Dover HEIL Command-SST Operation And Service Manual
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Dover HEIL Command-SST Operation And Service Manual

Dover HEIL Command-SST Operation And Service Manual

Automated side loader
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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
for this unit, other applicable manufacturers' manuals, and
the safety decals on the product.
Each operator of this unit must read and understand all
AUTOMATED SIDE LOADER
directions in this manual before they first operate this
OPERATION AND SERVICE MANUAL
vehicle.
Keep this manual in the cab for new operators and to
ISSUED JUNE 2020
remind all operators about safe use.
© 2020 Heil Environmental
TP1C-OM-0620

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  • Page 1 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 for this unit, other applicable manufacturers' manuals, and...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Introduction Contact Information ........................................4 How to Use This Manual ........................................5 Warranty Claims and Inquiries ........................................6 Electronic Parts Catalog ........................................7 Electronic Parts Catalog (Continued) ......................................8 Electronic Parts Catalog (Continued) ......................................9 Electronic Parts Catalog (Continued) ......................................10 Electronic Parts Catalog (Continued) ......................................11 Models ........................................12...
  • Page 4 TABLE OF CONTENTS Daily Checks and Inspections ......................................56 Features ........................................63 Features ......................................64 Features (Continued) ......................................65 Operation Specifications ......................................66 Operation Specifications (Continued) ......................................67 Operation Modes ......................................68 Operation Modes (Continued) ......................................69 Controls ........................................70 Main Push Button Controls ......................................71 Supporting Functions Push Button Controls ......................................72 Manual Control Push Button Controls ......................................73...
  • Page 5 TABLE OF CONTENTS Lifting and Loading Refuse (Continued) ......................................90 Compacting the Load ......................................91 Leaving the Route for the Landfill/Transfer Station (Continued) ......................................92 Landfill/Transfer Station/Recycle Center Procedures ........................................93 Setting up an Eject Unit for Unloading ......................................94 Unloading an Eject Unit ......................................95 End of Day Procedures ........................................98 ........................................100...
  • Page 6 TABLE OF CONTENTS Hydraulic Warm Up Temp Adjust Screen ......................................120 Cortex Controller Locations ........................................122 Cortex Controller Nodes ........................................123 Unit Calibration ........................................124 Unit Calibration (Continued) ........................................125 Unit Calibration (Continued) ........................................126 Body Controller Software ........................................127 Maintenance Recommended Spare Parts ........................................130 Body Preventive Maintenance ........................................133 Body Preventive Maintenance Chart ......................................134...
  • Page 7 TABLE OF CONTENTS Pump ......................................154 Electrical ........................................164 Sensors ......................................165 Schematics Electrical Schematics ........................................168 Electrical Schematic, Main Controller - 701-9287-010 ......................................169 Electrical Schematic, Body - 701-9287-011 ......................................170 Electrical Schematic, Body Valve - 701-9287-012 ......................................171 Electrical Schematic, Lift Valve - 701-9287-013 ......................................172 Electrical Schematic, Tailgate Valve - 701-9287-014 ......................................173 Electrical Schematic, Cab to Body RP 170 - 701-9287-016...
  • Page 8 TABLE OF CONTENTS Hydraulic Schematic, Oil Warming - 701-9298-012 ......................................192 Hydraulic Schematic, Tailgate Lock - 701-9298-013 ......................................193 Hydraulic Schematic, Tailgate Unlock - 701-9298-014 ......................................194 Hydraulic Schematic, Tailgate Raise - 701-9298-015 ......................................195 Hydraulic Schematic, Tailgate Down - 701-9298-016 ......................................196 Hydraulic Schematic, Top Door Close - 701-9298-017 ......................................197 Hydraulic Schematic, Top Door Open - 701-9298-018 ......................................198...
  • Page 9 TABLE OF CONTENTS CNG Fuel System Maintenance ........................................220 Maintenance Part Numbers ......................................221 Depressurizing/Re-Pressurizing Procedure ......................................222 Depressurizing/Re-Pressurizing Procedure (Continued) ......................................223 High Pressure Filter ......................................224 Welding and Hot Work Procedures ......................................225 Lifting the Vehicle / Towing the Vehicle ......................................226 CNG Fuel System Inspections ........................................227 Inspection/Preventive Care Schedule / Preparation Before Maintenance ......................................228...
  • Page 10 TABLE OF CONTENTS ......................................248 ......................................249 ......................................250 ......................................251 ......................................252 ..................................253 Index Issued June 2020 Copyright 2020, Heil Environmental Table of Contents Printed in U.S.A.
  • Page 11 AUTOMATED SIDE LOADER OPERATION AND SERVICE MANUAL ISSUED JUNE 2020 TP1C-OM-0620 Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.
  • Page 12 NOTES:...
  • Page 13 SECTION 1 INTRODUCTION Issued June 2020 Copyright 2020, Heil Environmental Introduction Printed in U.S.A.

  • Page 14: Introduction

    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 June 2020 Copyright 2020, Heil Environmental Introduction Printed in U.S.A.

  • Page 15: How To Use This Manual

    HOW TO USE THIS MANUAL Product Variance Terminology This manual may cover options not included on your unit. This manual uses terminology that is defined in the Also, the location and appearance of the controls on your Glossary which is in Section 1, Introduction. unit may be different than those shown in this manual.

  • Page 16: Warranty Claims And Inquiries

    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. For all parts, warranty claims, and inquiries, please give the dealer or service center the unit’s model and serial number located on the body serial plate.

  • Page 17: Electronic Parts Catalog

    ELECTRONIC PARTS CATALOG The Parts Central Electronic Parts Catalog (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. Note: This tool is currently for reference use only and the cart function is disabled.

  • Page 18: Electronic Parts Catalog (Continued)

    ELECTRONIC PARTS CATALOG (CONTINUED) Registration and Login Register online to gain access: https://epc.partscentral.com. Upon registration, you will receive an email notification confirming registration. Within 24 hours, your registration will be approved and you can log in using the login page. Issued June 2020 Copyright 2020, Heil Environmental Introduction...

  • Page 19: Electronic Parts Catalog (Continued)

    ELECTRONIC PARTS CATALOG (CONTINUED) Log in here with your supplied credentials: https://epc.partscentral.com/ After login, you will land on the User Dashboard. At the top right of the Dashboard, there will be two search fields. See the image below. You can search by Keyword(s) or Part Number within a specific Heil Body Serial Number. For example, if you are looking for the proximity switch for Body Serial Number HPS4959991, you can enter this information into these two fields and the search results will include all parts within the HPS4959991 body that contain the keywords proximity and switch within the part descriptions.

  • Page 20: Electronic Parts Catalog (Continued)

    ELECTRONIC PARTS CATALOG (CONTINUED) From the search results list, select the eye icon on the right to see part specifics (including any notes) or to quickly add it to cart. Alternatively, you can select the right arrow icon to view the part within its associated assembly/kit. Alternatively, you can search by just the Heil Body Serial Number, leaving the Keyword(s) / Part Number field blank.

  • Page 21: Electronic Parts Catalog (Continued)

    ELECTRONIC PARTS CATALOG (CONTINUED) For each assembly/kit, you can click on the interactive part callout reference numbers to highlight the corresponding part in the parts list, or you can click on a parts list line item to highlight its position on the illustration. See the image below. Issued June 2020 Copyright 2020, Heil Environmental Introduction...

