Dover Heil Rapid Rail Service Manual
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Dover Heil Rapid Rail Service Manual

Dover Heil Rapid Rail Service Manual

Continuous-pack automated side loader
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Rapid Rail
®
CONTINUOUS-PACK AUTOMATED SIDE LOADER
SERVICE MANUAL
ISSUE SEPTEMBER 2024
TP1RR-SM-0924
© 2024 Heil Environmental

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Summary of Contents for Dover Heil Rapid Rail

  • Page 1 Rapid Rail ® CONTINUOUS-PACK AUTOMATED SIDE LOADER SERVICE MANUAL ISSUE SEPTEMBER 2024 TP1RR-SM-0924 © 2024 Heil Environmental...

  • Page 2: Important Safety Notice

    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

    Rapid Rail TABLE OF CONTENTS General Information Introduction ...................................4 Service/Parts Assistance ...................................4 Recommended Spare Parts ...................................5 Electronic Parts Catalog (EPC) ...................................7 Hazard Symbols and Definitions ...................................10 Lockout/Tagout Procedure ...................................14 Storing Refuse in Container ...................................17 Maintenance/Lubrication Information ...................................17 Grease Lubrication Recommendation ...................................17 Oil Lubricant Recommendation ...................................17...
  • Page 4 Rapid Rail TABLE OF CONTENTS Maintenance and Adjustment Body Daily Checklist ...................................70 Body Preventive Maintenance Chart ...................................71 (PTO) Inspection and Preventive Maintenance ...................................73 Body Lubrication Guide ...................................74 Pack/Eject Cylinders Maintenance ...................................75 Cold Weather Warmup Procedure ...................................76 Preparing the Unit to Check the Oil Level ...................................77 Check Oil Level ...................................78...
  • Page 5 Rapid Rail TABLE OF CONTENTS Dual Strobe Light w/2 Pin Harness 263-1361 ...................................161 Valve End Loader Harness 263-1436-001 ...................................162 Middle Loader Harness - 263-1436-005 ...................................163 4-Button Control Harness 263-1436-014 ...................................164 Grabber Interlock Harness 263-1436-027 ...................................165 Middle Grabber Interlock Harness 263-1436-028 ...................................166 Grabber Interlock Proximity Harness 263-1436-029 ...................................167...
  • Page 6 Rapid Rail TABLE OF CONTENTS Cab to Body IFM, 021-029, 701-9042-012, ...................................206 Cab to Body IFM, 2014 Peterbilt COE, 701-9042-013, ...................................207 Cab Electrical Schematic 032-037, 701-9042-014, ...................................208 Flow Charts 701-8840 ...................................209 Flow Charts Pump On 701-8840 ...................................210 Flow Charts Gripper Close 701-8840 ...................................211 Flow Charts Gripper Open 701-8840 ...................................212...
  • Page 7 Rapid Rail Rapid Rail ® CONTINUOUS-PACK AUTOMATED SIDE LOADER SERVICE MANUAL ISSUED SEPTEMBER 2024 TP1RR-SM-0924 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A.
  • Page 8 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 9: Section 1 General Information

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

  • Page 10: Introduction

    Rapid Rail 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.

  • Page 11: Recommended Spare Parts

    Rapid Rail General Information RECOMMENDED SPARE PARTS PART NO. DESCRIPTION BODY AND TAILGATE ASSEMBLIES 003-4438 BEARING, SPHERICAL, PACKER, LOWER 005-4131 LINK, DOUBLE 005-4132 ASSEMBLY, LINK 048-6231 PIN, ACTUATOR, 1-1/2” DIA. 048-6024-001 PIN. 3/4" DIA 048-6235 PIN, SHEAVE 048-6238 PIN, PACKER, 1” DIA. 022-3996 TUBING, T/G SEAL, EPDM, RR 048-6023-001...
  • Page 12 Rapid Rail General Information 001-6991 CYLINDER, TAILGATE 001-6974 CYLINDER, GRIP 031-6194 VALVE, BODY 031-6395 VALVE, HUSCO, LOADER 031-2616 VALVE, SHUT OFF, SUCTION LINE 031-6194-006 VALVE, PILOT OPERATED ,DIRECTIONAL CONTROL 031-6194-008 VALVE, CONTROL DIRECTIONAL 031-6395-009 VALVE, RELIEF (INLET SECTION – SET @ 220PSI) 031-6395-008 VALVE, RELIEF ( IN/OUT SECTION –...

  • Page 13: Electronic Parts Catalog (Epc)

    Rapid Rail 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 Rapid Rail 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.
  • Page 15 Rapid Rail 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

    Rapid Rail 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 Rapid Rail 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 Rapid Rail 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 Rapid Rail 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: Lockout/Tagout Procedure

    Rapid Rail General Information LOCKOUT/TAGOUT PROCEDURE DANGER Serious injury or death may result if you do not follow this procedure. WARNING If you don't have functioning Lockout/Tagout gear/not an authorized employee, STOP and DO NOT initiate any service on the unit.

  • Page 21: Follow These Steps

    Rapid Rail General Information Figure 1. Examples of Lockout/Tagout Gear. Follow These Steps: 1. APPLY the brakes. MAKE SURE the brakes do not let the unit move and they work properly. 2. Chock all wheels. 3. SET the tailgate props when the tailgate is raised for any service, maintenance or cleaning. 4.
  • Page 22 Rapid Rail General Information c. ENSURE all employees are safely positioned or removed from the area. d. NOTIFY all affected employees that the Lockout/Tagout devices are being removed. Issued September 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 23: Storing Refuse In Container

    Rapid Rail 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 and impact unloading. Additionally, storing refuse in the body overnight can increase the risk of fire.

