Dover HEIL DuraPack Python Service Manual
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Dover HEIL DuraPack Python Service Manual

High-performance automated side loader
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DuraPack
Python
HIGH-PERFORMANCE AUTOMATED SIDE LOADER
SERVICE MANUAL
ISSUED JULY 2024
TP1DPPY-SM-0724
© 2022 Heil Environmental
.

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  • Page 1 ® ® DuraPack Python HIGH-PERFORMANCE AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED JULY 2024 TP1DPPY-SM-0724 © 2022 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 PLEASE NOTE THAT THIS MANUAL IS APPLICABLE TO THE HEIL BODY ONLY.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Introduction ...................................4 Service/Parts Assistance ...................................4 Recommended Spare Parts ...................................5 Electronic Parts Catalog (EPC) ...................................7 Precautionary Statements ...................................10 Lock-Out/Tag-Out Procedures ...................................14 Storing Refuse in the Body ...................................16 Maintenance/Lubrication Information ...................................16 Winch Gear Oil ...................................16 Grease Lubrication Recommendation ...................................16 Oil Lubricant Recommendation ...................................16...
  • Page 4 TABLE OF CONTENTS Propping the Body of a Service Hoist Unit ...................................67 Propping the Body of a Service Lift (Serviceable Eject) Unit ...................................70 Tailgate Support Props ...................................74 Side Access Doors ...................................75 Body Sump Doors ...................................75 Main Control and Regenerative Valves ...................................76 Regenerative Valve ...................................77...
  • Page 5 TABLE OF CONTENTS RP170 Cab Electrical Schematic, Waste Management, non-Power Of One - 701-9064-010 ...................................156 Control Panel, RP170 Cab Electrical Schematic, Waste Industries, Power Of One - 701-9064-101 ...................................157 RP170 Chassis Electrical Schematic, Waste Industries, Power Of One - 701-9064-102 ...................................158 Cab Pneumatic Schematic, Power Of One - 701-9064-103 ...................................159...
  • Page 6 NOTES Issued July 2024 Copyright 2024, The Heil Co. Printed in the U.S.A.
  • Page 7 ® ® DuraPack Python HIGH-PERFORMANCE AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED JULY 2024 TP1DPPY-SM-0724 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A.
  • Page 8 NOTES Issued July 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 9: General Information

    General Information SECTION 1 GENERAL INFORMATION Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. General Information...

  • Page 10: Introduction

    General Information INTRODUCTION The following sections are guides 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. In order to diagnose a problem quickly and effectively, a service person must be thoroughly familiar with the machine.

  • Page 11: Recommended Spare Parts

    General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION BODY AND TAILGATE ASSEMBLIES 022-3509 SEAL, TAILGATE 003-5142 BEARING, LOCK 022-4058 SEAL, SUMP DOOR 094-2834 PANEL, RUBBER, FOLLOWER, SIDE LOADER AND GRABBER ASSEMBLIES 093-3227 ASSEMBLY, DRIVE GEAR, GRABBER 062-0804 ASSEMBLY, ROLLER, TRI-CUFF 062-0805 ASSEMBLY, GRABBER, ROLLER, 4”...
  • Page 12 General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION 031-6297 ASSEMBLY, PNEUMATIC TOGGLE VALVE FITTING 060-0417 CAP, FILLER, 4” 067-0630 GAUGE, SIGHT, THERMOMETER 075-0712 FILTER, BREATHER 075-0953 FILTER, RETURN LINE 031-5601 DISCONNECT, QUICK ELECTRICAL 063-0108 SWITCH, PROXIMITY, NO SOURCING, 18 MM 063-0109 SWITCH, PROXIMITY, NO SOURCING, 30 MM 063-0120...

  • Page 13: 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 14 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 15 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 16: 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 17 General Information DANGER A tailgate in motion is dangerous. Serious injury or death can 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.
  • Page 18 General Information WARNING Moving equipment can be dangerous to bystanders. Death or serious injury can occur if a person is in the wrong area or is not attentive to the operations. Clear the area of all unnecessary people before you operate the controls. WARNING Raising the body with the tailgate closed can damage the underride bumper.
  • Page 19 General Information NOTICE Do not move the unit forward or backwards excessively fast (lurch) to dump the refuse load. Excessively fast movements with the body raised puts a very high load on the body raise cylinders and could damage one or both cylinders and make the body unstable unable to lower.

  • Page 20: 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 21 General Information 9. Turn off the power at the battery box by switching the battery disconnect to the OFF position. 10.Insert the red Lock-Out/Tag-Out clasp into the disconnect switch hole. 11.Insert the red key Lock-Out/Tag-Out lock with your tag exposed and visible into the paddle switch holes now that they are lined up.

  • Page 22: Storing Refuse In The Body

    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 General Information HYDRAULIC OIL SPECIFICATIONS (CONTINUED) High performance of air release characteristics Current Heil standard hydraulic oil is Shell Tellus S2 VX 32. Please see product TDS and MSDS for more detail information about it. We strongly recommend to use it on Heil products to get best system performance and oil service life. The following oils can be used on Heil products if Heil standard hydraulic oil (Shell Tellus S2 VX 32) is not available.