  • Page 22: Models

    MODELS Eject Service Hoist Eject and Service Hoist models use a Packer/Eject panel and two cylinders to compact the refuse from the hopper into the body (packer mode) and to push all of the refuse from the body (eject mode). The Eject model does not have Service Hoist Cylinders.

  • Page 23: Serial Plate Locations

    SERIAL PLATE LOCATIONS You determine the sides of the unit by facing the direction of forward travel. The left side is the “street side” and the right side is the “curb side”. The figure below shows the location of the body serial plate on the street side of the unit’s body. The loader serial plate will be located on the loader arm.

  • Page 24: Reading The Body Serial Plate

    READING THE BODY 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 with figure below. FMVSS 115. See the following table. Year of Manufacture Year Code Year Year Code...

  • Page 25: Hydraulic Oil Specifications

    The following oils can be used on Heil products if Heil HYDRAULIC OIL SPECIFICATIONS standard hydraulic oil (Shell Tellus S2 VX 32) is not available. But system performance and/or oil service life Hydraulic fluid is one of the most important component in may be compromised.

  • Page 26: Oil And Grease Lubricant Recommendations

    OIL LUBRICANT RECOMMENDATION NOTES: Use only non-detergent engine oil to lubricate all moveable mechanical parts not furnished with grease fittings. Apply sufficient oil to give good lubrication, but do not bathe parts in oil. Always wipe off excess oil. GREASE LUBRICANT RECOMMENDATION Use a grease gun.

  • Page 27: Product Nomenclature

    PRODUCT NOMENCLATURE Hydraulic Pump - The unit’s hydraulic pump provides the oil 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). The pump is activated when the operator turns ON the SYSTEM POWER switch located on the in-cab control panel and is deactivated when the operator turns OFF the SYSTEM POWER switch.
  • Page 28 Body Props – Always use both body props, one on each side of the unit, when you raise the body for maintenance or service procedures. WARNING Make sure hopper area is clear of people on both sides of unit before starting packer cycle. Packer completes one or two cycles when ANY packer EXTEND button is ON or when Auto-Pack is ON and cart lowers from hopper.
  • Page 29 Side Access Door – Use this street side door to enter the body when required for cleaning or other maintenance tasks. MAKE SURE the unit is in Lock-Out/Tag-Out mode and the keys removed from the ignition and in the operator’s control BEFORE you enter through the side door.
  • Page 30 NOTICE You must use the tailgate lock cylinder (described previously) to unlock the tailgate in order to raise the tailgate or to fully close (lock) the tailgate. DANGER Keep all parts of your body out from underneath the unit’s body and away from the cylinders when raising or lowering the body.
  • Page 31 WARNING Operating the unit’s controls with a suspended load, such as a raised tailgate or a container on a lift mechanism, will allow the load to move even when the hydraulic pump is OFF. Operator Controls – The standard operator controls for running the components are inside the vehicle cab. See Operation section for the different controls that may be installed in your unit.

  • Page 32: Glossary

    GLOSSARY TERM DEFINITION The refuse collection container body The complete body assembly or the area of the body where the refuse is stored. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. collapsed position The fully retracted position of a cylinder Cortex computer control system that continuously monitors the state of input devices and makes...
  • Page 33 GLOSSARY TERM DEFINITION 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). incident An unintended and undesired event that has the potential to harm. Diagnostic Display the information center for the operator and troubleshooting tool for the service mechanic.
  • Page 34 GLOSSARY TERM DEFINITION Revolutions Per Minute The Select-O-Pack feature allows the operator to set the number of lift cycles before automatic operation of the packer. Refer to Features , Select-O-Pack Adjust Screen , Operation Specifications and Compacting the Load for more information. side access door The side access door is located on the street side of the unit.

  • Page 35: Safety Messages And Decals

    SECTION 2 SAFETY MESSAGES AND DECALS Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.

  • Page 36: Precautionary Statements

    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.

  • Page 37: General Safety Precautions

    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.

  • Page 38: General Safety Precautions (Continued)

    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 ControlsOperation section of this manual.
  • Page 39 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.
  • Page 40 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.
  • Page 41 TOWING OF ANY EQUIPMENT Heil DOES NOT recommend that you tow any kind of equipment with the unit. The unit was NOT DESIGNED nor intended for towing. Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.

  • Page 42: Lock-Out/Tag-Out Procedure

    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.

  • Page 43: Decals

    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.

  • Page 44: Decal Placement

    DECAL PLACEMENT Note: DuraPack® Python® Lift Shown Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 45 DECAL PLACEMENT (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 46 DECAL PLACEMENT (CONTINUED) ITEM PART NO. DESCRIPTION ..............- ......REF 212-0980 DECAL, Danger, Stay Clear, Container Off Ground ......- ......1 212-1103 DECAL, Danger, Body Elevated, Large ..........- ......2 212-1104 DECAL, Danger, Body Elevated, Small ..........- ......1 212-1242 DECAL, Danger, Stand Clear, Automated Lift Device In Motion ..
  • Page 47 DECAL PLACEMENT (CONTINUED) ITEM PART NO. DESCRIPTION 212-2875 DECAL, Battery, Warning ..............- ......1 212-3505 ....... - ......1 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.

  • Page 48: Decal Images

    DECAL IMAGES Figure 5. Danger: Elevated body emtpied and propped, PN 212-1103 Figure 4. Danger: Stay clear container off ground, PN 212-0980 Figure 7. Danger: Elevated body propped, PN 212-1104 Figure 6. Danger: Stand clear automatic lift, PN 212-1242 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 49 DECAL IMAGES (CONTINUED) Figure 9. Warning: Figure 10. Danger: Never use bumper as Stand clear tailgate, step, PN 212-1631 PN 212-1634 Figure 8. Danger: Stand clear Figure 11. Danger: Do not enter under chassis, PN 212-1764 tailgate, PN 212-1801 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 50 DECAL IMAGES (CONTINUED) Figure 12. Warning: Lock-out / Tag-out, PN 212-1781 Figure 13. Danger: Access Door Closed, PN 212-1907 Figure 14. Caution: Side Access Door, PN 212-1780 Figure 15. Danger: Not an entrance or exit, PN 212-1642 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 51 DECAL IMAGES (CONTINUED) Figure 16. Warning: Operations Manual, PN Figure 17. Caution: Stand Clear Panel, PN 212-1783 212-1911 Figure 18. Danger: Do not Figure 20. Caution: Figure 19. Warning: use for towing, PN Ladder Battery disconnect 212-1820 safety/balance, PN switch, PN 212-2875 212-1914 Issued June 2020 Copyright 2020, Heil Environmental...
  • Page 52 DECAL IMAGES (CONTINUED) Figure 22. Warning: Overall height, PN 212-1584 Figure 21. Danger: Body Prop Operation, PN 212-1329 Figure 24. Danger: Raise Tailgate before Raising Body, PN 212-1626 Figure 23. Warning: Keep away from gear, PN 212-1330 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 53 DECAL IMAGES (CONTINUED) Figure 26. Warning: Figure 25. Safety Instructions, Proximity Switch Back-up Alarm, PN 212-1918 Adjustment, PN 212-2228 Figure 28. Hydraulic Oil Only, PN 212-1782 Figure 27. Oil Level, PN 212-2275 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 54 DECAL IMAGES (CONTINUED) Figure 30. Keep Sump Door Closed, PN 212-2605 Figure 29. Flag, Made in the USA, PN 212-2689 Figure 32. Safety Requirements, ANSI, PN 212-1841 Figure 31. Auto/Manual Mode, Python Lift, PN 212-2738-010 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 55 DECAL IMAGES (CONTINUED) Figure 34. ANSI Specifications, PN 212-1841 Figure 33. Warning: Overall Height, PN 212-1915 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 56 DECAL IMAGES (CONTINUED) Figure 36.Command-SST Loader Lubrication Guide, PN 212-3505 Figure 35. Body Lubrication Guide, PN 212-3518 Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 57 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.
  • Page 58 PRESSURE WASHER TECHNIQUE Figure 37. Recommended Technique Figure 38. Incorrect Technique Issued June 2020 Copyright 2020, Heil Environmental Safety Messages and Decals Printed in U.S.A.
  • Page 59 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.
  • Page 60 NOTES:...