  • Page 24: Standard Torque Data For Nuts And Bolts

    Rapid Rail General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS The following recommended torque data is 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 Rapid Rail General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Plain Heil Zinc Heil Plated Heil Deformed Thread Condition Fastener Lubricated Lock Nut Turns Torque Torque Fastener Torque Bolt Size Nut Type per Inch Value Value Torque Value Value (STD/Lock) Grade...
  • Page 26 Rapid Rail General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Plain Heil Zinc Heil Plated Heil Deformed Thread Condition Fastener Lubricated Lock Nut Turns Torque Torque Fastener Torque Bolt Size Nut Type per Inch Value Value Torque Value Value (STD/Lock) Grade...
  • Page 27 Rapid Rail General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Plain Heil Zinc Heil Plated Heil Deformed Thread Condition Fastener Lubricated Lock Nut Turns Torque Torque Fastener Torque Bolt Size Nut Type per Inch Value Value Torque Value Value (STD/Lock) Grade...

  • Page 28: Bolt Type Identification Chart

    Rapid Rail General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Plain Heil Zinc Heil Plated Heil Deformed Thread Condition Fastener Lubricated Lock Nut Turns Torque Torque Fastener Torque Bolt Size Nut Type per Inch Value Value Torque Value Value (STD/Lock) Grade...

  • Page 29: Torque For Hydraulic Tubes And Fittings

    Rapid Rail General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS 37 DEGREE FLARE (JIC) FITTINGS SET WRENCH TO (DRY TORQUE CAN VARY +/- 10%) 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.
  • Page 30 Rapid Rail General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) FROM SAE J2593 TABLE 7 (STEEL) SET WRENCH TO (DRY TORQUE +0%, -25%) BOSS (ORB) NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 3/16" 9 ft-lbs. 110 in-lbs. 1/4"...
  • Page 31 Rapid Rail General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 61) SET WRENCH TO *DRY TORQUE* NOMINAL TUBE OD BOLT SIZE BOLT TORQUE [FT-LBS] *+/- 4 BOLT TORQUE [IN-LBS] *+/- 50 FT-LBS IN-LBS 1/2"...

  • Page 32: Cold Weather Warmup Procedure

    Rapid Rail 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 33: Proximity Switch Troubleshooting

    Rapid Rail 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 when the switch is sensing metal.
  • Page 34 Rapid Rail General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Issued September 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 35: Decals On The Unit

    Rapid Rail 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, Decal Care, for directions on cleaning decals. Replace any decal that is damaged, missing, or not readable. When you replace a part that has a decal, make sure a new decal is installed on the new part.
  • Page 36 Rapid Rail General Information DECAL CARE (CONTINUED) Figure 5. Recommended Technique Figure 6. Incorrect Technique Issued September 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 37: Hydraulic Symbols

    Rapid Rail General Information HYDRAULIC SYMBOLS Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. General Information...
  • Page 38 Rapid Rail General Information HYDRAULIC SYMBOLS (CONTINUED) Issued September 2024 Copyright 2024, The Heil Co. General Information Printed in the U.S.A.

  • Page 39: Section 2 Pumps

    Rapid Rail Pumps SECTION 2 PUMPS Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Pumps...

  • Page 40: Tandem Vane Pump With Monoblock Separate Outlet Flow

    Rapid Rail Pumps TANDEM VANE PUMP WITH MONOBLOCK SEPARATE OUTLET FLOW Rapid Rail and Python Auto Side Loader Note: This pump style is commonly installed on units manufactured before 2022. Figure 7. Tandem Vane Pump with Monoblock The pump section (pump 1) closest to the input shaft operates the lift and shuts OFF first. The pump section (pump 2) farthest from the input operates the packer and stays ON at higher RPMs.

  • Page 41: Tandem Vane Pump O.i.g.a.i. Hydraulic System Troubleshooting

    Rapid Rail 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 42 Rapid Rail Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING (CONTINUED) Figure 8. Issued September 2024 Copyright 2024, The Heil Co. Pumps Printed in the U.S.A.

  • Page 43: Mount Pump Monoblock To Tandem Pump

    Rapid Rail 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 44 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.

  • Page 45: Section 3 Lift Arm

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

  • Page 46: Specifications

    Rapid Rail Lift Arm LIFT SPECIFICATIONS Valve Pressure Settings Pressures and Times Arm Valve Relief 2200 PSI Loader In/Out Relief 2350 PSI Release 1100 PSI Body Valve Relief 2400 PSI Grabber Pressure Switch 2000 PSI Cycle Times Loader Cycle 8-9 seconds Issued September 2024 Copyright 2024, The Heil Co.

  • Page 47: Lift Arm Nomenclature

    Rapid Rail Lift Arm LIFT ARM NOMENCLATURE Refer to the Parts Manual Section 2 for Lift Arm part numbers. Figure 10. Lift Arm Nomenclature Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Lift Arm...
  • Page 48 Rapid Rail Lift Arm LIFT ARM NOMENCLATURE (CONTINUED) Issued September 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.
  • Page 49 Rapid Rail Lift Arm LIFT ARM NOMENCLATURE (CONTINUED) Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Lift Arm...
  • Page 50 Rapid Rail Lift Arm LIFT ARM NOMENCLATURE (CONTINUED) Issued September 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.
  • Page 51 Rapid Rail Lift Arm LIFT ARM NOMENCLATURE (CONTINUED) Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Lift Arm...
  • Page 52 Rapid Rail Lift Arm LIFT ARM NOMENCLATURE (CONTINUED) Issued September 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.

  • Page 53: Lubrication Guide

    Rapid Rail Lift Arm LIFT ARM LUBRICATION GUIDE NOTICE Clean all fittings before applying grease and always pump enough grease into the joint to remove the old grease. Wipe off excess. Figure 11. Lift Arm Lubrication Guide Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A.

  • Page 54: Lift Arm Preventive Maintenance Chart

    Rapid Rail Lift Arm LIFT ARM PREVENTIVE MAINTENANCE CHART ® RAPID RAIL LOADER PREVENTIVE MAINTENANCE CHART ACTIVITY INTERVAL SERVICE/CHECK See the Rapid Rail Lift Lubrication Guide or the Grease Lift Twice Weekly (20 hrs) Lubrication decal on the lift arm. Check the Pin Retaining Bolts to ensure they are in place and not broken.

  • Page 55: Lift Arm Control Valve

    Rapid Rail Lift Arm LIFT ARM CONTROL VALVE A sectioned control valve for the loader (Shown Below) shows the different functions and relief valves. Figure 12. Lift Arm Control Valve Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Lift Arm...

