engine & Transmission & Fluid Levels Chassis Lubrication REFUSE COLLECTION SYSTEMS AND COMPONENTS CAB OUTSIDE AREA Check air pressure of tires. Add air if air pressure lower than recommended on any tire before going on route Check wear of tire tread.
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE BODY AND CHASSIS CURB SIDE INSPECTION Inspect level of hydraulic oil if tank is mounted on curb side. It must be full. Add recommended oil as necessary Inspect body structure for damage, loose or missing nuts and bolts and for cracked welds and metal Inspect body mounting brackets for cracked welds, missing bolts or nuts or movement Inspect decals on curb side body for damage and readability...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Loose or missing mounting hardware Tailgate is locked TAILGATE Inspect decals on tailgate and underride bumper for damage and readability Inspect tailgate seal for visible damage Inspect underride bumper for damage and loose components Inspect slide assembly Cylinders, hoses and fittings for leaks Hoses for wear and damage...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Loose or missing hardware for packer blade BODY AND CHASSIS STREET SIDE INSPECTION Tailgate is locked Inspect tailgate lock components Clamp components for wear and damage Loose or missing mounting hardware Inspect tailgate raise components Cylinder, hoses and fittings for leaks Hoses for wear and damage...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Inspect body mounting brackets for cracked welds, missing bolts or nuts or movement Inspect level of hydraulic oil if tank is mounted on streetside. It must be full. Add recommended oil as necessary Battery disconnect switch is turned to OFF then: Check wiring and battery cables from the battery box to the engine starter for wear and other damage.
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Make sure all people not necessary and any hazards are clear of the area and then: Operate the in-cab controls and make sure: If equipped, engage the PTO PRESS the System Enable button – the button turns green and the PUMP is ON PRESS the System Enable button –...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE The blade should move UP The slide should move OUT Operate each installed optional outside control located at the tailgate: Reeving Mechanism Release the cable hook from it storage eye and hold the hook PUSH the control lever –...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Make sure the arm mechanism is at the full LOWER position Roll Bar PULL the control lever – the roll bar should RAISE PUSH the control lever – the roll bar should LOWER Make sure the roll bar is at the full LOWER position Cart Tipper PULL the control lever –...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE Inspect the floor, ejector rails and ejector shoes Store the tailgate props and RAISE the tailgate completely PULL the ejector lever and FULLY EXTEND the ejector panel PUSH the ejector lever and FULLY RETRACT the ejector panel CLOSE the tailgate RED TAILGATE OPEN (TG OPEN) in-cab display indicator is OFF and the alarm is OFF;...
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® POWERTRAK COMMERCIAL INSPECTION CHECKS AND INSPECTIONS RESULTS CODE THROTTLE ADVANCE All optional switches If equipped, check the operation of each camera FINAL INSPECTION While you walk completely around the vehicle, look for: Fluid leaks Cracked or damaged welds and metal Loose or missing bolts, nuts and clamps Issued July 2020 Copyright 2020, Heil Environmental...
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn proper procedures for: Checking the unit each day Starting the unit in cold weather Setting the unit up for the route Removing power to the unit during periods of not using the unit Issued July 2020 Copyright 2020, Heil Environmental Before Going on Route...
® POWERTRAK COMMERCIAL BATTERY DISCONNECT SWITCH DAILY CHECKLIST The battery box is typically located on the streetside of the See the Daily Check section for the daily checks and chassis frame near the front of the body, however it can be procedures checklist.
® POWERTRAK COMMERCIAL BEFORE STARTING A ROUTE COLD WEATHER WARMUP PROCEDURE Before you start a route, do the following: When ambient air temperature is cold (below 0 degrees F), it is necessary to warm up the unit’s hydraulic oil before you Perform an inspection of the unit with the Daily start your daily route operation or to check the oil level.
® POWERTRAK COMMERCIAL 3. Add oil if necessary. Refer to the Service Manual for PREPARING THE UNIT TO CHECK THE instructions for filling the oil tank. HYDRAULIC OIL LEVEL Current Heil standard hydraulic oil is Shell Tellus S2 VX Before checking the oil level or adding oil, make sure the oil 32.