  • Page 61: Operation

    SECTION 3 OPERATION Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 62: Daily Checklist

    DAILY CHECKLIST Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 63: Daily Checklist

    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.
  • Page 64 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 Air regulator (typically located at front of body)

  • Page 65: Refuse Vehicle Daily Inspection

    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.

  • Page 66: Daily Checks And Inspections

    INSPECTION RESULTS CODE CHECKS AND INSPECTIONS INSPECT PER APPLICABLE MANUFACTURER MANUAL Cab/Drive Wheels and Tires Tractor and Chassis Electrical Chassis Engine & Transmission & Fluid Levels Tractor, 5th Wheel and Chassis Lubrication REFUSE COLLECTION SYSTEMS AND COMPONENTS CAB OUTSIDE AREA Check air pressure of tire.
  • Page 67 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS Hoses for wear and damage Cylinders for damage Loose or missing mounting hardware Worn fiber guards – replace hoses/fittings as necessary – MAKE SURE TO INSTALL FIBER GUARD ON NEW HOSE TO PREVENT HYDRAULIC LEAKS REACHING ENGINE SURFACES WHICH CAN CREATE A FIRE HAZARD Inspect decals on body prop for damage and readability Inspect body structure for damage, loose or missing nuts and bolts and for cracked welds and metal...
  • Page 68 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS 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 BODY AND CHASSIS STREET SIDE INSPECTION Tailgate is locked Inspect tailgate lock components Latch components for wear and damage...
  • Page 69 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS Inspect body mounting brackets for cracked weld, missing bolts or nuts or movement Inspect decals on body prop for damage and readability Inspect level of hydraulic oil if tank is mounted on streetside. It must be full. Add recommended oil as necessary If equipped, the hopper cover is DOWN 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.
  • Page 70 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS Push the System Power knob DOWN – the switch’s red light is OFF and the PUMP ON light is OFF Pull the System Power knob UP – the switch’s red light is ON and the PUMP ON light is ON The FILTER CHANGE light is OFF.
  • Page 71 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS Lower the body completely The BODY T/G UP light and alarm are OFF Open the tailgate The BODY T/G UP light and alarm are ON Set the tailgate props Inspect the tailgate seal for damage Store the tailgate props and raise the tailgate completely Close the tailgate The BODY T/G UP light and alarm are OFF...
  • Page 72 INSPECTION RESULTS CODE CHECKS AND INSPECTIONS 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 June 2020 Copyright 2020, Heil Environmental Operation...

  • Page 73: Features

    FEATURES Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 74: Features

    FEATURES Auto/Manual Pack Mode Auto/Manual Pack Mode is a standard feature on all Cortex Display for displaying the current status of inputs/outputs, engine speed, temperatures, etc. This can also be used for packer will complete its cycle automatically with a configuring or selecting different options in the Cortex momentary activation of the packer extend push button.

  • Page 75: Features (Continued)

    FEATURES (CONTINUED) Spear Mode Lift Light (Continued) When Spear Mode is ON, the loader arm and grabber will Once you have left any of the above-mentioned conditions, be in its preset position to pick cans. See Spearing the Lift Light will remain on for an additional 10 seconds Dimension Adjust Screen before automatically turning OFF.

  • Page 76: Operation Specifications

    OPERATION SPECIFICATIONS Pump System The pump will be on only when the in-cab red Triggered off the grabber release push-button, this SYSTEM POWER switch is activated, the pump system initiates a pack cycle once the programmed push button is ON (Green), the hopper side door is number of lift cycles have been completed.

  • Page 77: Operation Specifications (Continued)

    OPERATION SPECIFICATIONS (CONTINUED) NOTES: Warning Signals The arm extended light will activate any time the arm is extended or grabbers are not fully open. The arm extended light and alarm will activate when the arm is extended or grabbers are not fully open, the transmission is in gear and the foot brake is not applied.

  • Page 78: Operation Modes

    OPERATION MODES C.Coordinated/Manual Mode There are several Operation Modes available to Operators. 1. Description: Switches between Joystick controls and Some modes should only be used by Authorized Service Manual Control Key Pad controls Personnel, such as Service and Calibration Modes. 2.

  • Page 79: Operation Modes (Continued)

    OPERATION MODES (CONTINUED) G.Calibration Mode Follow the InSight Diagnostic Display instructions to WARNING calibrate the unit . Contact Heil Technical Service at 866-310-4345 for more information. Moving equipment can be dangerous. Serious injury or 1. Description: Allows Qualified Service to calibrate the death may occur if a person is in the wrong area or is not unit after a cylinder replacement attentive to the operations.

  • Page 80: Controls

    CONTROLS Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 81: Main Push Button Controls

    6. T/G LOCK - Locks the Tailgate, command active MAIN PUSH BUTTON CONTROLS (Green) or no command (Blue) The Main Push Button Controls are located in the cab. This 7. T/G UNLOCK - Unlocks the Tailgate, command key pad is water-resistant with a lighted ring around each active (Green) or no command (Blue) button.

  • Page 82: Supporting Functions Push Button Controls

    SUPPORTING FUNCTIONS PUSH BUTTON WARNING CONTROLS In Above/Below Grade Mode, there are NO interlocks to prevent the lift arm from striking the body or ground. The Supporting Functions Push Button Controls are Extreme caution must be used when operating the unit in located in the cab.

  • Page 83: Manual Control Push Button Controls

    4. UP - Moves the Lift Arm in the UP direction, ON MANUAL CONTROLS PUSH BUTTON (Green) or OFF (Blue) CONTROLS 5. DOWN - Moves the Lift Arm in the DOWN direction, The Manual Controls Push Button Controls is typically ON (Green) or OFF (Blue) located in the cab, under the curb side seat and can be 6.

  • Page 84: Joystick Controls

    5. UNDUMP - In COORDINATED MODE, push joystick JOYSTICK CONTROLS FORWARD and HOLD for to move lift OUT and DOWN to place container on the ground. Release The joystick controls all of the lift functions and has five (5) joystick to stop the movement of the lift. push buttons to control various functions of the loader.

  • Page 85: Joystick Controls (Continued)

    4. MANUAL ARM RAISE/LOWER WITH JOYSTICK JOYSTICK CONTROLS (CONTINUED) UP/DOWN OR MANUAL UNDUMP (BLUE B. 5 Push-Button Controls BUTTON) The joystick has 5 push-buttons on the handle that a. DEPRESS and HOLD this button while moving control the grabber head rotation, pick angle, pick the joystick FORWARD or BACK to adjust height, can shake and proportional grabber open/close Grabber Head Pick Height.