  • Page 56: Lift Arm Proximity Switches

    Rapid Rail Lift Arm LIFT ARM PROXIMITY SWITCHES The lift arm has five sourcing proximity switches, four 30mm and one 18mm. WARNING Before adjusting any switch, make sure the unit is in Lock-Out mode. See the Lock-Out/Tag-Out Procedures Figure 13. Lift Arm Proximity Switches Issued September 2024 Copyright 2024, The Heil Co.
  • Page 57 Rapid Rail Lift Arm LIFT ARM PROXIMITY SWITCHES (CONTINUED) A. In-Proximity Switch (N.O.) This switch is located on the street side of the unit on the backside of the loader carriage. The sensing striker for the switch is welded on the street side of the loader track assembly. This switch is used to stop the In/Out cylinder when the arm is retracting before the cylinder is fully collapsed.

  • Page 58: Carriage Assembly Roller Bearing Torque Check

    Rapid Rail Lift Arm CARRIAGE ASSEMBLY ROLLER BEARING TORQUE CHECK There are eighteen (18) bearings in the carriage assembly. If the torque is less than specified, the life of the bearing is much shorter. If the torque is greater than specified, the bearings will freeze and fail prematurely. NOTICE It is critical that you routinely check the torque of the following roller bearings on the loader’s carriage assembly.

  • Page 59: Universal Belt And Tri-Cuff Grabber Adjustments

    Rapid Rail 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 60 Rapid Rail 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 61 Rapid Rail 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.
  • Page 62 Rapid Rail Lift Arm Issued September 2024 Copyright 2024, The Heil Co. Lift Arm Printed in the U.S.A.

  • Page 63: Section 4 Body And Tailgate

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

  • Page 64: Nomenclature

    Rapid Rail Body and Tailgate NOMENCLATURE Figure 17. Nomenclature Issued September 2024 Copyright 2024, The Heil Co. Body and Tailgate Printed in the U.S.A.

  • Page 65: Specifications

    Rapid Rail Body and Tailgate SPECIFICATIONS Hydraulic Oil Tank ............................. 40 Gal. Hydraulic In-Tank Oil Filter ........................3-Micron Hydraulic Oil Tank Suction Strainer ....................100 Mesh Screen Hydraulic Pump ........................Gear or Vane Type Operate-in-gear - Remote Mount ................. 2 Pumps @ 22 GPM @ 1200 RPM Front Mount .................

  • Page 66: Proximity Switches

    Rapid Rail Body and Tailgate PROXIMITY SWITCHES The BODY-UP 5 WIRE PROXIMITY SWITCH (063-0034) is located on the left body prop up bracket with the striker located on the body above the switch. This switch turns on an alarm when the body is raised off the chassis. See Figure 18 NOTICE If the Body Up 5 Wire Proximity Switch does not activate the alarm, do not operate the truck.

  • Page 67: Body/Tailgate/Packer Valve

    Rapid Rail Body and Tailgate BODY/TAILGATE/PACKER VALVE The Body/Packer Valve is located between the chassis rails and controls the packer panel left and right movements, body raise/lower and tailgate raise/lower functions. Figure 19. Body/Packer Valve Figure 20. Body/Packer Valve Hydraulic Schematic Copyright 2024, The Heil Co.

  • Page 68: Body / Tailgate / Packer Valve Troubleshooting

    Rapid Rail Body and Tailgate BODY / TAILGATE / PACKER VALVE TROUBLESHOOTING NOTICE If spools are sticking, operation of the manual overrides can free them. A. Packer Does Not Move 1. Operate manual overrides on packer pilot valve. 2. If Packer now moves: check for electrical problems such as wiring, solenoid coil, and current from controller or pressure switch failure.
  • Page 69 Rapid Rail Body and Tailgate BODY / TAILGATE / PACKER VALVE TROUBLESHOOTING (CONTINUED) Figure 21. Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body and Tailgate...

  • Page 70: Body Props

    Rapid Rail Body and Tailgate BODY PROPS The factory-supplied body props are located on both sides under the body and forward of the rear wheels. Refer the figure below. Follow these steps to lower the body props. Figure 22. Factory Body Props Issued September 2024 Copyright 2024, The Heil Co.

  • Page 71: Tailgate Support Props

    Rapid Rail 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 72 Rapid Rail Body and Tailgate Figure 23. Tailgate Support Props Issued September 2024 Copyright 2024, The Heil Co. Body and Tailgate Printed in the U.S.A.

  • Page 73: Welding And Electronic Devices / Electrical Lubricants

    Rapid Rail Body and Tailgate 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 74 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Maintenance and Adjustment Printed in the U.S.A.

  • Page 75: Section 5 Maintenance And Adjustment

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

  • Page 76: Body Daily Checklist

    Rapid Rail 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 77: Body Preventive Maintenance Chart

    Rapid Rail 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 78 Rapid Rail Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE For greasable PTOs (non-wet spline), remove the pump’s bolt flange about 2 inches from the PTO and apply grease to female pilot of PTO pump flange. Failure to lubricate female pilot of PTO as given may cause damage to the pump shaft.

  • Page 79: Pto Inspection And Preventive Maintenance

    Rapid Rail 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 80: Body Lubrication Guide

    Rapid Rail 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. Issued September 2024 Copyright 2024, The Heil Co.

  • Page 81: Pack/Eject Cylinders Maintenance

    Rapid Rail 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 82: Cold Weather Warmup Procedure

    Rapid Rail Maintenance and Adjustment COLD WEATHER WARM-UP 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 or to check the oil level. The hydraulic oil is sufficiently warmed when the temperature is between 120°...

  • Page 83: Preparing The Unit To Check The Oil Level

    Rapid Rail 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 Body – fully down Tailgate –...

  • Page 84: Check Oil Level

    Rapid Rail 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 85: Drain And Clean The Hydraulic Oil Tank

    Rapid Rail 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 86 Rapid Rail 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 87: Purge The Hydraulic System

    Rapid Rail 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 88: Pressure Adjustment Settings

    Rapid Rail Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS A. Unit Preparation Follow these unit preparation steps prior to making any pressure adjustments listed in this section. 1. Make sure area around unit is clear to enable arm and fork operation. 2.
  • Page 89 Rapid Rail Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS (CONTINUED) Figure 26. Body Valve Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Maintenance and Adjustment...