® POWERTRAK COMMERCIAL HYDRAULIC OIL TANK WITH SIGHT GAUGE Figure 54. Hydraulic Oil Tank with Sight Gauge Issued July 2020 Copyright 2020, Heil Environmental Before Going on Route Printed in the U.S.A.
® POWERTRAK COMMERCIAL CYCLE ALL HYDRAULIC FUNCTIONS DANGER A tailgate in motion is dangerous. Serious injury or death Check the operation of all hydraulic controls on the unit. may occur if a person is struck by a moving tailgate or See Section 4 for proper operation of controls.
® POWERTRAK COMMERCIAL CHECK THE TRAVELING OR “IN-TRANSIT” POSITION If equipped, the PTO is DISENGAGED. The System Enable button is OFF. NOTICE You properly ADJUST and CLEAN the mirrors. BEFORE you drive any distance greater than one (1) mile All outside lights turn ON and OFF. or BEFORE you park a unit, you must make sure that the If equipped, the side access door is CLOSED and upper panel (slide) and sweep blade control levers are in...
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: Setting up the unit for a route Loading refuse Packing the load Packing on-the-move Washout system Setting up the unit for the landfill or transfer station Issued July 2020 Copyright 2020, Heil Environmental On-Route Operation Procedures Printed in the U.S.A.
® POWERTRAK COMMERCIAL If equipped, the PTO is DISENGAGED. DRIVING TO PICK-UP LOCATIONS The System Enable button is OFF. You properly ADJUST and CLEAN the mirrors. NOTICE All outside work lights turn OFF. BEFORE you drive any distance greater than one (1) mile If equipped, the body side access door is CLOSED or BEFORE you park a unit, you must make sure that the and LATCHED.
® POWERTRAK COMMERCIAL BEFORE LOADING (CONTINUED) LOADING REFUSE MANUALLY 2. The ejector panel should be: Use the following procedures at each stop along the route to manually load refuse into the unit with the lift arm. a. For normal route pickup, about three (3) feet from Observe the DANGER and WARNING notices.
® POWERTRAK COMMERCIAL b. The slide will move OUT and the blade will move LOADING REFUSE MANUALLY (CONTINUED) UP. STOP the blade UP operation when the blade is at the pinch point with the hopper sill. Packing Refuse into the Body c.
® POWERTRAK COMMERCIAL LOADING REFUSE MANUALLY (CONTINUED) NOTES: DANGER Do not use riding step when vehicle speed is more than 10 MPH or to travel more than 2 tenths (0.2) of a mile. Do not use riding step when vehicle operates in reverse. Always face vehicle when using riding step.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A REEVING DANGER MECHANISM Crush or Pinch Hazard. An option for Rear End Loaders (RELs), a reeving Lifting or dragging uncontrolled items with hook and cable mechanism is a cylinder assembly that is located on the may cause items to move in a way that can pinch or crush centerline of the roof with which an operator can raise and the operator.
® POWERTRAK COMMERCIAL d. PULL the control lever for the reeving mechanism LOADING REFUSE WITH A REEVING until the reeving mechanism lifts the refuse MECHANISM (CONTINUED) container over the hopper sill and the refuse empties into the hopper. RELEASE the control b.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A REEVING MECHANISM (CONTINUED) h. RELEASE the container’s trunnion bar from the latch bar. See Using a Latch Bar i. MOVE the container to its pick-up location. Figure 58. Reeving Mechanism or Winch Setup Figure 59.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A REEVING MECHANISM (CONTINUED) DANGER Your body or clothing can become caught by the blade while it moves. Serious injury or death may occur if a person is in or near the hopper when the blade and slide assembly move.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A REEVING DANGER MECHANISM (CONTINUED) Do not use riding step when vehicle speed is more than 10 d. PUSH the slide and blade levers at the same time MPH or to travel more than 2 tenths (0.2) of a mile. Do not and RELEASE the levers.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A WINCH DANGER An option for Rear End Loaders (RELs), a winch is a Crush or Pinch Hazard. mechanism with a hook and cable that an operator uses to Lifting or dragging uncontrolled items with hook and cable raise, dump and lower a commercial refuse container may cause items to move in a way that can pinch or crush The winch hook and cable are not intended for any other...