  • Page 86: Joystick Controls

    H.A.L.O. JOYSTICK CONTROLS (OPTIONAL) NOTES: The optional Heil Autonomous Lift Option (H.A.L.O.) joystick controls all of the lift functions. When equipped, an operator can grab, dump and return a cart to its original location with the push of the red button on the joystick. See Features and Lifting and Loading Refuse Figure 43.

  • Page 87: Propping The Body Of A Service Hoist Unit

    PROPPING THE BODY OF A SERVICE HOIST WARNING UNIT Interconnected body props are installed on the unit. Both Operators MUST KNOW how to SAFELY prop up the props MUST be used. unit’s body. You may need to prop the body up when you clean the inside of the body or for maintenance or repair WARNING procedures.

  • Page 88: Propping The Body Of A Service Hoist Unit (Continued)

    Raising the Body (Continued) PROPPING THE BODY OF A SERVICE HOIST UNIT (CONTINUED) 1. If equipped with quick disconnects, uncouple prior to raising the body. Factory Body Props 2. Make sure there is adequate slack in hoses that do The factory-supplied body props are located on both sides not have disconnects.

  • Page 89: Propping The Body Of A Service Hoist Unit (Continued)

    PROPPING THE BODY OF A SERVICE HOIST NOTES: UNIT (CONTINUED) Raising the Body (Continued) 7. NEVER open the override valve when the body is elevated. 8. Perform the maintenance or service procedures. Lowering the Body 1. PRESS the UP button until the body is not resting on the body props.

  • Page 90: Propping The Tailgate

    Factory Tailgate Props PROPPING THE TAILGATE YOU MUST USE BOTH of the two support props at the YOU MUST prop the tailgate when you open it for service rear of each unit whenever you open the tailgate for service or maintenance. Use the instructions that follow and prop or maintenance.

  • Page 91: Propping The Tailgate (Continued)

    PROPPING THE TAILGATE (CONTINUED) B. How to Store the Tailgate Props 1. When you finish using the props, take the unit out of the Lock-Out/Tag-Out mode, insert the ignition key, and start the engine. 2. RAISE the tailgate enough so that you can REMOVE each prop bar from its pin, then ROTATE each prop so that you can put the props in the stored position.

  • Page 92: Side Access Door

    SIDE ACCESS DOOR A hinged access door is located on the street side of the unit and provides access to the body area for cleanout purposes. Never enter the door unless the truck engine is stopped, the ignition key is removed, and the unit is in Lock-Out/Tag-Out mode .

  • Page 93: Before Starting A Route / Cold Weather Warmup Procedure

    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.

  • Page 94: Battery Disconnect Switch / Storing Refuse In The Body

    BATTERY DISCONNECT SWITCH NOTES: The battery box is typically located on the streetside of the chassis frame near the front of the body, however it can be mounted at a different location on different chassis. Become familiar with the location of the battery box and battery disconnect switch on your unit.

  • Page 95: Check Hydraulic Oil Level

    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.

  • Page 96: Check The Traveling Or "In-Transit" Position

    Use of Curbside Drive CHECK THE TRAVELING OR “IN-TRANSIT” POSITION If equipped, drive from the curbside driver position ONLY on the collection route. DO NOT use this station during Whenever you drive to and from a route, along the route travel to and from a route, landfill, or transfer station.

  • Page 97: On-Route Operation Procedures

    ON-ROUTE OPERATION PROCEDURES Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 98: Driving To Pick-Up Locations

    Use of Curbside Drive DRIVING TO PICK-UP LOCATIONS If equipped, drive from the curbside driver position ONLY Whenever you drive to and from a route, along the route on the collection route. DO NOT use this station during (when not picking up refuse containers), and to and from travel to and from a route, landfill, or transfer station.

  • Page 99: Lifting And Loading Refuse

    LIFTING AND LOADING REFUSE Use the following procedures at each stop along the route to load refuse into the unit. Observe all DANGER and WARNING hazard alerts. NOTICE Refer to Tables 1 and 2. Overhead Clearances . If local rules and laws require more clearance, you must follow them.

  • Page 100: Lifting And Loading Refuse (Continued)

    Note: All units are equipped with the Auto-Lift feature. LIFTING AND LOADING REFUSE When operating in Normal Mode, Weigh Mode or (CONTINUED) Spear Mode, this feature is enabled automatically and allows the operator to partially automate the lifting, dumping and returning of the refuse container DANGER to the ground.

  • Page 101: Compacting The Load

    COMPACTING THE LOAD determines that all conditions are OK. The Cortex Loads can be compacted automatically or manually. In RPMs are above safe operating speeds or the Cortex addition to the auto-pack mode during loading, you can Controller determines that conditions are not correct for pack the refuse manually any time after loading the refuse pump operation.

  • Page 102: Leaving The Route For The Landfill/Transfer Station (Continued)

    Use of Curb Side Drive LEAVING THE ROUTE FOR THE LANDFILL/ TRANSFER STATION If equipped, drive from the curbside driver position ONLY on the collection route. DO NOT use this station during At the end of the route, or when the unit has a full load, travel to and from a route, landfill, or transfer station.

  • Page 103: Landfill/Transfer Station/Recycle Center Procedures

    LANDFILL/TRANSFER STATION/ RECYCLE CENTER PROCEDURES Issued June 2020 Copyright 2020, Heil Environmental Operation Printed in U.S.A.

  • Page 104: Setting Up An Eject Unit For Unloading

    Raise the Tailgate (Continued) SETTING UP AN EJECT UNIT FOR UNLOADING 1. PRESS and HOLD the T/G RAISE button until the Set up the Unit tailgate is COMPLETELY raised, which is about 30º above the body. See the figure below. After positioning unit on firm stable ground for unloading at the landfill, set up as follows.

  • Page 105: Unloading An Eject Unit

    4. Depress and HOLD the PACK RET button to fully UNLOADING EJECT UNITS retract the packer to the front head. Release the button. After positioning unit on firm stable ground for unloading at the landfill and setting up as described in Setting Up Eject 5.
  • Page 106 UNLOADING AN EJECT UNIT (CONTINUED) DANGER Prop the Tailgate Stand clear when tailgate is in motion and during Before you clean and inspect the tailgate seal, prop the unloading cycle. Do not stand under or cross under raised tailgate. Doing so may result in injury or death. tailgate with the two factory body props.
  • Page 107 UNLOADING AN EJECT UNIT (CONTINUED) NOTICE Clean Behind the Packer Panel Sump doors should be closed at all times except when 1. Extend the packer panel to the rear of the body. open for cleaning. 2. Disengage the PTO or Pump Switch 3.

  • Page 108: End Of Day Procedures

    6. Make sure all cylinders (except tailgate lock cylinders END OF DAY PROCEDURES and arm raise cylinders) are in their retracted position. Parking the Unit 7. APPLY the parking brake. 1. Park the unit in the space designated by your employer/supervisor.
  • Page 109 SECTION 4 Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.
  • Page 110 mechanic. The next few pages cover basic functionality. For additional information, see Body Controller Software For the operator, it shows operation warnings and explains why the system may prevent a function so the operator can correct and operate in a safe and productive manner. For the service technician, it displays information regarding sensor failures, and with proper training, can be used to test sensors and other inputs and output functions.