  • Page 90: Hydraulic Pressures

    Rapid Rail Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS (CONTINUED) D.Pressures HYDRAULIC PRESSURES LOADER RELEASE IN RELIEF BODY MAIN GRABBER PRESS. PACKER PRESS. SWITCH MAIN RELIEF RELIEF SWITCH RELIEF 2200 1100 2350 2400 2000 2200 Notes: 1. Main Pressure settings have a tolerance range of +/- 50 p.s.i. and are to be set at operating speed. 2.

  • Page 91: Cracked Weld Joints

    Rapid Rail Maintenance and Adjustment REPAIRING CRACKED WELD JOINTS Repair all cracked weld joints immediately after finding cracked weld joints. If you are unsure of the proper repair procedure, call Heil Technical Services at 866-310-4345. OIL LUBRICANT RECOMMENDATION Use only non-detergent engine oil to lubricate all moveable mechanical parts not furnished with grease fittings. Apply sufficient oil to give good lubrication, but do not bathe parts in oil.
  • Page 92 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.

  • Page 93: Section 6 Body Controller Hardware

    Rapid Rail Body Controller Hardware SECTION 6 BODY CONTROLLER HARDWARE Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Hardw are...

  • Page 94: Body Controller Hardware

    Rapid Rail Body Controller Hardware CORTEX CONTROLLER 98 I/O ASSEMBLY There are no serviceable parts within the Cortex Controller housing. Do not open the Cortex Controller housing. Send the Cortex Controller to Heil Environmental for repair or programming. Refer to the figure below. Note: the ST A and ST B are keyed specifically and not interchangeable.

  • Page 95: Pin Number Diagram

    Rapid Rail Body Controller Hardware CORTEX CONTROLLER PIN NUMBER DIAGRAM Refer to the figure below for the Cortex Controller female pin locations. Figure 30. Cortex Cable Connection, Female Pin Positions. CORTEX CONTROLLER 81-PIN CABLE ASSEMBLY Refer to the following steps for assembly and connecting the Cortex Controller Cable. A.
  • Page 96 Rapid Rail Body Controller Hardware Figure 32. Issued September 2024 Copyright 2024, The Heil Co. Body Controller Hardw are Printed in the U.S.A.
  • Page 97 Rapid Rail Body Controller Hardware CORTEX CONTROLLER 81-PIN CABLE ASSEMBLY (CONTINUED) B. Male and Female Controller Connector Close-Up View See figure below to identify the female cable and male controller connection points. Figure 33. Male and Female Connection Points for Controller and Cable. Copyright 2024, The Heil Co.
  • Page 98 Rapid Rail Body Controller Hardware CORTEX CONTROLLER 81-PIN CABLE ASSEMBLY (CONTINUED) C. Connecting the 81-Pin Cable Connector 1. With the locking mechanism retracted, carefully align the keys and grooves and gently press down. See figure below. Figure 34. Align Keys and Grooves to Connect Cable to Controller. 2.
  • Page 99 Rapid Rail Body Controller Hardware Figure 36. Continue to Push until Locking Mechanism is Flush and an Audible Click is Heard. Figure 37. Notice Locking Mechanism is Flush with Connector. Cable is Connected to the Controller. 3. Repeat steps to attach the second cable connector to the adjacent side of the controller. 4.

  • Page 100: Insight™ Standard Diagnostic Display

    Rapid Rail 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 38. Insight Display Front Photo Figure 39. Insight Display Rear Photo M12 connector M52 thread for fixing nut Locating pins...

  • Page 101: Diagnostic Display Cable

    Rapid Rail Body Controller Hardware INSIGHT™ STANDARD DIAGNOSTIC DISPLAY CABLE See the figure below for a rear view of the display with cable connected. Figure 41. Rear View of Display with Cable Connected CORTEX CONTROLLER PROGRAMMING Contact Heil Environmental for re-programming of the Cortex Controller. Copyright 2024, The Heil Co.
  • Page 102 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.

  • Page 103: Section 7 Body Controller Software

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

  • Page 104: Rapid Rail Cortex Controller Program 109-0357

    Rapid Rail Body Controller Software Rapid Rail ® Cortex Controller Program 109-0357 SECTION 1: CORTEX CONTROLLER HARDWARE 1.02: Inputs The CORTEX Controller Inputs are activated by a positive +12 volt signal. All Switches, Proximity, Pressure, Toggle, Push buttons, etc., used as input devices to the Controller, supply a +12 volt signal to an CORTEX Controller input to turn the Input ON unless otherwise specified.
  • Page 105 Rapid Rail Body Controller Software 1.06: CORTEX - Connector Pin Details The table below gives connection details between Cortex Controller Input/output and Connector Pins. – CONNECTOR RAPID RAIL RAPID RAIL PIN-OUT DETAILS IN-CAB INPUT FUNCTIONS CHASSIS SERVICE BRAKE SIGNAL IN0501 ST A-41 TRANSMISSION TEMP.
  • Page 106 Rapid Rail Body Controller Software CONNECTOR RAPID RAIL RAPID RAIL PIN-OUT DETAILS CHASSIS REVERSE SIGNAL IN1203 ST B-13 PACKER PROXIMITY SWITCH IN1101 ST B-07 FILTER PRESSURE SWITCH IN0801 ST A-37 LOADER UN DUMP PROXIMITY SWITCH IN1201 ST B-11 LOADER UP PROXIMITY SWITCH IN0003 ST A-28 GRIPPER FULL OPEN PROXIMITY SWITCH...

  • Page 107: Section 3: Default Parameters

    Rapid Rail Body Controller Software Section 2: J1939 Details The Engine information is directly read through the SAE J1939 standard. SAE J1939 is the vehicle bus standard used for communication and diagnostics among vehicle components, like heavy duty truck industry.J1939 is used in heavy vehicles for on-street and OFF-road operations and works on the physical layer with CAN-high speed according to ISO11898.