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A WINCH WARNING (CONTINUED) A refuse container that is not in good condition with 1. Move the slide and blade into the START retaining washers in place may not be secured with the POSITION. See Figure 43 latch bar and can suddenly move.
® POWERTRAK COMMERCIAL b. The slide will move OUT and the blade will move LOADING REFUSE WITH A WINCH UP. STOP the blade UP operation when the blade (CONTINUED) is at the pinch point with the hopper sill. e. After the refuse container is empty of refuse, c.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A WINCH NOTES: (CONTINUED) DANGER Do not use riding step when vehicle speed is more than 10 MPH or to travel more than 2 tenths (0.2) of a mile. Do not use riding step when vehicle operates in reverse. Always face vehicle when using riding step.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH AN ARM CAUTION MECHANISM A refuse container that is not in good condition may not be An option for Rear End Loaders (RELs), an arm secured by the arm mechanism and can suddenly move. mechanism is an assembly that uses arms that mate with a Minor or moderate injury can occur when a person is refuse container’s slots to lift, dump and lower a refuse...
® POWERTRAK COMMERCIAL LOADING REFUSE WITH AN ARM MECHANISM (CONTINUED) c. After the refuse container is empty of refuse, PUSH the control lever for the arm mechanism until the refuse bin rests firmly on the ground. (RELEASE the Throttle Advance Switch if you pressed it during loading.) d.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH AN ARM MECHANISM (CONTINUED) DANGER Your body or clothing can become caught by the blade while it moves. Serious injury or death may occur if a person is in or near the hopper when the blade and slide assembly move.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH AN ARM DANGER MECHANISM (CONTINUED) Do not ride on or in the hopper opening. Use riding step c. Watch for refuse that is pushed out of the hopper. and obey all safety messages. d. PUSH the slide and blade levers at the same time 6.
® POWERTRAK COMMERCIAL 2. Load the refuse from a container into the hopper. LOADING REFUSE WITH A ROLL BAR See Figure 44 and Figure 45 MECHANISM a. Set the refuse container in front of the roll bar until An option for Rear End Loaders (RELs), a Roll Bar the container touches or nearly touches the roll Mechanism is an assembly that uses a bar to lift, dump and bar.
® POWERTRAK COMMERCIAL h. MOVE the container to its pick-up location. LOADING REFUSE WITH A ROLL BAR 3. Sweep the refuse from the hopper and pack it into MECHANISM (CONTINUED) the body. d. When the refuse container’s cover is not closed a.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A ROLL BAR MECHANISM (CONTINUED) Figure 64. Roll Bar Setup Figure 65. Loading Refuse with Roll Bar Issued July 2020 Copyright 2020, Heil Environmental On-Route Operation Procedures Printed in the U.S.A.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A ROLL BAR MECHANISM (CONTINUED) 5. Leave the blade against the refuse. DANGER Do not use riding step when vehicle speed is more than 10 MPH or to travel more than 2 tenths (0.2) of a mile. Do not use riding step when vehicle operates in reverse.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A CART TIPPER A cart tipper is a Rear End Loader (REL) option attached to the tailgate that allows an operator to secure a residential refuse container and unload its contents into the hopper Use the instruction that follow to load refuse from a commercial refuse container into the hopper with a cart tipper.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A CART TIPPER DANGER (CONTINUED) The slide in/out and blade up/down operations can push a. PULL the control lever for the cart tipper until the refuse out of the hopper or break objects. Refuse broken refuse container lifts over the hopper sill and the by the blade can cause severe injury or death.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A CART TIPPER DANGER (CONTINUED) Your body or clothing can become caught by the blade while it moves. Serious injury or death may occur if a person is in or near the hopper when the blade and slide assembly move.
® POWERTRAK COMMERCIAL LOADING REFUSE WITH A CART TIPPER USING A LATCH BAR (CONTINUED) The latch bar is an assembly and its major components are two latch assemblies, two latch bars, two container guides d. PUSH the slide and blade levers at the same time and a bash bar.