  • Page 24: 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 25 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Thread Heil Plain Dry Fastener Heil Lubricated Heil 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 Thread Heil Plain Dry Fastener Heil Lubricated Heil 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 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Thread Heil Plain Dry Fastener Heil Lubricated Heil 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 28 General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Thread Heil Plain Dry Fastener Heil Lubricated Heil 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 29: 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 30: 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 31 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 32 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 33 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-LBS] BOLT TORQUE [IN-LBS] ALUMINUM FT- LBS [IN-LBS] 1/2"...
  • Page 34 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-LBS] BOLT TORQUE [IN-LBS] ALUMINUM FT-LBS [IN- TUBE OD LBS] 1/2" 5/16-18 x 1.25 17 ft-lbs. 200 in-lbs.

  • Page 35: 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 36: 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 37 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Copyright 2024, The Heil Co. Issued July 2024 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 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. General Information...

  • Page 40: Hydraulic Symbols

    General Information HYDRAULIC SYMBOLS Issued July 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.
  • Page 41 General Information HYDRAULIC SYMBOLS (CONTINUED) Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. General Information...

  • Page 42: Electrical Symbols

    General Information ELECTRICAL SYMBOLS Issued July 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.
  • Page 43 Pumps SECTION 2 PUMPS Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Pumps...

  • Page 44: Tandem Vane Pump With Monoblock Separate Outlet Flow

    Pumps TANDEM VANE PUMP WITH MONOBLOCK SEPARATE OUTLET FLOW Rapid Rail and Python Auto Side Loader Figure 7. Tandem Vane Pump with Monoblock In the Monoblock Operate-in-Gear-at-Idle hydraulic system, the pump section (pump 1) closest to the input shaft operates the lift and shuts OFF first.

  • Page 45: 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 side loading operations at standard idle speed. It is comprised of two major components, the monoblock tandem vane pump and attached unloader valve assembly. On Rapid Rail systems the P1 or front section (closest to the pump input shaft) operates the loader section of the truck while the P2 or rear section (farthest from the input shaft) operates the body section, which includes the packer.
  • Page 46 Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING (CONTINUED) Figure 8. Issued July 2024 Copyright 2024, The Heil Co. Pumps Printed in the U.S.A.

  • Page 47: Mount Pump Monoblock To Tandem Pump

    Pumps MOUNT PUMP MONOBLOCK TO TANDEM PUMP Follow these steps when mounting a monoblock to the tandem pump. 1. Loosen the rear end cap bolts and front mounting cap bolts to allow slight movement between the P1, center pump, and P2 housings.
  • Page 48 NOTES Issued July 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.

  • Page 49: Lift Arm

    Lift Arm SECTION 3 LIFT ARM Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Lift Arm...

  • Page 50: Nomenclature

    Lift Arm NOMENCLATURE Figure 10. Lift Arm Nomenclature Issued July 2024 Copyright 2024, The Heil Co. 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: Lift Arm 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 53: 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 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 Lift Arm 14. To replace the arm, perform these steps in reverse. Issued July 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.

  • 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 NOTES Issued July 2024 Copyright 2024, The Heil Co. Body and Tailgate Printed in the U.S.A.

  • Page 69: Body And Tailgate

    BODY AND TAILGATE SECTION 4 BODY AND TAILGATE Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body and Tailgate...

  • Page 70: Body Nomenclature

    BODY AND TAILGATE BODY NOMENCLATURE Shown below are some of the features of the body. Issued July 2024 Copyright 2024, The Heil Co. Body and Tailgate Printed in the U.S.A.

  • Page 71: Tailgate Nomenclature

    BODY AND TAILGATE TAILGATE NOMECLATURE Shown below are some of the features of the tailgate. Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body and Tailgate...

  • Page 72: Optional Flat Tailgate Nomenclature

    BODY AND TAILGATE OPTIONAL FLAT TAILGATE NOMENCLATURE The optional Flat Tailgate weighs about the same as the standard bubble tailgate. This tailgate is not designed to save weight but to transfer more weight to the front axle to achieve a more desirable weight distribution. Shown below are some of the features of the optional Flat Tailgate.

  • Page 73: Propping The Body Of A Service Hoist Unit

    BODY AND TAILGATE PROPPING THE BODY OF A SERVICE HOIST UNIT Operators MUST KNOW how to SAFELY prop up the unit’s body. You may need to prop the body up when you clean the inside of the body or for maintenance or repair procedures. Observe and obey the following DANGER and WARNING notices while you prop the body with the factory body props.
  • Page 74 BODY AND TAILGATE PROPPING THE BODY OF A SERVICE HOIST UNIT (CONTINUED) The factory-supplied body props are located on both sides under the body and forward of the rear wheels. Refer to the figure to the right and carefully follow the body propping procedures below. Follow These Steps to Raise the Body: 1.
  • Page 75 BODY AND TAILGATE PROPPING THE BODY OF A SERVICE HOIST UNIT (CONTINUED) 12. NEVER open the override valve when the body is elevated. 13. Perform the maintenance or service procedures. Figure 27. Factory Body Props Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A.