  • Page 108: Section 4: I/O Functions

    Rapid Rail Body Controller Software Section 4: I/O Functions The following sheets detail the functionality of the 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 5.04 for more details about Diagnostic display options and INSIGHT display.
  • Page 109 Rapid Rail Body Controller Software A04 Input Function -- Chassis Neutral Signal (In Cab Input IN0400) This circuit monitors the Transmission Neutral circuit. This input is enabled when the Engine transmission is put into Neutral. Condition Modifiable Parameters Default Setting None Function Logic: Input Device...
  • Page 110 Rapid Rail Body Controller Software A07 Input Function -- Packer Left Rocker Switch (In Cab Input IN0502) This circuit monitors the ON/OFF status of the Packer Left Rocker Switch. This Switch is used to activate the Packer Left input. Condition Modifiable Parameters Default Setting None...
  • Page 111 Rapid Rail Body Controller Software Function Logic: Input Device Status Status Loader Grip Rocker Switch Activated IN1100 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Softw are...
  • Page 112 Rapid Rail Body Controller Software A11 Input Function -- Loader Release Rocker Switch (In Cab Input IN0401) This circuit monitors the ON/OFF status of the Loader Release Rocker Switch. This switch is used to activate the Loader Arm Release input. Condition Modifiable Parameters Default Setting...
  • Page 113 Rapid Rail Body Controller Software Function Logic: Input Device Status Status Loader Out Rocker Switch Activated IN0300 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Softw are...
  • Page 114 Rapid Rail Body Controller Software A15 Input Function -- Loader Up Rocker Switch (In Cab Input IN0603) This circuit monitors the ON/OFF status of the Loader Up Rocker Switch. This input is used to activate the Loader Up input. Condition Modifiable Parameters Default Setting None...
  • Page 115 Rapid Rail Body Controller Software 4.02: Standard In-Cab Output Functions B01 Output Function -- Filter Bypass Indicator (In Cab Output OUT0305) This output function controls the filter bypass indicator. Activation of this light indicates that the filter is or has been in bypass, within the past fifteen minutes.
  • Page 116 Rapid Rail Body Controller Software In-Cab Alarm Activated OUT0301 Note: With either (A OR B OR C OR D) true, will activate the In-Cab Alarm (E). Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 117 Rapid Rail Body Controller Software B03 Output Function – Hydraulic Pump, Loader – P1 (In Cab Output OUT0103) This output function controls the Hydraulic Pump for the Loader-P1. Circuit will engage the pump upon activation of the chassis Service Brake or transmission Neutral signal or upon pressing the Grabber Open push button. Condition Modifiable Parameters Default Setting...
  • Page 118 Rapid Rail Body Controller Software Pack Left Solenoid Activated IN0801 Pack Left Indicator Activated IN0500 Note: With condition (A) true, the Pack Left Indicator (B) will activate. Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 119 Rapid Rail Body Controller Software B06 Output Function – Packer Right Indicator (In Cab Output OUT0106) This output function controls the indicator lamp for the Pack Right function. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component Status...
  • Page 120 Rapid Rail Body Controller Software Note: With Condition ‘A’ true , will activate the Packer Pressure Switch indicator output. Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 121 Rapid Rail Body Controller Software B09 Output Function – Whelen Strobe Indicator (In Cab Output OUT0001) This output function controls the Whelen Strobe indicator. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component Status Status Turn Signal...
  • Page 122 Rapid Rail Body Controller Software Trans Temp Indicator Activated OUT0307 Note: With condition (A) true, the indicator (B) will flash, once per second, when Fault #31 is set. This indicates the transmission fluid temperature has exceeded a safe operating range. Issued September 2024 Copyright 2024, The Heil Co.
  • Page 123 Rapid Rail Body Controller Software 4.03: Standard Body Input Functions C01 Input Function – Body/Tailgate Raised Alarm Proximity Switch (Body Input IN1901) This circuit monitors the ON/OFF status of the Body/Tailgate Raised proximity switch. This input is ON when the Body / Tailgate is in Raised position.
  • Page 124 Rapid Rail Body Controller Software Input Device Status Status Packer Pressure Switch Activated IN0602 Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 125 Rapid Rail Body Controller Software C05 Input Function – Chassis Reverse Signal (Body Input IN1203) This circuit monitors the ON/OFF status of the Chassis Reverse signal. This input is ON when the Engine transmission is put into Reverse. This input, when turned ON, will enable the Reverse flood lights and Whelen Strobe lights.
  • Page 126 Rapid Rail Body Controller Software Loader Undump Prox. Switch Activated IN1201 Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 127 Rapid Rail Body Controller Software C09 Input Function – Loader Up Proximity Switch (Body Input IN0003) This circuit monitors the ON/OFF status of the Loader Up proximity switch. This input is ON when the Loader Arm is in the Raised position. Condition Modifiable Parameters Default Setting...
  • Page 128 Rapid Rail Body Controller Software Input Device Status Status STARR Jumper input Activated IN0600 Issued September 2024 Copyright 2024, The Heil Co. Body Controller Softw are Printed in the U.S.A.
  • Page 129 Rapid Rail Body Controller Software C13 Input Function – Grabber Closed Pressure Switch (Body Input IN0900) This circuit monitors the ON/OFF status of the Grabber Closed pressure switch. This input is ON when the pressure in the Grabber cylinder reaches the set point. Condition Modifiable Parameters Default Setting...
  • Page 130 Rapid Rail Body Controller Software D02 Output Function – Loader Release Output (Body Output OUT0004) This output function controls the Loader Release Output. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component Status Status System Power Switch Activated...
  • Page 131 Rapid Rail Body Controller Software met. With condition (A) true and condition (B) ON, condition (C) will activate the output or condition (E) ON and condition (I) OFF will activate the output after 1.2 seconds (see note for D01) or condition (F) will activate the output after 0.5 seconds until the following occurs: If condition (G) is OFF, condition (D) will deactivate the output.
  • Page 132 Rapid Rail Body Controller Software D04 Output Function -- Loader Out Output (Body Output OUT0002) This output function controls the Loader Out output. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component Status Status System Power Switch Activated...
  • Page 133 Rapid Rail Body Controller Software (i.e. ON) then the lift will raise for ca. 0.3 seconds then stop to prevent damage to the body of the unit. Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Softw are...
  • Page 134 Rapid Rail Body Controller Software D06 Output Function -- Loader Down Output (Body Output OUT0300) This output function controls the Loader Down output. Condition Modifiable Parameters Default Setting Loader Grip Time 1.2 sec. (See Note for D01) Conditions Necessary to activate the circuit: Condition Function or Component Status...
  • Page 135 Rapid Rail Body Controller Software D08 Output Function -- Loader Un-Dump Output (Body Output OUT0000) This output function controls the Loader Un-Dump output. Condition Modifiable Parameters Default Setting Un-dump Time 0.5 Sec. Conditions Necessary to activate the circuit: Condition Function or Component Status Status System Power Switch...
  • Page 136 Rapid Rail Body Controller Software D10 Output Function – Pack Left Solenoid (Body Output OUT0105) This output function controls the Pack Left solenoid. Condition Modifiable Parameters Default Setting Packer Reverse Delay 0.5 Sec. Packer Startup Time 5.0 Sec. Conditions Necessary to activate the circuit: Condition Function or Component Status...
  • Page 137 Rapid Rail Body Controller Software Note: With condition (A OR B) true AND (C OR D) true, condition (E) will activate the Loader Latch Solenoid (F). Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Softw are...
  • Page 138 Rapid Rail Body Controller Software D12 Output Function – Reverse Flood Lights (Body Output OUT0104) This output function controls the Reverse Flood Light output. Condition Modifiable Parameters Default Setting None Conditions Necessary to activate the circuit: Condition Function or Component Status Status Chassis Reverse Signal...
  • Page 139 Rapid Rail Body Controller Software 4.05: Optional In-Cab Input Functions E01 Input Function – Auto-Neutral (Force to Neutral) Enable Switch (In-Cab Input IN0503) This circuit monitors the ON/OFF status of the Auto-Neutral Enable switch. Refer section 3.01 for additional information on the pump default operation speeds.
  • Page 140 Rapid Rail Body Controller Software 4.06: Optional In-Cab Output Functions F01 Output Function – Allison Wires 142/117 (In-Cab Output OUT0107) This output function controls Allison wires 142 and 117 which are part of the Auto-Neutral (Force to Neutral) function of the transmission.
  • Page 141 Rapid Rail Body Controller Software Neutral (Force to Neutral) functions. Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Body Controller Softw are...
  • Page 142 Rapid Rail Body Controller Software 4.07: Optional Body Input Functions G01 Input Function – Low Engine Torque Pressure Switch (Body Input IN0601) This circuit monitors the ON/OFF status of the low engine torque pressure switch. This input will be ON when the Engine Torque is low and will disable the Packer pump.