® POWERTRAK COMMERCIAL USING A LATCH BAR (CONTINUED) Figure 71. Latch Bars Rotated Up Figure 70. Latch Bars Rotated Down Issued July 2020 Copyright 2020, Heil Environmental On-Route Operation Procedures Printed in the U.S.A.
® POWERTRAK COMMERCIAL PACKING ON-THE-MOVE ACHIEVING PAYLOADS ® Read this section for advice and tips on how to pack Heil PowerTrak Commercial units can pack on-the move. the most efficient loads with your unit. The operator does this manually while on the riding step (if equipped) between stops.
® POWERTRAK COMMERCIAL LEAVING THE ROUTE FOR THE LANDFILL/ NOTES: TRANSFER STATION At the end of the route, or when the unit has a full load, prepare the unit to go to the landfill. See Driving to Pick- up Locations and make sure the unit is properly set up for travel.
® POWERTRAK COMMERCIAL SECTION 9 LANDFILL/TRANSFER STATION/ RECYCLE CENTER PROCEDURES Issued July 2020 Copyright 2020, Heil Environmental Landfill/Transfer Station/Recycle Center Printed in the U.S.A.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: Setup conditions to dump the refuse Unloading the refuse Using the sump and (optional) washout system Preparing the unit to return to route. Issued July 2020 Copyright 2020, Heil Environmental Landfill/Transfer Station/Recycle Center Printed in the U.S.A.
® POWERTRAK COMMERCIAL 2. Shift the transmission to NEUTRAL. OVERVIEW OF LANDFILL/TRANSFER 3. SET the parking brake. STATION/RECYCLE CENTER PROCEDURES 4. For a manual transmission, engage the PTO and Use the following information as an overview of the steps to MOVE the PUMP ON switch to ON.
® POWERTRAK COMMERCIAL UNLOADING REFUSE (CONTINUED) CAUTION A. Unlocking and Raising the Tailgate (Continued) Do not drive the unit for an extended distance. The unit may become unstable and you may cause damage to the 3. HOLD the lever until the tailgate is COMPLETELY tailgate cylinders.
® POWERTRAK COMMERCIAL UNLOADING REFUSE (CONTINUED) C.Clean and Inspect the Tailgate B. Ejecting Refuse (Continued) DANGER Always prop the tailgate when you leave it raised for maintenance, service or cleaning procedures. Any part of your body between the unit’s body and the tailgate while you prop the tailgate or when the tailgate is propped is dangerous.
® POWERTRAK COMMERCIAL UNLOADING REFUSE (CONTINUED) D.Lowering the Tailgate DANGER A tailgate in motion is dangerous. Serious injury or death may occur if a person is struck by a moving tailgate or becomes trapped between the tailgate and the body. Clear the area near the tailgate of all unnecessary people before you lower the tailgate.
® POWERTRAK COMMERCIAL UNLOADING REFUSE (CONTINUED) H.Sump Doors and Washout System ® The PowerTrak Commercial unit does not have sump E. Locking the Tailgate doors. Swing the tailgate clamps up and tighten each clamp, If equipped, use the optional washout system to clean locking the tailgate.
® POWERTRAK COMMERCIAL SECTION 10 END OF DAY PROCEDURES Issued July 2020 Copyright 2020, Heil Environmental End of Day Procedures Printed in the U.S.A.
® POWERTRAK COMMERCIAL PREVIEW Read this section to learn about: Parking the Unit Washout System Final Inspection Report to Employer/Supervisor Ignition Keys Issued July 2020 Copyright 2020, Heil Environmental End of Day Procedures Printed in the U.S.A.
® POWERTRAK COMMERCIAL 6. Make sure all cylinders (except tailgate lock END OF DAY PROCEDURES cylinders) are in their retracted position and make sure that the upper panel (slide) and sweep blade Parking the Unit control levers are in the NEUTRAL position.. 1.
® POWERTRAK COMMERCIAL 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 be checked and serviced. *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000...