  • Page 76: Propping The Body Of A Service Lift (Serviceable Eject) Unit

    BODY AND TAILGATE PROPPING THE BODY OF A SERVICE LIFT (SERVICEABLE EJECT) UNIT Operators MUST KNOW how to SAFELY prop up the unit’s body. You may need to prop the body up when you clean the inside of the body or for maintenance or repair procedures. Observe and obey the following DANGER and WARNING notices while you use a service lift to raise the body.
  • Page 77 BODY AND TAILGATE PROPPING THE BODY OF A SERVICE LIFT (SERVICEABLE EJECT) UNIT (CONTINUED) The factory-supplied body props are located on both sides under the body and forward of the rear wheels. Refer to the figure to the right and carefully follow the body propping procedures below. Follow These Steps to Raise the Body: 1.
  • Page 78 BODY AND TAILGATE PROPPING THE BODY OF A SERVICE LIFT (SERVICEABLE EJECT) UNIT (CONTINUED) 8. Using the lifting device, slowly lift the body in a controlled manner high enough to lower the factory body props. See the figure below. 29. Front Body Chain Hook Lugs 9.
  • Page 79 BODY AND TAILGATE PROPPING THE BODY OF A SERVICE LIFT (SERVICEABLE EJECT) UNIT (CONTINUED) 10. Using the lifting device, slowly lower the body in a controlled manner until the body is resting on the prop stands. See the figure below. 31.

  • Page 80: 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 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.

  • Page 81: Side Access Doors

    BODY AND TAILGATE SIDE ACCESS DOORS Hinged access doors are located on each side of the unit. See the figure below. WARNING Make sure the unit is in the Lock-Out/Tag-Out mode when you do maintenance or service procedures, when you go in the hopper, enter the side access doors, or climb on the body or equipment.

  • Page 82: Main Control And Regenerative Valves

    BODY AND TAILGATE MAIN CONTROL AND REGENERATIVE VALVES The image below shows the regenerative valve and body valve locations on the street side of the unit. Issued July 2024 Copyright 2024, The Heil Co. Body and Tailgate Printed in the U.S.A.

  • Page 83: Regenerative Valve

    BODY AND TAILGATE REGENERATIVE VALVE (031-6227) Part time regenerative valve during packer extend. Full time dump valve during packer retract. Also see Regenerative Valve Troubleshooting Guide Figure 34. Regenerative Valve Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body and Tailgate...

  • Page 84: Air Supply Regulator

    BODY AND TAILGATE AIR SUPPLY REGULATOR – PNEUMATIC DIAGRAMS Figure 35. Air Supply Regulator WELDING AND ELECTRONIC DEVICES / ELECTRICAL LUBRICANTS Before welding on any unit with electronic devices like the Cortex Controller™, electronic control units (ECUs), and 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.

  • Page 85: Repairing Cracked Weld Joints

    BODY AND TAILGATE 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. INSPECT PROXIMITY SWITCHES See Proximity Switch Troubleshooting for recommended procedures for inspecting proximity switches.
  • Page 86 NOTES Issued July 2024 Copyright 2024, The Heil Co. Maintenance and Adjustment Printed in the U.S.A.

  • Page 87: Maintenance And Adjustment

    Maintenance and Adjustment SECTION 5 MAINTENANCE AND ADJUSTMENT Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Maintenance and Adjustment...

  • Page 88: 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 89: 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 90 Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE to female pilot of PTO pump flange. Failure to lubricate female pilot of PTO as given may cause damage to the pump shaft. Greasing is NOT required on wet spline PTOs such as the Chelsea 890/897 series.

  • Page 91: 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 92: 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. Also see Lift Arm Lubrication Guide.

  • Page 93: Pack/Eject Cylinders Maintenance

    Maintenance and Adjustment PACKER/EJECTOR CYLINDERS 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 94: Pressure Adjustments

    Maintenance and Adjustment PRESSURE ADJUSTMENTS 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. MAKE SURE the unit is on flat, stable ground and apply the parking brake and chock the wheels. 3.
  • Page 95 Maintenance and Adjustment PRESSURE ADJUSTMENTS (CONTINUED) C.Standard Pressures and Cycle Times ® ® DURAPACK PYTHON STANDARD PRESSURES AND CYCLE TIMES ® MODEL LIFT LIFT UP / GRABBER REACH BODY PACKER TOP DOOR LIFT CYCLE PACKER CNrG MAIN DOWN RELIEF RELIEF MAIN PRESSU TIME...
  • Page 96 Maintenance and Adjustment PRESSURE ADJUSTMENTS (CONTINUED) D.Packer Pressure Switch (Continued) 7. For Operate-In-Gear-At-Idle units, start the engine, leave it idling and place the transmission in neutral. Set the parking brake. 8. Deadhead the packer fully extended. 9. Increase the pressure switch setting until the test light stays on. 10.
  • Page 97 Maintenance and Adjustment 5. Using allen wrench loosen jam nut on body main relief. 6. Using allen wrench on main relief adjusting screw, adjust main relief by turning "in" (clockwise) to increase pressure or “out” (counter-clockwise) to decrease pressure. 7. Using allen wrench tighten jam nut. When tightening jam nut, use allen wrench to hold adjusting screw to prevent adjustment screw from turning.