  • Page 111: Screens

    SCREENS Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 112: Main Screen

    MAIN SCREEN When the truck key switch is on, the home screen below will be displayed. This screen will show the operator various cab control conditions, including if: Pump is ON/OFF, Side Door is CLOSED, Tailgate is CLOSED, Tailgate is LOCKED, Select-O-Pack ON/OFF, Hydraulic Oil LOW/OK, Filter Pressure OK.
  • Page 113 Triggered off the grabber release push-button, this system initiates a pack cycle once the programmed number of lift cycles have been completed. Valid range is 0-5 cans per pack. Select-O-Pack is OFF when set to 0. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 114: Grabber Pressure Adjust Screen

    GRABBER PRESSURE ADJUST SCREEN Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 115: Pick Height Adjust Screen

    PICK HEIGHT ADJUST SCREEN Decrease the value to increase the Pick Height. Valid range is +/- 6 inches. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 116: Spearing Dimension Adjust Screen

    SPEARING DIMENSION ADJUST SCREEN 4" to 8"), set at 0.10" increments. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 117: Option Config

    OPTION CONFIG SCREEN The Option Configuration Screen allows Authorized Service Personnel to turn unit options ON or OFF when unit options have been installed or removed from the unit. Whelen Lights High Pressure Filter Tailgate Lock Top Door Hopper Cover Packer Travel Veolia Arc Lights Dual Control Panels...

  • Page 118: Maintenance Screen

    MAINTENANCE SCREEN The Maintenance Screen can be used by Authorized Service Personnel to turn Service Mode ON/OFF, Weight Mode ON/ OFF, and Spear Mode ON/OFF, as well to view the unit's cumulative Packer Count, Arm Count and Maintenance Hours. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 119: General Counters Screen

    GENERAL COUNTERS SCREEN The General Counters Screen shows Daily and Total Arm Cycles, Daily and Total Pack Cycles, Maintenance Hours, Filter Bypass Hours and Total Pump Hours. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 120: Inputs Screens

    INPUTS SCREENS Inputs are signals the controller receives from sensors or switches. Examples being: Prox switch signals, lift raise cylinder sensor, lift extend cylinder sensors, packer position sensor, pump on/off push button, system power button, packer extend or retract push buttons and so on.

  • Page 121: Inputs Screens (Continued)

    INPUTS SCREENS (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 122: Inputs Screens (Continued)

    INPUTS SCREENS (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 123: Inputs Screens (Continued)

    INPUTS SCREENS (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 124: Outputs Screens

    OUTPUTS SCREENS Outputs are signals sent out of the something ON or to make something happen. Any signal that is sent out of the controller is an output. Output examples are: Signals sent to valve coils that move a valve spool or to turn on a light.

  • Page 125: Outputs Screens (Continued)

    OUTPUTS SCREENS (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 126: Outputs Screens (Continued)

    OUTPUTS SCREENS (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 127: Analog Raw Values Screen

    ANALOG RAW VALUES Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 128: Statistical Data Screen

    STATISTICAL DATA The Statistics Screen shows Pack Extend and Retract Times, Total Pack Time (includes delays), Total Lift Cycle Time, Average Lift Cycle Time, and Can Counts (based on weight). Pressing button 1 + 4 + OK resets statistics. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 129: Hydraulic Warm Up Flow Adjust Screen

    HYDRAULIC WARM UP FLOW ADJUST SCREEN Valid range is 850-1150 PSI. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 130: Hydraulic Warm Up Temp Adjust Screen

    HYDRAULIC WARM UP TEMP ADJUST SCREEN Valid range is 70 - 110°F. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.
  • Page 131 SECTION 5 Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 132: Cortex Controller Locations

    decreases wiring running the length of the vehicle, facilitates troubleshooting, and increases the reliability of the system. Figure 52. Cortex Controller Location (Red Arrow) Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 133: Cortex Controller Nodes

    Illustrations and part numbers of the five body controller nodes are shown below. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.

  • Page 134: Unit Calibration

    6. On the Supporting Functions Push Button UNIT CALIBRATION Controls , turn OFF Coordinated Mode (COORD MODE button light will be solid blue). This allows for DANGER manual control using the Manual Control Push For certain steps within this procedure, there are no Button Controls interlocks to prevent lift arm movement.

  • Page 135: Unit Calibration (Continued)

    Lift Valve Minimum Currents Calibration UNIT CALIBRATION (CONTINUED) 14.Extend each cylinder (raise, extend, dump, and Cylinder Position Calibration (Continued) grabber) approximately half way. This will provide the needed movement for calibration. 10.Carefully move the arm to where it is clear of the body (there are no interlocks during this stage).

  • Page 136: Unit Calibration (Continued)

    Lift Valve Minimum Currents Calibration (Continued) Packer Minimum Currents Calibration 19.Press and hold the OUT push button until the arm 25.Place packer approximately halfway between home starts to move in the out direction. Press “OK” to and pack positions. Press “OK” to confirm the confirm the position.

  • Page 137: Body Controller Software

    BODY CONTROLLER SOFTWARE This section is to be supplied. Issued June 2020 Copyright 2020, Heil Environmental Printed in U.S.A.
  • Page 138 NOTES:...
  • Page 139 SECTION 6 MAINTENANCE Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 140: Recommended Spare Parts

    RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION QUANTITY 075-0953 FILTER, RETURN LINE 075-0712 FILTER, BREATHER 022-3509 SEAL, TAILGATE 022-4058 SEAL, SUMP DOOR 093-3447-350 WEAR PAD ASSEMBLY, INNER BOOM 093-3447-451 WEAR PAD ASSEMBLY, SIDE UPPER, OUTER BOOM 093-3447-550 WEAR PAD ASSEMBLY, SIDE UPPER, OUTER BOOM 093-3447-650 WEAR PAD ASSEMBLY, BOTTOM, OUTER BOOM 093-3447-750...
  • Page 141 RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION QUANTITY 001-6911 CYLINDER, INFINITY, PACKER, 28 YD 001-6906 CYLINDER, INFINITY, PACKER, 33 YD 031-6639 VALVE, BODY 031-6647 VALVE, TAILGATE 031-6638 VALVE, ARM 063-0141 ARC SENSOR 108-8626-500 SWITCH BANK #1, BODY FUNCTIONS 108-8626-501 SWITCH BANK #2, LIGHTS/LIFT FUNCTIONS 108-8626-502 SWITCH BANK #3, BODY FUNCTIONS 108-8626-503...
  • Page 142 RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION QUANTITY 263-1857-016 HARNESS, OIL TANK 263-1857-017 HARNESS, BODY REAR 263-1857-018 HARNESS, TOP DOOR 263-1886-001 HARNESS, CAB TO BODY, AUTOCAR 263-1886-002 HARNESS, CAB TO BODY, MACK LR 263-1886-003 HARNESS, CAB TO BODY, PETERBILT 263-1886-004 HARNESS, CAB CONTROL PANEL 263-1886-005 HARNESS, CAB CONTROL PANEL SPLITTER 263-1886-006...

  • Page 143: Body Preventive Maintenance

    BODY PREVENTIVE MAINTENANCE CHART Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 144: Body Preventive Maintenance Chart

    BODY AND LOADER 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 * Daily = 8 hrs.
  • Page 145 *HOURS OF OPERATION * Daily = 8 hrs. Weekly = 40 hrs. Monthly = 200 hrs. 6 Months = 1000 hrs. Yearly = 2000 hrs. 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.