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® POWERTRAK COMMERCIAL *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE Operator Controls Front Mount Pump or Power Take-Off Check seals for leaks and operation. (PTO) Replace if necessary Check drive line for smooth operation. Replace as necessary. Check set screws for tightness. Tighten as necessary.
® POWERTRAK COMMERCIAL 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 75.
® POWERTRAK COMMERCIAL IMPORTANT SAFETY INFORMATION NOTICE For CNG units, this manual should be used in conjunction with any associated CNG Fuel System and Cylinder Manufacturers' Operation, Inspection and Maintenance Manuals. Always read and understand all associated manuals alongside the Heil Operation Manual and Heil Parts and Service Manual before operating or servicing the unit. CNG training is required for any person inspecting, operating, or performing maintenance on a CNG unit.
® POWERTRAK COMMERCIAL IMPORTANT SAFETY INFORMATION (CONTINUED) A. Safety Notices Throughout this manual, safety notices are included to warn operators and maintenance technicians of the dangers associated with the described equipment operations and maintenance. Improper operation or maintenance procedures may cause serious injury or death. Safety notices accompany potentially hazardous situations throughout this manual. Please read and follow instructions carefully.
® POWERTRAK COMMERCIAL IMPORTANT SAFETY INFORMATION (CONTINUED) WARNING Never open system components while the system is under pressure. Treat all cylinders as full until defueling has been completed. WARNING Never weld or perform any type of "hot work" on any part of a compressed natural gas vehicle unless the compressed natural gas fuel system has been purged with inert gas.
® POWERTRAK COMMERCIAL PROPERTIES OF NATURAL GAS SIGNS OF A FUEL LEAK CNG is a naturally occurring hydrocarbon gas mixture An odorant which smells like rotten eggs is added to which consists primarily of methane. This gas is lighter than compressed natural gas to aid in detection of a leak.
® POWERTRAK COMMERCIAL 2. High Pressure Gauge CNG FUEL SYSTEM COMPONENTS The high pressure gauge indicates the fuel pressure The following pages detail a typical CNG system in the fuel system. The gauge has a range of 0 to configuration. Your CNG fuel system configuration may 5000 psi.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM COMPONENTS (CONTINUED) B. Fuel Management Module Components (Continued) 5. Fast Fill/HD Bus Fuel Receptacle The fast fill/HD bus fuel receptacle is the filling port for fueling the vehicle at public fueling stations. 6. Slow Fill/NGV1 Fuel Receptacle The slow fill/NGV1 fuel receptacle is the filling port for fueling the vehicle at slow fueling facility, usually overnight.
® POWERTRAK COMMERCIAL 6. Pressure Regulator CNG FUEL SYSTEM COMPONENTS The pressure regulator reduces the pressure of fuel (CONTINUED) in the system from high pressure (3,600 psi) to low pressure (70-100 psi for the Momentum FMM) for the C.CNG Fuel System Components (Continued) engine to use.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM COMPONENTS NOTES: (CONTINUED) C.CNG Fuel System Components (Continued) 9. Pressure Relief Devices The Pressure Relief Devices (PRD) are thermally- activated valves that open at a temperature of approximately 230°F. In the event of a fire, they are designed to release the fuel stored in the cylinders a safe distance from the vehicle to prevent over- pressurizing the fuel cylinders.
® POWERTRAK COMMERCIAL 3. Do not use road flares. FUEL SYSTEM SHUT DOWN PROCEDURE 4. Do not smoke or allow anyone else to smoke near the vehicle. 1. Turn OFF the Fuel Management Module (FMM) Manual Shut-Off Valve. 5. Turn OFF the ignition switch, set the parking brake and turn OFF the battery at the main disconnect.
® POWERTRAK COMMERCIAL Emergency Venting/Defueling Procedure CNG VEHICLE OPERATOR EMERGENCY RESPONSE (CONTINUED) If an emergency arises in which the fuel must be purged immediately, an emergency vent can be performed as CNG Vehicle Emergency Shut Down Procedure follows: 1. Ensure that an electrical ground connection has been WARNING established between the cylinders, the vent system, and earth ground.