  • Page 98: Regenerative Valve (031-6227) Troubleshooting Guide

    Maintenance and Adjustment REGENERATIVE VALVE (031-6227) TROUBLESHOOTING GUIDE Issued July 2024 Copyright 2024, The Heil Co. Maintenance and Adjustment Printed in the U.S.A.
  • Page 99 Maintenance and Adjustment REGENERATIVE VALVE (031-6227) TROUBLESHOOTING GUIDE (CONTINUED) Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Maintenance and Adjustment...
  • Page 100 Maintenance and Adjustment REGENERATIVE VALVE (031-6227) TROUBLESHOOTING GUIDE (CONTINUED) Issued July 2024 Copyright 2024, The Heil Co. Maintenance and Adjustment Printed in the U.S.A.

  • Page 101: Packer/Ejector Panel Adjustment

    Maintenance and Adjustment PACKER/EJECTOR PANEL ADJUSTMENT Proper maintenance of the packer panel and ejector panel is important to the overall operation of the unit. Failure to maintain proper adjustment can affect payload and cause cylinder or structural damage. A. Retract Stroke Make this adjustment with the hydraulic system at operating temperature and the engine RPM held at a level to cause the packer panel to move at its fastest speed during retract.

  • Page 102: 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 103: 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 104: 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 105 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.

  • Page 106: Purge The Hydraulic System

    Maintenance and Adjustment PURGE THE HYDRAULIC SYSTEM If the hydraulic system becomes contaminated because of component failure or some other reason, you must purge the hydraulic system. To purge the system, follow these steps: 1. Extend the packer/ejector cylinder to lower the oil level in the tank. 2.

  • Page 107: Tailgate Lubrication

    Maintenance and Adjustment TAILGATE LUBRICATION See Grease Lubrication Recommendation and Body Lubrication Guidein this section. CLEAN AND INSPECT THE TAILGATE SEAL Daily, 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.
  • Page 108 NOTES Issued July 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.

  • Page 109: Body Controller Hardware

    Body Controller Hardware SECTION 6 BODY CONTROLLER HARDWARE Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body Controller Hardw are...
  • Page 110 Body Controller Hardware NOTES Issued July 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.

  • Page 111: Cortex Controller™ 40 I/O Assembly

    Body Controller Hardware CORTEX CONTROLLER™ 40 I/O ASSEMBLY Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body Controller Hardw are...
  • Page 112 Body Controller Hardware CORTEX CONTROLLER™ 40 I/O ASSEMBLY There are no serviceable parts within the Cortex Controller™ housing. Refer to the figure below. Do not open the Cortex Controller™ housing. Send the Cortex Controller™ to Heil Environmental for repair or programming. Figure 43.

  • Page 113: Pin Number Diagram

    Body Controller Hardware CORTEX CONTROLLER™ PIN NUMBER DIAGRAM Refer to the figure below for the Cortex Controller™ female pin locations. Figure 44. Cortex Cable Connection, Female Pin Positions. CORTEX CONTROLLER™ 55-POLE CABLE ASSEMBLY Follow these steps to assembly the Cortex Controller Cable. A.
  • Page 114 Body Controller Hardware Figure 45. Cable Controller Plastic Male Hinge Pins and Controller Female Slot Connectors Issued July 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.
  • Page 115 Body Controller Hardware CORTEX CONTROLLER™ 55-POLE CABLE ASSEMBLY (CONTINUED) B. Female Controller Connector Close-Up View See the figure below to identify the controller female connector. Figure 46. Female Controller Connector Slots Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body Controller Hardw are...
  • Page 116 Body Controller Hardware CORTEX CONTROLLER™ 55-POLE CABLE ASSEMBLY (CONTINUED) C.Connecting the 55-Pole Cable Connector Refer to the figure below and then slide cable male connectors into controller female connectors. Figure 47. Cable Connector Pivoting on Controller Issued July 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.
  • Page 117 Body Controller Hardware CORTEX CONTROLLER™ 55-POLE CABLE ASSEMBLY (CONTINUED) D.Pivot Cable Connector and Latch 1. While keeping left side of cable connector seated, carefully pivot cable connector until flush with controller. See the figure below. Figure 48. Slowly Press Down While Keeping Left Cable Connector Pivot Point in Place 2.
  • Page 118 Body Controller Hardware 3. To remove cable from controller, reverse above process. Issued July 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.

  • Page 119: Insight™ Standard Diagnostic Display

    Body Controller Hardware INSIGHT™ STANDARD DIAGNOSTIC DISPLAY See the figures below for front and rear photos and rear illustration. Contact Heil for re-programming of the display. Figure 50. Insight Display Front Photo Figure 51. Insight Display Rear Photo M12 connector M52 thread for fixing nut Locating pins Figure 52.

  • Page 120: Diagnostic Display Cable

    Body Controller Hardware INSIGHT™ STANDARD DIAGNOSTIC DISPLAY CABLE See the figure below for a rear view of the display with cable connected. Figure 53. Rear View of Display with Cable Connected CORTEX CONTROLLER™ PROGRAMMING Contact Heil Environmental for re-programming of the Cortex Controller. PROGRAMMING CABLES AND ADAPTERS Description Part Number...

  • Page 121: Body Controller Software

    Body Controller Software SECTION 7 BODY CONTROLLER SOFTWARE Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Body Controller Softw are...