  • Page 143: Section 5: Special Features

    Rapid Rail Body Controller Software Section 5: Special Features 5.01: Auto/Manual Pack Mode Auto/Manual Pack Mode is a standard feature on all Cortex Controller controlled products. While in Auto Mode the packer will make an approx. 180º sweep continuously pausing for 0.5 seconds at the end of each sweep (or when the packer pressure switch is seen during the sweep).
  • Page 144 Rapid Rail Body Controller Software 5.04: INSIGHT Display Functionality:- Cortex Controller uses a hand held device (INSIGHT) for displaying the current status of Input / Output, Engine speed, Temperatures etc., and can be used to SET/RESET any particular Input/Output bit. This can also be used for configuring or selecting different options in Cortex controller.
  • Page 145 Rapid Rail Body Controller Software Note: By holding the OK button down for 10 seconds and entering “4 – 3 – 2 – 1” then OK again, we can get access to the screen to Reset the Arm Cycle counts and Packer cycle counts. Copyright 2024, The Heil Co.
  • Page 146 Rapid Rail Body Controller Software 5. H.M.I Display: This is used for displaying the current status of the Input / Output, Engine Run Speed, Temperature, Auto/Manual mode etc. This can be programmed for graphically representing a process. This can also be used for changing the set points for Analog values.
  • Page 147 Rapid Rail Body Controller Software 5.04.03:Rear Panel Housing connection: Table below provides Wiring details for the Interface cable of INSIGHT display unit Illustration Description Note n.c. ---- 8...32 V DC TERMINAL 31 CAN-H CAN-L 5.04.04: Display Status LED’s: LED Color Flashing Frequency Description Permanently OFF...

  • Page 148: Section 6: Diagnostics

    Rapid Rail Body Controller Software Section 6: Diagnostics 6.01: Testing I/O Voltage To test the voltage at an input or output terminal a Digital Multi Meter is always the best tool. Incandescent test lights cannot be used to test inputs from certain electronic input device. The amperage required to light an incandescent tester may exceed the maximum output of the device.
  • Page 149 Rapid Rail Body Controller Software 6.04.01: Critical Faults Fault #31- High Transmission Temperature Operate In Gear At Idle systems monitor the temperature of the transmission sump fluid and the fluid flowing out of the torque converter to the cooler. This fault will be set when either of these temperature levels exceed operating range. The maximum operating temperature for the transmission sump fluid is 250°F.
  • Page 150 Rapid Rail Body Controller Software 6.04.01: Critical Faults (Continued) Fault #42- Loss of Engine Idle Calibration _ The Engine Idle parameter has been erased from memory. Indication: A. Engine Idle needs to be calibrated. B. Internal data storage device has malfunction. Replace CORTEX CONTROLLER Disabled Functions: Hydraulic Pump Fault Reset: Cycling the System Power Switch will allow three minutes of further operation or complete the engine speed calibration procedure.
  • Page 151 Rapid Rail Body Controller Software .04.02: System Faults Fault #54- Filter Bypass Switch Fault _ The CORTEX CONTROLLER has lost the signal from the filter pressure switch while neither hydraulic pump was in operation. This is recognized as a fault because there should be no hydraulic pressure to bypass the filter under this condition.
  • Page 152 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 153: Section 8 Schematics

    Rapid Rail Schematics SECTION 8 SCHEMATICS Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 154: 063-0034 Body And Tailgate Prox Switch