  • Page 146: Body Lubrication Guide

    Figure 53. Body Lubrication Guide Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 147: Packer/Ejector Cylinders Preventive Maintenance

    PACKER/EJECTOR CYLINDERS PREVENTIVE HEIL PACKER/EJECTOR CYLINDERS MAINTENANCE PREVENTIVE MAINTENANCE CHART WARNING DAILY Make sure that the unit is in Lock-Out/Tag-Out mode Using a plastic bladed shovel, clean behind the before you perform maintenance/service procedures, or packer panel and pockets around sphericals. DO when you enter or climb on the hopper/body/related NOT damage cylinder rods by striking with any assemblies.

  • Page 148: Loader Preventive Maintenance

    LOADER PREVENTIVE MAINTENANCE CHART Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 149: Loader Preventive Maintenance Chart

    LOADER 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. REF NO.
  • Page 150 Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 151: Grabber Belts Adjustment

    GRABBER BELTS ADJUSTMENT most 90-gallon cans without excessive mashing of the container. The Grabber Belts only need adjustment to accommodate different size residential cans. See Grabber Pressure Adjust Screen for instructions on how to adjust the grabber pressure. Contact Heil Technical Services at 866-310-4345 for more information. Issued June 2020 Copyright 2020, Heil Environmental Maintenance...

  • Page 152: Loader Arm Wear Pads

    LOADER ARM WEAR PADS Inspect loader arm wear pads monthly (200 hours) and replace as necessary. Regular inspection and maintenance extends the service life of the loader arm. Contact Heil Technical Services at 866-310-4345 for more information. Lower Pads (Inner Boom) Upper Pads (Outer Boom) Issued June 2020 Copyright 2020, Heil Environmental...

  • Page 153: Proximity Switch Troubleshooting

    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 154 PROXIMITY SWITCH TROUBLESHOOTING TABLE If the controller input light stays on when a switch is Check the proximity switch electrical circuits for the source of unplugged (the signal wire is carrying +12V DC) the problem. If proximity switch LED light is NOT ON. 1.

  • Page 155: Hydraulic

    HYDRAULIC Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 156: Check Hydraulic Oil Level

    CHECK HYDRAULIC OIL LEVEL 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 157: Change Hydraulic Oil Filter Element

    CHANGE HYDRAULIC OIL FILTER ELEMENT To change the hydraulic oil filter, refer to the figure below and follow these steps: 1. Remove nuts and filter cover. 2. Remove the filter element with the by-pass assembly and discard as required. 3. Clean the housing with a clean, lint-free cloth. 4.

  • Page 158: Drain And Clean The Hydraulic Oil Tank

    DRAIN AND CLEAN THE HYDRAULIC OIL NOTICE TANK If your employer or company has Lock-Out/Tag-Out Change the hydraulic oil at least annually or every 2000 procedures that are different from the following hours of operating time, whichever comes first. procedures, use your employer’s or company’s procedures.

  • Page 159: Drain And Clean The Hydraulic Oil Tank (Continued)

    19.With the packing panel in the retracted position and DRAIN AND CLEAN THE HYDRAULIC OIL lift in the in-transit position, check tank oil level. If TANK (CONTINUED) necessary, add recommended as described under Check the Hydraulic Oil Level 11.Install the drain plug in the tank bottom. 12.Reconnect and tighten all hose connections that PURGE THE HYDRAULIC SYSTEM were disconnected.

  • Page 160: Purge The Hydraulic System / Clean And Inspect The Tailgate Seal

    PURGE THE HYDRAULIC SYSTEM CLEAN AND INSPECT THE TAILGATE SEAL If the hydraulic system becomes contaminated because of Periodically check the tailgate seal to make sure it mates component failure or some other reason, you must purge properly with the body and inspect for possible wear, the hydraulic system.

  • Page 161: Pressure Adjustment Settings

    PRESSURE ADJUSTMENT SETTINGS A. Unit Preparation Follow these unit preparation steps prior to making any pressure adjustments listed in this section. 1. Make sure area around unit is clear. 2. Place wheel chocks on both sides of driver side rear wheel. 3.
  • Page 162 PRESSURE ADJUSTMENT SETTINGS (CONTINUED) C. Pressures GRABBER GRAB / TOP DOOR TAILGATE CNRG TAILGATE BODY MAIN RELIEF RELEASE OPEN / RAISE PORT RAISE PORT RELIEF CLOSE RELIEF 1300 psi 1300 psi 1300 psi 2500 psi D.Contact Heil Technical Services at 866-310-4345 for help with pressure adjustments. Issued June 2020 Copyright 2020, Heil Environmental Maintenance...

  • Page 163: Valve Locations

    VALVE LOCATIONS Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 164: Pump

    PUMP efficient and provide only the flow needed. Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.
  • Page 165 LOAD SENSE PISTON PUMP (219-2426) NOMENCLATURE Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.
  • Page 166 LOAD SENSE PISTON PUMP (219-2426) NOMENCLATURE (CONTINUED) Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.
  • Page 167 LOAD SENSE PISTON PUMP (219-2426) COMPENSATOR The Compensator regulates the hydraulic pressure and is preset at the factory. It is set to signal the pump to provide and maintain Stand-By Pressure (500 psi). Also, it limits the working pressure to 2500 psi. It also acts as a variable flow switch for the pump.
  • Page 168 PUMP INSPECTION NOTICE Important Inspection Tasks Damaged tubes and hoses should be replaced Check pressure fluid level in tank. immediately! Check cleanliness/condition of the hydraulic fluid. Check visually the hydraulic accumulators. Check visually all electrical connections of motor, NOTICE solenoids, sensors, and pressure switches. A check of the hydraulic fluid can be regarded only as a rough indicator for the fluid condition (milky/black appearance, gumming, sludge at the tank bottom, or smell...
  • Page 169 PUMP MAINTENANCE NOTICE Important Inspection Tasks The complete hydraulic system has to be depressurized prior to any works at accumulators. No soldering, welding, Hydraulic Fluid or machining is allowed at hydraulic accumulators! The service life of hydraulic fluids is highly dependent on Incompetent handling may cause severe accidents! the operation temperature and the conditions.
  • Page 170 Cleanliness is mandatory when working on hydraulic PUMP REPAIR systems! This is especially true with systems with an Axial Pumps. All surfaces where joints are to be Important Inspection Tasks separated should be cleaned prior to disassembly. All A. Troubleshooting ports should be plugged to prevent contaminants to enter an open system.
  • Page 171 1. Open the tank shut-off valve to purge as much air as PUMP START-UP PROCEDURE possible out of the hose, filling the inlet hose with oil. 2. Tighten the inlet retainer screws, top off fluid level of NOTICE the reservoir if necessary. When installing a new pump, you MUST prime (fill) the new pump with hydraulic fluid BEFORE operating, otherwise damage WILL occur.
  • Page 172 Troubleshooting Pump on Command-SST ™ No pump function? Is pump switch on? Turn on Check for 12v pump at PTO Coil. Is switch correct voltage Troubleshoot present? electrical Check standby pressure Standby pressure Is pressure with engine running greater than 400 between 400-500 and pump switch on.
  • Page 173 Troubleshooting Hot Shift PTO on Command-SST™ With engine running and pump switch on, do the hydraulics work? Are cycle Check PTO Coil for times correct proper voltage. When with spec? pump switch is on, is voltage present? Check standby pressure Troubleshoot at body valve.