  • Page 122: Automated Side Loader Cortex Controller™ Program 109-0285

    Body Controller Software Automated Side Loader Cortex Controller™ Program 109-0285 (Rev 20210223) Section 1: CORTEX Controller Hardware 1.01: CORTEX Controller Indicator Lights The CORTEX Controller used here is a single control unit with 40 Input / Outputs, which operates with a voltage ranging from (10 to 32) Volt DC.
  • Page 123 Body Controller Software 1.06: CORTEX - Connector Pin Details The table below gives connection details between CORTEX Controller Input/output and Connector Pins. Connect PROGRAM: 109-0285 REVISION: 20191118 Automate Pin-Out d Side Detail ASL – (7000 O.I.G.A.I / O.I.N / Multipack / Python) Unit Loader Unit STANDARD INPUTS...
  • Page 124 Body Controller Software B03 LIFT LOWERED PROX (PYTHON UNIT) %IX0.06 P1-11 B04 THROTTLE ADVANCE SWITCH (MULTIPACK UNIT) %IX0.06 P1-11 B05 LIFT RAISED PROX (7000 O.I.G.A.I. AND O.I.N. UNITS) %IX0.06 P1-11 B06 PACKER TRAVEL POSITION SWITCH %IX0.13 P1-2 B07 TRASMISSION TEMPERATURE SWITCH %IX0.13 P1-2 B08 IN-CAB ENABLE, REAR STROBE...
  • Page 125 Body Controller Software D07 LIFT RAISE INTERLOCK (O.I.G.A.I. AND O.I.N. UNITS WITH 3 LEVER) %QX0.10 P1-40 D08 GRABBER OPEN SOLENOID (PYTHON) %QX0.11 P1-22 GRABBER OPEN INTERLOCK SOLENOID (O.I.G.A.I. AND O.I.N. UNITS WITH 3 %QX0.11 P1-22 LEVER) D10 JOYSTICK ENABLE (MULTIPACK OR PYTHON) %QX0.13 P1-42 D11 TRANS TEMP INDICATOR (7000 O.I.G.A.I)
  • Page 126 Body Controller Software CLUTCH SHIFT PTO PUMP TANDEM VANE 1-45 1-45 1800 1500 1800 PUMP 25 default 25 default 3.03 PYTHON PUMP OPERATION PUMP VANE PUMP CONTROL MANIFOLD GROUND SPEED PUMP 1 PUMP 1 PUMP 2 MAX. MAX. PUMP 2 MAX. MAX.
  • Page 127 Body Controller Software 3.06: Option Config Python OIGAI Option Description Conflicts Body Raised Ind ON, enables Body Raised warning and indicator circuits. Intended for Dump None Bodies Rear Strobe Not Used Rear Strobe Pump Not Used Front Strobe ON, enables Front Strobe Output Out of Dim.
  • Page 128 Body Controller Software Front Strobe Pump Not Used Low Torque Limit ON, Enables Low Torque Pressure Switch Function None Lift Stow ON, Allow operator to stow the lift Grabber Open and Lift Retract on the fly. None Coordinated Dump ON, Enables Auto Lift None Low Hyd Oil Ind ON, Enables Low Oil Level Detection...
  • Page 129 Body Controller Software Select Truck Type Allow Program Setup, Chooses Body Type J1939 Baud Rate Changes controller J1939 Baud Rate 250k/500k Section 4: I/O Functions The following sheets details Input, and Output functions provided through the CORTEX Controller. Note: Status of all the Inputs/Outputs can be monitored using the Insight In-Cab display. Refer section 5.05 for more details about Diagnostic display options and INSIGHT display.
  • Page 130 Body Controller Software Function Logic: Input Device Status I/O Address Status Filter Pressure Switch Activated %IX0.05 A06 Packer Full Retract Proximity Switch (Input %IX0.07) This circuit monitors the ON/OFF status of the Packer Retract Proximity Switch. This input is ON when the Packer has reached its home position (i.e.
  • Page 131 Body Controller Software Function Logic: Input Device Status I/O Address Status Low Torque Pressure Activated %IX2.05 Switch A08 Packer Extend Push Button (Input %IX0.14) This circuit monitors the ON/OFF status of the Packer Extend button. When this button is pressed, the Packer Extend input is Function Logic: Input Device Status...
  • Page 132 Body Controller Software A13 Grabber Full Open Proximity Switch (Input %IX2.00) This circuit monitors the ON/OFF status of the Grabber Open proximity switch. This input is ON when the Grabber is fully Open (i.e. Release the Can). Function Logic: Input Device Status I/O Address Status...
  • Page 133 Body Controller Software A19 Lift Retracted Proximity Switch (Input %IX2.07) This circuit monitors the ON/OFF status of the Lift Retracted Switch. This input is ON when the Lift is in the stowed position. Function Logic: Input Device Status I/O Address Status Lift Retracted Prox.
  • Page 134 Body Controller Software B04 Throttle Advance Switch (Input %IX0.06) This circuit monitors the ON/OFF status of the tailgate Throttle Advance Switch. This circuit is used only on a MULTIPACK unit. Related Option Configurations Selected Truck Status Functionality Multi-Pack Input %IX0.06 Is Used as Throttle Advance Switch. Function Logic: Input Device Status...
  • Page 135 Body Controller Software Transmission Temp. Switch Activated %IX0.13 B08 Rear Strobe In-Cab Enable (Input %IX1.07) This input is controlled by the strobe light switch in the control panel and is used to enable Tailgate mounted strobe lights. Related Option Configurations Option Status Functionality Low Hyd.
  • Page 136 Body Controller Software Selected Truck Type 7000 OIN Input %IX2.01 Is Used as Body Lowered Prox. Selected Truck Type 7000 OIGAI Input %IX2.01 Is Used as Body Lowered Prox. Selected Truck Type Python OIGAI Input %IX2.01 Is Used as Body Lowered Prox. Function Logic: Input Device Status...
  • Page 137 Body Controller Software Related Option Configurations Option Status Functionality Selected Truck Type 7000 OIN Configures controller for DPF 7000, Operate in Neutral Selected Truck Type 7000 OIGIA Configures controller for DPF 7000, Operate in Gear at Idle Selected Truck Type Python OIGIA Configures controller for DPF Python, Operate in Gear at Idle Selected Truck Type...
  • Page 138 Body Controller Software Note: With the hydraulic system enabled and, condition (A AND B) true, OR C true, will activate (Packer Pump). Selected Truck Type (PYTHON) Option Configurations Low Torque Limit Input %IX0.12 (Low Torque Press Sw.) disengages Pump 2 Condition Logic Function or Component...
  • Page 139 Body Controller Software Coordinated Dump Enables Auto-Lift Lift Stow Enables Lift Auto Stow Condition Modifiable Parameters Default Setting Grabber Close Time 1.74 Sec. Conditions Necessary to activate the circuit: Condition Logic Function or Component Status I/O Address Status Auto-Lift Joystick Enable Activated Grabber Close Button Activated...