    Rapid Rail Schematics BODY AND TAILGATE PROXIMITY SWITCH 063-0034 18MM PROXIMITY SWITCH 063-0108 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 155: 30Mm Proximity Switch 063-0109

    Rapid Rail Schematics 30MM PROXIMITY SWITCH 063-0109 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...
  • Page 156 Rapid Rail Schematics Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 157: Brake Light Harness 108-6186

    Rapid Rail Schematics BRAKE LIGHT HARNESS 108-6186 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 158: Logic Box Harness 108-6805

    Rapid Rail Schematics LOGIC BOX HARNESS 108-6805 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 159: Power Relay Module 108-8458

    Rapid Rail Schematics POWER RELAY MODULE 108-8458 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 160: Packer/Reverse Relays - 108-8468-016

    Rapid Rail Schematics PACKER/REVERSE RELAYS - 108-8468-016 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 161: Plug In Controls Splitter Harness 263-0093

    Rapid Rail Schematics PLUG IN CONTROLS SPLITTER HARNESS 263-0093 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 162: Tailgate Middle Cluster Harness 263-0891-004

    Rapid Rail Schematics CAMERA FLOOD LIGHTS TAILGATE MIDDLE CLUSTER HARNESS 263-0891- Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 163: Side Flood Lamp Harness 263-0942

    Rapid Rail Schematics SIDE FLOOD LAMP HARNESS - 263-0942 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 164: Vickers Packer Valve Harness 263-1040

    Rapid Rail Schematics VICKERS PACKER VALVE HARNESS 263-1040 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 165: Interlink Body Raise Harness 263-1153

    Rapid Rail Schematics INTERLINK BODY RAISE HARNESS 263-1153 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 166: Alarm Adapter Harness 263-1309-002

    Rapid Rail Schematics ALARM ADAPTER HARNESS 263-1309-002 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 167: Dual Strobe Light W/2 Pin Harness 263-1361

    Rapid Rail Schematics DUAL STROBE LIGHT W/2 PIN HARNESS 263-1361 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 168: Valve End Loader Harness 263-1436-001

    Rapid Rail Schematics VALVE END LOADER HARNESS 263-1436-001 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 169: Middle Loader Harness - 263-1436-005

    Rapid Rail Schematics MIDDLE LOADER HARNESS - 263-1436-005 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 170: 4-Button Control Harness 263-1436-014

    Rapid Rail Schematics 4-BUTTON CONTROL HARNESS 263-1436-014 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 171: Grabber Interlock Harness 263-1436-027

    Rapid Rail Schematics GRABBER INTERLOCK HARNESS 263-1436-027 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 172: Middle Grabber Interlock Harness 263-1436-028

    Rapid Rail Schematics MIDDLE GRABBER INTERLOCK HARNESS 263-1436-028 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 173: Grabber Interlock Proximity Harness 263-1436-029

    Rapid Rail Schematics GRABBER INTERLOCK PROXIMITY HARNESS 263-1436-029 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 174: Muni Lights Harness 263-1481

    Rapid Rail Schematics MUNI LIGHTS HARNESS 263-1481 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 175: Cycle Counter Harness 263-1502

    Rapid Rail Schematics CYCLE COUNTER HARNESS 263-1502 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 176: Grabber Work Light Harnesses 263-1513

    Rapid Rail Schematics GRABBER WORK LIGHT HARNESSES 263-1513 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 177: Grabber/Hopper Work Light Harness 263-1515

    Rapid Rail Schematics GRABBER/HOPPER WORK LIGHT HARNESS 263-1515 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 178: Battery Box Harness 263-1517

    Rapid Rail Schematics BATTERY BOX HARNESS 263-1517 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 179: Battery Power Harness 263-1517-003

    Rapid Rail Schematics BATTERY POWER HARNESS 263-1517-003 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 180: Battery Harness 263-1518

    Rapid Rail Schematics BATTERY HARNESS 263-1518 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 181: Jumper Harness 263-1530

    Rapid Rail Schematics JUMPER HARNESS 263-1530 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 182: Reverse Signal Relay Harness 263-1541

    Rapid Rail Schematics PETERBILT REVERSE SIGNAL RELAY HARNESS, 263-1541 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 183: Transmission Temperature Relay Harness 263-1565-002

    Rapid Rail Schematics TRANSMISSION TEMPERATURE RELAY HARNESS 263-1565-002 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 184: Transmission Temperature Jumper Harness 263-1565-003

    Rapid Rail Schematics TRANSMISSION TEMPERATURE JUMPER HARNESS 263-1565-003 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 185: Insight™ Diagnostic Display Module Harness - 263-1714

    Rapid Rail Schematics INSIGHT™ DIAGNOSTIC DISPLAY MODULE HARNESS - 263-1714 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 186: Low Hydraulic Oil Extension Harness - 263-1754

    Rapid Rail Schematics LOW HYDRAULIC OIL EXTENSION HARNESS - 263-1754 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 187: Battery Box Harness Installation - 372-5570

    Rapid Rail Schematics BATTERY BOX HARNESS INSTALLATION – 372-5570 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 188: Battery Connection Schematic 701-8038

    Rapid Rail Schematics BATTERY CONNECTION SCHEMATIC 701-8038 Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.

  • Page 189: Tailgate Middle Cluster Schematic 701-8950-001

    Rapid Rail Schematics TAILGATE MIDDLE CLUSTER SCHEMATIC 701-8950-001 Copyright 2024, The Heil Co. Issued September 2024 Printed in the U.S.A. Schematics...

  • Page 190: Ccc Chassis Interface Harness 263-1471-001

    SEE NOTE BELOW. CCC Chassis Interface Harness 263-1471-001 10/27/2010...

  • Page 191: Condor Chassis Interface Harness 263-1471-002

    SEE NOTE BELOW. Condor Chassis Interface Harness 263-1471-002 10/27/2010...

  • Page 192: Granite Chassis Interface Harness 263-1471-003

    Granite Chassis Interface Harness 263-1471-003 01/27/2011...

  • Page 193: Acx Chassis Interface Harness - 263-1471-006

    ACX Chassis Interface Harness 263-1471-006 02/06/2015...