® POWERTRAK COMMERCIAL STARTING VEHICLE FUELING PROCEDURE A. CNG Fueling Steps NOTICE Two options exist for filling a vehicle with CNG – timed fill or fast fill. Despite the size of the receptacle, the Starting a natural gas vehicle requires a delay between the fueling hose connects in the same manner for either battery power being turned on and the starter motor being activated.
® POWERTRAK COMMERCIAL e. Disconnect the fuel hose, and return it to the fuel FUELING PROCEDURE (CONTINUED) dispenser. B. Types of Fueling Hoses Dependent upon the fueling station, different types of fueling hoses may be utilized. Refer to the figures below and on the next page to determine which type of fueling hoses you will be using.
® POWERTRAK COMMERCIAL 2. Type 2: FUELING PROCEDURE (CONTINUED) This fueling hose operates in the following manner: B. Types of Fueling Hoses (Continued) a. Locate fill receptacle and remove dust cap. 1. Type 1 (Continued): b. Slide fueling hose nozzle onto the fueling receptacle.
® POWERTRAK COMMERCIAL FUELING PROCEDURE (CONTINUED) TRANSFER FUELING (DEFUELING) PROCEDURES 3. Type 3: Defueling is generally the process of removing any residual To utilize this hose: fuel from the fuel tanks and on-board fuel delivery system a. Locate fill receptacle and remove dust cap. prior to performing any welding or a major repair.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM MAINTENANCE Routine maintenance of the compressed natural gas system in accordance with the CNG Fuel System Inspections Section will ensure that the system and components are functioning properly. Refer to your Heil Service Manual for CNG fuel system schematics.
® POWERTRAK COMMERCIAL MAINTENANCE PART NUMBERS NOTES: When replacing CNG components, replace with equal or higher pressure rated components. PART NUMBER DESCRIPTION 151-4773-107 High-Pressure Coalescing Filter Element Kit Refer to Engine Low-Pressure Fuel Filter Element 151-4773-126 Fast-Fill Fuel Receptacle O-Ring To be supplied #6 O-Ring Face Seal –...
® POWERTRAK COMMERCIAL DEPRESSURIZING PROCEDURE DEPRESSURIZING PROCEDURE (CONTINUED) It is necessary to prepare the truck to be serviced. A mechanic’s initial focus while preparing the vehicle for 2. Close ALL cylinder Manual Shut-Off Valves (one on service should be safety. The primary preparation involves each cylinder) by turning the valve clockwise to the relieving the pressure within the system BEFORE OFF position.
® POWERTRAK COMMERCIAL DEPRESSURIZING PROCEDURE RE-PRESSURIZING PROCEDURE (CONTINUED) Once the high-pressure filter drain or change procedure is complete, perform the following procedure to re-pressurize 9. Turn OFF the power supply if an electrical the lines. component of the system requires service. 10.Perform any maintenance ONLY after completing 1.
® POWERTRAK COMMERCIAL HIGH PRESSURE FILTER DRAIN HIGH PRESSURE FILTER CHANGE PROCEDURE PROCEDURE 1. Remove the excess fuel in the filter per the 1. Remove the excess fuel in the filter per the depressurization procedure. Depressurizing Procedure 2. Make sure the FMM Manual Shut-Off Valve is in the 2.
® POWERTRAK COMMERCIAL WELDING AND HOT WORK PROCEDURES WELDING AND HOT WORK PROCEDURES (CONTINUED) WARNING 7. Slowly relieve excess pressure by turning the bleed valve cap counter-clockwise until a hissing sound is Never weld on a compressed natural gas vehicle unless heard.
® POWERTRAK COMMERCIAL LIFTING THE VEHICLE NOTES: WARNING Never use any part of the fuel system as a lifting point to raise the vehicle. Do not allow fuel system components to come into contact with any part of the lifting device. The fuel system can become damaged, resulting in a leak.
® POWERTRAK COMMERCIAL 5. Have the fuel system and cylinders inspected by a PRE-TRIP INSPECTION certified CSA Cylinder and Fuel System Inspector if damage is found on any part of the components or Perform a Pre-Trip Inspection each day before driving the structural parts of the fuel system.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM INSPECTION/PREVENTIVE CARE SCHEDULE ITEM FREQUENCY Check Vent Lines Daily Drain Low Pressure Filter Daily Daily Perform Daily CNG Fuel System Inspection on next page. Replace Low Pressure Filter Refer to the engine manufacturer for maintenance and replacement guidelines.