  • Page 140 Body Controller Software Grabber Open Button Deactivated %IX0.01 Note: During the Auto-Pack cycle (condition A true), condition ((B OR C OR D) AND E) will activate the output. Retract function can be manually operated by pressing the Retract button (A1 AND A2) . Condition ‘E’ will initiate a Retract action during an Auto-Pack cycle.
  • Page 141 Body Controller Software and Joystick Enabled Activated %QX0.13 Note: This Output can be used in MULTIPACK and PYTHON units. With Condition (B AND C) true condition A will activate the Lift Raise output. With Auto-Lift mode enabled the Grabber Close button will close the Grabber for the duration of the Grabber Close Time, then trigger the Lift Raise and Retract functions to bring the lift into the dump position.
  • Page 142 Body Controller Software Note: With condition (A OR B) true, the Lift Extended Indicator will be activated. C09 Tailgate Open Indicator (In Cab Output %QX0.12) This output function controls the Tailgate Open indicator light. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component...
  • Page 143 Body Controller Software Note: With conditions (A) true, conditions (B OR C OR D OR E OR F) will engage the pump within the speed parameters. 11 In Cab Alarm (Output %QX0.15) This output function controls the Cab Alarm circuit. Related Option Configurations Option Status...
  • Page 144 Body Controller Software D01 Body Raised Indicator (Output %QX0.01) This output function controls the Body Raised Indicator light Related Option Configurations Option Status Functionality Body Raise Ind Input %IX2.01 Is Used as Dump Body Down Prox. Conditions Necessary to activate the circuit: Condition Function or Component Status...
  • Page 145 Body Controller Software D04 Front Strobe Light (Output %QX0.06) This circuit operates the Front Strobe light circuit. Related Option Configurations Option Status Functionality Front Strobe Output %QX0.06 Is Used as Front Strobe Circuit Out of Dim. Signal Disabled Republic Input %IX1.07 Is Used as Turn Signal, Rear Strobes are disabled with chassis turn signal Conditions Necessary to activate the circuit: Condition...
  • Page 146 Body Controller Software D06 Grabber Close Solenoid, (Output %QX0.10) This output function controls the Grabber Close circuit. The lift has two modes for lift operation, Auto-Lift mode and Manual mode. The default mode is Manual mode. To toggle the control between the two modes, press and hold the Grabber Close and Grabber Open buttons simultaneously for five seconds or until the In-Cab alarm stops sounding.
  • Page 147 Body Controller Software D08 Grabber Open Solenoid (Output %QX0.11) This output function controls the Grabber Open circuit. The lift has two modes for lift operation, Auto-Lift mode and Manual mode. The default mode is Manual mode. To toggle the control between the two modes, press and hold the Grabber Close and Grabber Open button simultaneously for five seconds or until the In-Cab alarm stops sounding.
  • Page 148 Body Controller Software Conditions Necessary to activate the circuit: Condition Logic Function or Component Status Status Address Grabber Lift Interlock Activated Lift Raised Proximity Activated %IX0.06 Note: This Output can be used only in 7000 (O.I.G.A.I / O.I.N) units with 3 lever control. Conditions (A AND B) true, will activate the Grabber open Interlock output.
  • Page 149 Body Controller Software Note: This Output is used only in MULTIPACK or PYTHON units. The output will come ON under three distinct conditions: 1. Pump Enabled (A), Engine Speed < 900 RPMs(B) and the chassis is in Neutral (C). (i.e. stationary operation.) 2.
  • Page 150 Body Controller Software Select-O-Pack Adjustment: 1. Turn the System Power OFF 2. Press and hold the Retract Button for 5 seconds (The beeper will begin to sound at 5 seconds) 3. Each additional activation of the Retract Button will allow one additional lift cycle before automatically packing the load.
  • Page 151 Body Controller Software Fig: INSIGHT Display Unit 5.05.01: Operating Elements INSIGHT is a basic 2.8” color Display unit, which consists of 4 freely programmable backlit function keys and a H.M.I (Graphic) display terminal: The display is fitted with the following operating elements: 1.
  • Page 152 Body Controller Software Operating State Transition Conditions Flashing States Color Frequency 1. Operating system initialized or INIT state 2.Waiting for correct supply voltage Yellow (Reset) 3. Temporary state replaced by RUN or STOP Run state Operating voltage reached minimum value Green 2 Hz Green...
  • Page 153 Body Controller Software 5.05.04: Display Status LED’s: LED Color Flashing Description Frequency Permanently OFF No Operating Voltage Green 5 Hz No Operating system loaded Green 2 Hz RUN State (application is running) Green Permanently ON STOP State (application stopped) 5 Hz Application stopped due to under voltage Permanently ON FATAL ERROR or STOP state with error...
  • Page 154 Body Controller Software code. There are two classes of faults the first is a system fault. A system fault indicates a possible electrical problem with some part of a specific circuit. The second is a Critical Fault. A critical fault indicates that a problem is occurring which has or will shut the hydraulic pump system down.
  • Page 155 Body Controller Software Indications: A. Low Hydraulic Oil B. Signal wire break or disconnect. Disabled Functions: Hydraulic Pump Fault Reset: Fill Oil Tank or Restore Low Oil signal. Fault #41- Critical Fault, J1939 Engine Comms Error (standard equipment) The CORTEX Controller has is not receiving J1939 engine messages. Indications: A.
  • Page 156 Body Controller Software Indication: A. The filter bypass pressure switch has been disconnected. B. An open has occurred in the filter bypass input circuit. C. The filter pressure switch has failed to open. Disabled Functions: None Fault Reset: Cycle System Power Switch or Restore filter pressure switch input to CORTEX Controller Note: This fault is applicable on dry valve pump units only.
  • Page 157 Schematics SECTION 9 SCHEMATICS Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 158: Cortex Controller™ Cab Schematic - 701-9064-001