  • Page 174: Electrical

    ELECTRICAL Issued June 2020 Copyright 2020, Heil Environmental Maintenance Printed in U.S.A.

  • Page 175: Sensors

    SENSORS A. Hydraulic Oil Temperature Sensor D.Pressure Transducers (0-3600 PSI) Hydraulic Oil Tank Body Pressure - Body Valve Lift Pressure - Lift Valve B. Lift Position Sensors Grabber Pressure - Grabber Hydraulic Tubing Raise Sensor - Inside Cylinder, J1939 Dump Rotation Pressure - Dump Rotation Hydraulic Extend Sensor - Inside Cylinder, J1939 Tubing, weigh cans (<350 lbs) on-the-fly;...
  • Page 176 NOTES:...
  • Page 177 SECTION 7 SCHEMATICS Issued June 2020 Copyright 2020, Heil Environmental Schematics Printed in U.S.A.

  • Page 178: Electrical Schematics

    ELECTRICAL SCHEMATICS Reference the schematics on the following pages. Printed copies of 1-6 are included in the manual kit. 1. Electrical Schematic, Main Controller - 701-9287-010 2. Electrical Schematic, Body - 701-9287-011 3. Electrical Schematic, Body Valve - 701-9287-012 4. Electrical Schematic, Lift Valve - 701-9287-013 5.
  • Page 179 263-1857-010 NOTE: RELAYS ARE HEIL PN: 108-8391 (DOT INDICATES EMPTY POSITION) FUSES ARE 15 & 20 AMP HEIL PN: 108-7113-215 & 108-7113-220 TERMINALS (TYCO PN) 1-968857-1 WIRE SEALS (TYCO PN) 828905-1 HOLE PLUGS (TYCO PN) 828922-1 FUSE BLOCK IS HEIL PN: 108-8502-001 FUSE BLOCK COVER IS HEIL PN: 108-8502-002 RELAY BOX DETAIL REV A...
  • Page 180 (OPTION) (OPTION) BODY HOPPER DOWN COVER OPEN PROX. SW. PROX. SW. 263-1857-011 263-1857-017 REV A...
  • Page 181 263-1857-016 263-1857-012 REV A...
  • Page 182 263-1857-013 REV A...
  • Page 183 263-1857-018 263-1857-014 REV A...
  • Page 184 IN-CAB DIAGNOSTIC DISPLAY BROWN BLACK GRAY BLUE WHITE IN CAB CONTROL PANEL REFERENCE CAB CONTROL KIT REF. SALES ORDER (OPTIONAL) CHASSIS PROVIDED WHELEN STROBE R.H. L.H. TO CHASSIS RP170 (POWER AND GROUND) CONNECTOR THROTTLE ADVANCE RELAY TO CHASSIS RP170 (POWERTRAIN) CONNECTOR 263-1886-001 - AUTOCAR 263-1886-003 - MACK LR...
  • Page 185 REV A...
  • Page 186 IN-CAB DIAGNOSTIC DISPLAY BROWN BLACK GRAY BLUE WHITE IN CAB CONTROL PANEL REFERENCE CAB CONTROL KIT REF. SALES ORDER (OPTIONAL) CHASSIS PROVIDED WHELEN STROBE R.H. L.H. TO CHASSIS RP170 (POWER AND GROUND) CONNECTOR THROTTLE ADVANCE RELAY TO CHASSIS RP170 (POWERTRAIN) CONNECTOR 263-1886-002 - PETERBILT REV A...
  • Page 187    REV A...
  • Page 188 CAN NETWORK (701-9287-015 REV A, 03/01/20) Issued June 2020 Copyright 2020, Heil Environmental Schematics Printed in U.S.A.

  • Page 189: Hydraulic Schematics

    HYDRAULIC SCHEMATICS Reference the schematics on the following pages. A printed copy of 1 is included in the manual kit. 9298-019 9298-021 9298-022 9298-023 Issued June 2020 Copyright 2020, Heil Environmental Schematics Printed in U.S.A.

  • Page 191: Hydraulic Schematic, System At Idle - 701-9298-001

    T/G RAISE CYL. T/G RAISE CYL. T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower...

  • Page 192: Hydraulic Schematic, Arm Out - 701-9298-002

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 193: Hydraulic Schematic, Arm In - 701-9298-003

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 194: Hydraulic Schematic, Arm Up - 701-9298-004

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 195: Hydraulic Schematic, Arm Down - 701-9298-005

    T/G RAISE CYL. T/G RAISE CYL. T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower...

  • Page 196: Hydraulic Schematic, Arm Dump - 701-9298-006

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 197: Hydraulic Schematic, Arm Undump - 701-9298-007

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 198: Hydraulic Schematic, Arm Grab - 701-9298-008

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 199: Hydraulic Schematic, Arm Release - 701-9298-009

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 200: Hydraulic Schematic, Packer Extend - 701-9298-010

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 201: Hydraulic Schematic, Packer Retract - 701-9298-011

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 202: Hydraulic Schematic, Oil Warming - 701-9298-012

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 203: Hydraulic Schematic, Tailgate Lock - 701-9298-013

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 204: Hydraulic Schematic, Tailgate Unlock - 701-9298-014

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 205: Hydraulic Schematic, Tailgate Raise - 701-9298-015

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 206: Hydraulic Schematic, Tailgate Down - 701-9298-016

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 207: Hydraulic Schematic, Top Door Close - 701-9298-017

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 208: Hydraulic Schematic, Top Door Open - 701-9298-018

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 209: Hydraulic Schematic, Arm Out Down Undump - 701-9298-019

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 210: Hydraulic Schematic, Arm In Up Dump - 701-9298-020

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 211: Hydraulic Schematic, Arm In And Packer Retract - 701-9298-021

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 212: Hydraulic Schematic, Arm In And Packer Extend - 701-9298-022

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 213: Hydraulic Schematic, Arm Out Down Release - 701-9298-023

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Raise / Lower Open / Close Lock / Unlock Extend Cylinder...

  • Page 214: Hydraulic Schematic, Arm Out Down Grab - 701-9298-024

    T/G RAISE CYL. T/G RAISE CYL. TOP DOOR CYL. T/G LOCK CYL. T/G LOCK CYL. (OPTION) PG 3 1300 psi 1700 psi 1300 psi 1300 psi (A4 & B4) 1300 psi 1300 psi Tailgate Top Door Tailgate Lock Lock / Unlock Raise / Lower Open / Close Extend Cylinder...

  • Page 215: Compressed Natural Gas (Cng) Option

    SECTION 8 COMPRESSED NATURAL GAS (CNG) OPTION Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option Printed in U.S.A.

  • Page 216: Important Safety Information

    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.

  • Page 217: Important Safety Information (Continued)

    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.

  • Page 218: Important Safety Information (Continued)

    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.

  • Page 219: Properties Of Natural Gas / Signs Of A Fuel Leak

    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. If you air, which means if gas were to leak, it would float upwards notice this kind of lingering odor coming from your vehicle, and quickly dissipate into the atmosphere.

  • Page 220: Cng Fuel System Functions And Components

    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.