® POWERTRAK COMMERCIAL 3. NOTES: CNG FUEL CYLINDER AND SYSTEM INSPECTION WARNING If a CNG-fueled vehicle has been involved in an accident or fire, the system and cylinders must be inspected by a certified CNG fuel system inspector. NOTICE Inspections must be performed by qualified inspectors using guidelines from the fuel cylinder manufacturer in addition to the guidelines listed here.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM TROUBLESHOOTING Heil offers support via the technical assistance line, as well as products, such as a Fuel Module Mini-Tester (Part Number 044-0488), to assist with troubleshooting. Please provide the following when calling Heil Technical Services at 866-310-4345 with troubleshooting questions: 1.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM TROUBLESHOOTING (CONTINUED) The following table lists possible problems, along with causes, corrections, and results. PROBLEM OBSERVED POSSIBLE CAUSES CORRECTIVE/ RESULTS AND OTHER DIAGNOSTIC ACTIONS ACTIONS Vehicle's starter will not Interrupt door switch signal Disconnect the 12-pin If operation of the door operate.
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM TROUBLESHOOTING (CONTINUED) The following table lists possible problems, along with causes, corrections, and results. PROBLEM OBSERVED POSSIBLE CAUSES CORRECTIVE/DIAGNOSTIC RESULTS AND OTHER ACTIONS ACTIONS Vehicle's starter operates Fuel is not making it *The manual valve on the front *If the voltage does NOT but the vehicle does not through the fuel module to...
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM TROUBLESHOOTING (CONTINUED) The following table lists possible problems, along with causes, corrections, and results. PROBLEM OBSERVED POSSIBLE CAUSES CORRECTIVE/DIAGNOSTIC RESULTS AND OTHER ACTIONS ACTIONS The fuel module pressure Confirm that the 12-pin *If the voltage across 2 Heil Standard CNG and transducer, the fuel gauge electrical connector at the rear...
® POWERTRAK COMMERCIAL CNG FUEL SYSTEM TROUBLESHOOTING (CONTINUED) The following table lists possible problems, along with causes, corrections, and results. PROBLEM OBSERVED POSSIBLE CAUSES CORRECTIVE/DIAGNOSTIC RESULTS AND OTHER ACTIONS ACTIONS The fuel cylinder pressure Confirm that the 3pin electrical *If the voltage across A transducer or the connector at the transducer is and B is 0 or significantly...
® POWERTRAK COMMERCIAL CNG FRONT OF BODY / TOP OF BODY DECAL PLACEMENT In addition to the decal shown below, there may be other decals placed on the Fuel Management Module (FMM), tank compartments or elsewhere on the CNG system components. Refer to the CNG Fuel System Manufacturer's Operation and Maintenance Manuals for replacement decal part numbers.
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® POWERTRAK COMMERCIAL Summary of Features HEIL CNr Display screen inside the cab which gives live When equipped, the optional Heil CNrG Solenoid System pressure monitoring for each tank and system. will monitor and display live in-cab CNG system and tank Visual warning in form of messages and color on the Display.
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® POWERTRAK COMMERCIAL HEIL CNr (CONTINUED) Pressure Transducer Sensors WARNING ALL Pressure Transducer Sensors MUST be functioning for System to be able to detect a leak. WARNING Tank MUST be empty before removing tank Pressure Transducer Sensor. Figure 85. Pressure Transducer Sensor behind FMM Plugged directly into the live port of the valve of each tank Unplugged/Faulty...
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® POWERTRAK COMMERCIAL Solenoid System Function HEIL CNr (CONTINUED) The valve body on each CNG tank has an integrated solenoid. The solenoids are normally closed when the The Alarm Summary Screen can be reached by pressing ignition is OFF and open when ignition is ON and a voltage the right arrow on the display twice.