    SCHEMATIC, CAB CONTROLS, DPF PYTHON, 7000, MULTIPACK 701-9064-001 8/23/2012...

  • Page 159: Cortex Controller™ Cab To Body Schematic - 701-9064-002

    SCHEMATIC, CAB TO BODY, DPF PYTHON, 7000, MULTIPACK 701-9064-002 8/7/2012...

  • Page 160: Cab Controls Ifm R2000 - 701-9064-003

    SCHEMATIC, CAB CONTROLS 701-9064-003 8/27/12...

  • Page 161: Rp170 Cab Electrical Schematic, Non-7 Waste Management, Non-Power Of One - 701-9064-009

    SCHEMATIC, CAB ELECT DPF PYTHON (RP170) 701-9064-009 5/15/18...

  • Page 162: Rp170 Cab Electrical Schematic, Waste Management, Non-Power Of One - 701-9064-010

    SCHEMATIC, CAB ELECTRICAL 2020 PYTHON (RP170) CHASSIS 701-9064-010 07/18/18...

  • Page 163: Control Panel, Rp170 Cab Electrical Schematic, Waste Industries, Power Of One - 701-9064-101

            108-8610 E F G H FUSES SHOWN PLUGGED REAR STROBE REFERENCE ABOVE DIAGRAM FOR RELAY 108-8610 FUSE HOLDER CONNECTOR PIN OUT. F3 15A F1 15A F2 15A IGNITION RELAY 108-8610 TO CHASSIS RP170 (POWER AND GROUND) CONNECTOR THROTTLE...

  • Page 164: Rp170 Chassis Electrical Schematic, Waste Industries, Power Of One - 701-9064-102

    (OPTIONAL) (OPTIONAL) (OPTIONAL) TO CHASSIS RP170 OIL LEVEL FRONT MOUNT HOT SHIFT PTO (EXTERIOR LIGHTING) SWITCH HYDRAULIC PUMP MOUNT HYDRAULIC CONNECTOR PUMP NO CONNECTION TO BODY HARNESS, OUTPUT DEVICE (OPTIONAL) (OPTIONAL) LIFT CONTROL SOLENOIDS CAB FLOOD CAB STROBE (GREEN) (YELLOW) (BLUE) (RED) TO BODY HARNESS, INPUT DEVICE...

  • Page 165: Cab Pneumatic Schematic, Power Of One - 701-9064-103

    PNEUMATIC DIAGRAM, CAB DPF PYTHON, INTEGRATED AUTOCAR 701-9064-103 6/26/17...