  • Page 221: Cng Fuel System Components (Continued)

    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.

  • Page 222: Cng Fuel System Components (Continued)

    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.

  • Page 223: Cng Fuel System Components (Continued)

    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.

  • Page 224: Fuel System Shut Down Procedure

    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.

  • Page 225: Cng Vehicle Operator Emergency Response (Continued)

    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.

  • Page 226: Starting Vehicle / Fueling Procedure

    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.

  • Page 227: Fueling Procedure (Continued)

    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.

  • Page 228: Fueling Procedure (Continued)

    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.

  • Page 229: Fueling Procedure (Continued) / Transfer Fueling (Defueling) Procedures

    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.

  • Page 230: Cng Fuel System Maintenance

    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. WARNING System components must not be under pressure during servicing.

  • Page 231: Maintenance Part Numbers

    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 –...

  • Page 232: Depressurizing/Re-Pressurizing Procedure

    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.

  • Page 233: Depressurizing/Re-Pressurizing Procedure (Continued)

    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.

  • Page 234: High Pressure Filter

    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.

  • Page 235: Welding And Hot Work Procedures

    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. Close the bleed valve when the hissing stops. the compressed natural gas fuel system has been purged with inert gas.

  • Page 236: Lifting The Vehicle / Towing The Vehicle

    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. Serious personal injury or death can occur if the gas is ignited.

  • Page 237: Cng Fuel System Inspections

    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. vehicle.

  • Page 238: Inspection/Preventive Care Schedule / Preparation Before Maintenance

    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.

  • Page 239: Daily Cng Fuel System Inspection

    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.
  • Page 240 DAILY CNr Inspect the following items each day before vehicle operation. If all items pass inspection, the vehicle is cleared for operation. If any issues are identified, a qualified CNG System Technician should make the necessary repairs. 1. Check all CNrG Tailgate guards and covers for damage.

  • Page 241: Cng Fuel System Troubleshooting

    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.

  • Page 242: Cng Fuel System Troubleshooting (Continued)

    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.

  • Page 243: Cng Fuel System Troubleshooting (Continued)

    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...

  • Page 244: Cng Fuel System Troubleshooting (Continued)

    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...

  • Page 245: Cng Fuel System Troubleshooting (Continued)

    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...

  • Page 246: Cng Front Of Body / Top Of Body Decal Placement

    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.
  • Page 247 In addition to the decals 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 System Manufacturer's Operation and Maintenance Manuals for replacement decal part numbers. Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option...
  • Page 248 Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option Printed in U.S.A.
  • Page 249 Figure 67.CNG Fuel (4.25" x 2.63"), PN 212-3327 Figure 66.CNG Fuel (5.88" x 3.88"), PN 212-3326 Figure 69. Danger, Venting Requires Figure 68. Warning: Vehicle uses Special Instructions/Tools, PN 212-3428 CNG fuel, PN 212-3387 Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option Printed in U.S.A.
  • Page 250 Figure 70. Patent Pending, PN 45002153 Figure 71. Warning, Never weld on CNG vehicle unless purged, PN 212-3286 Figure 72. Attention, CNG Vent Location, PN 212-3495 Figure 73. Warning, CNrG Solenoid System, CNG tank empty before removing transducer, PN 212-3388 Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option...
  • Page 251 Figure 75. CNG Tank Manual Figure 74. FMM Manual Shutoff Valve, PN 212-3422 Shutoff Located Inside, PN 212-3423 Figure 77. Notice, CNrG Figure 76. Notice, CNrG Solenoid Solenoid System, Fuel Fill System, Transducers MUST be Mode MUST Be Engaged, PN functioning, PN 212-3389 212-3429 Issued June 2020...
  • Page 252 Figure 78. Heil CNrG Tailgate Fuel Delivery System, PN 212-3400 Issued June 2020 Copyright 2020, Heil Environmental Compressed Natural Gas (CNG) Option Printed in U.S.A.
  • Page 253 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.
  • Page 254 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 80. Pressure Transducer Sensor behind FMM Plugged directly into the live port of the valve of each tank Unplugged/Faulty and behind the FMM (Fuel Management Module) box live...
  • Page 255 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.
  • Page 256 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.
  • Page 257 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.
  • Page 258 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.
  • Page 259 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.
  • Page 260 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.
  • Page 261 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.
  • Page 262 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...
  • Page 263 INDEX preparing the unit to check the oil level when to change the oil filter element check the hydraulic oil level achieving payloads clean and inspect the tailgate seal auto-lift 22, 66, 90 clean behind the packer panel Auto-Pack clean out hopper sump auto-pack mode clean/inspect tailgate seal cold weather warmup procedure...
  • Page 264 INDEX compressed natural gas (CNG) option fueling procedure 216, 217, 218, 219 high pressure filter change procedure daily checklist high presure filter drain procedure daily checks and inspections important safety information 206, 207, 208 danger 22, 26 inspection/preventive care schedule decal images 38, 39, 40, 41, 42, 43, 44, 45, 46 lifting the vehicle...
  • Page 265 INDEX electronic parts catalogs registration and login emptying the body grabber end of day procedures grabber belts adjustment extend/EXTEND grease lubricant recommendation grease lubrication recommendations GRIP factory body props 77, 78, 79 factory tailgate props 80, 81 features harm "on-the-fly" adjust pick height and angle hazard auto-lift/manual lift mode Heil Autonomous Lift Option (H.A.L.O.)
  • Page 266 INDEX hotshift PTO Tailgate Down - 701-9298-016 troubleshooting Tailgate Lock - 701-9298-013 how to use this manual Tailgate Raise - 701-9298-015 hydraulic Tailgate Unlock - 701-9298-014 pump Top Door Close - 701-9298-017 hydraulic heater circuit Top Door Open - 701-9298-018 hydraulic oil specifications hydraulic valve locations hydraulic oil tank...
  • Page 267 INDEX lower the tailgate pick height adjust screen lower/LOWER spearing dimension adjust screen statistical data screen models interlock in-transit position nomenclature notice 22, 26 jostick controls joystick controls off/OFF oil lubricant recommendation LATCHED oil lubrication recommendations leaving route for the landfill/transfer station on/ON lift arm 17, 22...
  • Page 268 INDEX packer/eject panel & cylinders packer/ejector cylinders preventive maintenance packing near full load raise the tailgate packing on-the-move raise/RAISE parking the unit recommended spare parts reflective safety materials precautionary statements remove refuse from the engine and exhaust areas preparing the unit to check the hydraulic oil level reports to employer/supervisor preparing to return to route retract/RETRACT...
  • Page 269 INDEX traveling position unit unit calibration cylinder position calibration lift valve minimum currents calibration 125, 126 packer calibration packer minimum currents calibration test lift arm operation UNLATCHED unloading unloading an eject unit 95, 96, 97 UNLOCK use of curb side drive 88, 92 use of curbside drive use personal protective equipment...
  • Page 270 NOTES:...
  • Page 271 HEIL ENVIRONMENTAL WARRANTY STATEMENT The Heil Co. d/b/a Heil Environmental ("Heil") warrants its solid waste collection equipment to be free from defects in material and workmanship under normal use for a period of one (1) year or 2000 hours of operation (whichever comes first) from the date of equipment In-Service or during the period of coverage offered by an extended warranty program, when proper service and maintenance as described in Heil Service Bulletins and Parts &...
  • Page 272 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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