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® POWERTRAK COMMERCIAL HEIL CNr (CONTINUED) Leak Detection/Solenoid Lock (Continued) The figures on this page show example display screenshots of possible leak detection notifications. Other leak detection notifications exist and are not shown here. WARNING You must follow all safety/emergency procedures of your company in the event of a CNG leak.
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® POWERTRAK COMMERCIAL HEIL CNr (CONTINUED) Solenoid Failure Detection The system is capable of detecting solenoid failures to open (in the event of a wiring or component issue) when the ignition is turned ON as per requirement of NFPA 52. Whenever there is a single solenoid issue, the main screen will show which solenoid has failed as seen on the figure to the top right of this page.
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® POWERTRAK COMMERCIAL HEIL CNr NOTICE (CONTINUED) Authorized Service Personnel should contact Heil Technical Service for the maintenance bypass code to Maintenance Bypass unlock the CNG solenoids. The following are the steps must be followed by a qualified maintenance technician after getting any display messages described in this manual.
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® POWERTRAK COMMERCIAL CNG Tank Option Configuration HEIL CNr (CONTINUED) The system is designed for different tank configurations and is a common design which will work from 3 tank to 7 Low Fuel Level Detection tank system. This helps the customer to upgrade to higher DGE (Diesel Gallon Equivalents) by adding more tanks The system is capable of detecting low fuel levels and will without need to modify anything in this system.
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® POWERTRAK COMMERCIAL System Outputs HEIL CNr (CONTINUED) The display screenshot shown below (within the maintenance mode menu) is used for troubleshooting and System Inputs maintenance to gather information for the current status of the Solenoids on each Tank (ON or OFF). It also provides The display screenshot shown below (within the the status of the System Alarm for the Cortex Controller.
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® POWERTRAK COMMERCIAL System Over Voltage HEIL CNr (CONTINUED) The display notification shown in the figure below will only be displayed in the event that the System Voltage is greater Ignition Power OFF than 36 volts for 10 seconds, indicating that there is voltage too high to safely operate the Cortex Controller and The display notification shown in the figure below will only Display.
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® POWERTRAK COMMERCIAL Fuel Fill Mode HEIL CNr OPTION (CONTINUED) For the CNrG Solenoid System only, engage Fuel Fill Mode on the in- System Under Voltage for fast fill fueling. The "FUEL FILL MODE" button turns green when engaged. After Fuel Fill Mode is engaged, the Fuel Fill Mode remains The display notification shown in the figure active for one (1) hour or until the ignition key switch cycles ON-OFF- below will only be displayed in the event that...
INDEX cold weather warmup procedure comb lift and arm mechanism compressed natural gas (CNG) option accident CNG front of body decal placement achieving payloads CNG fuel cylinder and system inspection arm mechanism 16, 23, 79 CNG fuel system troubleshooting 182, 183, 184, 185, 186 CNG top of body decal placement CNG vehicle operator emergency response...
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INDEX compressed natural gas (CNG) option extend/EXTEND signs of a fuel leak starting vehicle system components 162, 163, 164, 165 factory body props towing the vehicle final inspection transfer fueling (defueling) front head 16, 23 vehicle fire procedures FULLY RETRACTED POSITION weekly system inspection welding and hot work procedures contact information...
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INDEX Heil CNrG optional solenoid system system under voltage tank option configuration latch bar 16, 23 hopper 16, 23 latch bar assembly hopper light switch LATCHED hopper sill leaving the route for the landfill/transfer station how to use this manual LOAD POSITION hydraulic oil tank 16, 106...
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INDEX notice 23, 29 raise/RAISE raising the tailgate recommended hydraulic oil reeving mechanism 16, 23, 78 off/OFF on/ON remove refuse from the engine and exhaust areas operator optional container lift controls reports to employer/supervisor optional outside controls 77, 78, 79, 80, 81 retract/RETRACT overhead clearances riding step...
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INDEX warning 23, 29 warranty claims and inquiries washout system tailgate when working in or around the vehicle tailgate cylinders winch 23, 78 tailgate lever winch assembly tailgate props tailgate raise cycle throttle advance 16, 23 throttle advance switch 75, 76 to the mechanic to the operator 7, 8...
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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 &...
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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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