  • Page 166: Chassis Pneumatic Schematic, Power Of One - 701-9064-104

    PNEUMATIC DIAGRAM, BODY/LIFT DPF PYTHON, INTEGRATED AUTOCAR 701-9064-104 6/26/17...

  • Page 167: Control Panel, Rp170 Cab Electrical Schematic, Waste Management, Power Of One - 701-9064-111

            SCHEMATIC CAB ELECTRICAL 2020 WM PYTHON, POWER OF ONE 701-9064-111 10/15/19...

  • Page 168: Control Panel, Rp170 Chassis Electrical Schematic, Waste Management, Power Of One - 701-9064-112

    SCHEMATIC, CHASSIS ELECTRICAL 2020 WM PYTHON, POWER OF ONE 701-9064-112 10/15/19...

  • Page 169: Hydraulic Schematics

    Schematics HYDRAULIC SCHEMATICS Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 170: Durapack Python Dump Non-Hoc Lift Valve Hydraulic Schematic - 701-8776

    DP PYTHON DUMP NON HOC LIFT VALVE HYDRAULIC SCHEMATIC 701-8776 10/09...

  • Page 171: Durapack Python Eject Non-Hoc Lift Valve Hydraulic Schematic - 701-8777

    DP PYTHON EJECT NON HOC LIFT VALVE HYDRAULIC SCHEMATIC 701-8777 10/09...

  • Page 172: Lift Arm Hydraulic Schematic

    Schematics LIFT ARM HYDRAULIC SCHEMATIC NOTE: Solenoid “A” is energized when pump is tuned on. Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 173: Lift Arm Up And In Flow Diagram - 701-8776-001

    Schematics LIFT ARM UP AND IN FLOW DIAGRAM - 701-8776-001 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 174: Lift Arm Release Flow Diagram - 701-8776-002

    Schematics LIFT ARM RELEASE FLOW DIAGRAM - 701-8776-002 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 175: Lift Arm Grab Flow Diagram - 701-8776-003

    Schematics LIFT ARM GRAB FLOW DIAGRAM - 701-8776-003 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 176: Lift Arm Reach In Flow Diagram - 701-8776-004

    Schematics LIFT ARM REACH IN FLOW DIAGRAM - 701-8776-004 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 177: Lift Arm Reach Out Flow Diagram - 701-8776-005

    Schematics LIFT ARM REACH OUT FLOW DIAGRAM - 701-8776-005 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 178: Lift Arm Down Flow Diagram - 701-8776-006

    Schematics LIFT ARM DOWN FLOW DIAGRAM - 701-8776-006 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 179: Non-Regenerative Packer Extend Flow Diagram For Dump Units - 701-8433-007

    Schematics NON-REGENERATIVE PACKER EXTEND FLOW DIAGRAM FOR DUMP UNITS - 701-8433-007 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 180: Regenerative Packer Extend Flow Diagram For Dump Units - 701-8433-007

    Schematics REGENERATIVE PACKER EXTEND FLOW DIAGRAM FOR DUMP UNITS - 701- 8433-007 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 181: Body Lower Flow Diagram - 701-8433-009

    Schematics BODY LOWER FLOW DIAGRAM - 701-8433-009 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 182: Body Raise Flow Diagram - 701-8433-009

    Schematics BODY RAISE FLOW DIAGRAM - 701-8433-009 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 183: Non Regenerative Packer Extend Flow Diagram For Eject Units - 701-8433-010

    Schematics NON REGENERATIVE PACKER EXTEND FLOW DIAGRAM FOR EJECT UNITS - 701-8433-010 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 184: Regenerative Packer Extend Flow Diagram For Eject Units - 701-8433-010

    Schematics REGENERATIVE PACKER EXTEND FLOW DIAGRAM FOR EJECT UNITS - 701- 8433-010 Issued July 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 185: Tailgate Raise And Tailgate Lower Flow Diagrams - 701-8433-5

    Schematics TAILGATE RAISE AND TAILGATE LOWER FLOW DIAGRAMS - 701-8433-5 Copyright 2024, The Heil Co. Issued July 2024 Printed in the U.S.A. Schematics...

  • Page 187: Index

    INDEX flow diagram, body lower flow diagram, body raise access doors flow diagram, lift arm down air supply regulator flow diagram, lift arm grab automated side loader Cortex Controller™ software flow diagram, lift arm reach in program 109-0285 flow diagram, lift arm reach out flow diagram, lift arm release flow diagram, lift arm up and in battery disconnect switch...
  • Page 188 INDEX tailgate lubrication tailgate nomenclature main control valve tailgate support props maintenance/lubrication information tandem vane pump O.I.G.A.I. hydraulic system mount pump monoblock to tandem pump troubleshooting tandem vane pump with monoblock separate outlet flow torque for hydraulic tubes and fittings notice universal belt and tri-cuff grabber adjustments oil lubrication recommendation...
  • Page 189 HEIL ENVIRONM ENT AL WARRANT Y ST AT EM ENT 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 190 www.heil.c om Cus tom er Care: 866-ASK-HEIL (866-275-4345) The Heil Co. 4301 Gault Avenue North Fort Payne, AL 35967-9984 Parts Central: 800-528-5308 Tec hnic al Servic e: 866-310-4345 Tec hSupport@DoverESG.c om...

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