  • Page 194: Non-Rpm International Chassis Interface Harness 263-1471-008

    International Chassis Interface Harness 263-1471-008 11/10/2010...

  • Page 195: International Vza Chassis Interface Harness - 263-1471-009

    International Chassis Interface Harness 263-1471-009 01/16/2012...

  • Page 196: Peterbilt Cab To Various Chassis Interface Harness 263-1471-012

    SEE NOTE BELOW. Peterbilt Chassis Interface Harness 263-1471-012 08/28/2013...

  • Page 197: Freightliner Chassis Interface Harness - 263-1471-013

    Freightliner Chassis Interface Harness 263-1471-013 11/10/2010...

  • Page 198: Kensworth Conventional Chassis Interface Harness - 263-1471-016

    108-6461-010 108-6461-010 Conventional Kenworth Chasis Interface Harness 263-1471-016 11/15/2010...

  • Page 199: Bumper Harness With Diodes 263-0936

    WIRE AMP CONNECTOR WIRE COLOR WIRE DISCRIPTION P/N: 282105-1 INCLUDE PLUG WHITE GROUND (14 GA) BROWN CLEARANCE LIGHTS YELLOW LEFT HAND TURN GREEN RIGHT HAND TURN WHITE\RED BRAKE LIGHTS PINK BACK-UP LIGHTS ORANGE TAILGATE OPEN SIGNAL BROWN\WHITE TAILLIGHTS YELLOW/WHITE SMART LAMP CONTROL WHITE/BLACK CAB SPARE WHITE/BLUE...

  • Page 200: Body Harness 263-1412-007

    Body Harness 263-1412-007 12/03/2012...

  • Page 201: Tailgate Harness With Smart Lamp 263-1412-008

    RH TURN RH STOP LH STOP LH TURN & TAIL & TAIL & TAIL & TAIL CENTER BRAKE CLEARANCE CLEARANCE LIGHT LIGHT 0.33 WHITE 760-3 0.33 BLACK CLEARANCE LIGHT CLEARANCE CLEARANCE CLEARANCE 417-49 417-49 LIGHT LIGHT LIGHT CLEARANCE SMART LAMP SMART LAMP LIGHT Tailgate Harness...
  • Page 202 Tailgate Harness 263-1412-014 04/30/2015...

  • Page 203: Husco Valve Harness, V.3 263-1920

    Husco Harness 263-1436-025 10/27/2015...

  • Page 204: Bumper Assembly Harness 701-8951

    RHTF 1 2 3 GRAY "SYNC" YEL/WHT "SMART" WHT "GND" BROWN "CLEAR" BRN/WHT "TAIL" GREEN "RTURN" BLK/WHT WHT/RED "STOP" YEL/WHT-"SMART" WHITE-"GND" 3 2 1 3 2 1 BROWN-"CLEAR" RHBT RHTT WHT/BLU-"SPARE" WHT/BLK-"SPARE" YELLOW-"LTURN" BRN/WHT-"TAIL" GREEN-"RTURN" WHT/RED-"STOP" PINK-"REV" ORANGE-"TAILGATE" WHT "GND" PINK "REV"...

  • Page 205: Ifm Cab To Body Schematic 701-9042-002

    PINOUT FOR HARNESS 263-1706-001 PINOUT FOR HARNESS 263-1706-002 PINOUT FOR HARNESSES 263-1706-003, & 263-1706-004, PINOUT FOR HARNESSES 263-1706-005 & 263-1706-006 BLUNT CUT WIRES #10 RING TERMINALS 263-1706-005 263-1706-006 PINOUT FOR HARNESSES 263-1706-007 PINOUT FOR HARNESS 263-1706-008 F3 15A PINOUT FOR HARNESS 263-1706-009 18GA TWISTED PAIR 18 GA TWISTED PAIR Cortex Controller ™...

  • Page 206: Control Box Harness 263-1479-009

    Control Box Harness 263-1479-009 10/07/2010...

  • Page 207: Control Panel Harness 263-1479-010

    Control Panel Harness 263-1479-010 06/22/2011...

  • Page 208: Chassis Harness 263-1503

    RELAY BOX LOADER CONNECTOR FINESSE VALVE LOW TORQUE BODY VALVES BODY UP PROX BODY UP LSW CO-COLLECTOR OPTION VALVES PACKER PSW OPTION LIGHTS Chassis Harness 263-1503 03/30/2015...

  • Page 209: Cortex Controller™ Cab Control Electrical Schematic 701-9042-001

    PTO MOUNTED OAI NON PTO MOUNTED PUMP OAI PUMP SEE NOTE "A" SEE DETAIL "A" DETAIL "A" Cortex Controller™ Cab Control Electrical Schematic 701-9042-001 02/18/2016...

  • Page 210: Cortex Controller™ Peterbilt Coe Cab To Body Schematic 701-9042-003

    F3 15A Cortex Controller™ Peterbilt COE Cab to Body Schematic 701-9042-003 01/14/2014...

  • Page 211: Cab To Body Harness, Ifm 701-9042-002

    IFM, CAB TO BODY HARNESS 701-9042-002 10/10/2018, REV C.
  • Page 212 CONNECTORS DO NOT APPEAR AS THEY DO HERE ON EVERY HARNESS. REFERENCE GRAPHICAL REPRESENTATION TO RIGHT FOR PINOUT OF CONNECTORS D1-A, D2, & D2-A PER HARNESS. IFM, CAB TO BODY HARNESS 701-9042-012 11/30/2023...
  • Page 213 IFM, CAB TO BODY HARNESS, PETERBILT 701-9042-013 06/25/2021...
  • Page 214 CONNECTORS DO NOT APPEAR AS THEY DO HERE ON EVERY HARNESS. REFERENCE GRAPHICAL REPRESENTATION TO RIGHT FOR PINOUT OF CONNECTORS D1-A, D2, & D2-A PER HARNESS. IFM, CAB TO BODY HARNESS 701-9042-012 11/30/2023...
  • Page 215 IFM, CAB TO BODY HARNESS, PETERBILT 701-9042-013 06/25/2021...
  • Page 216 TWISTED PAIR CAB, ELECTRICAL 701-9042-014 06/28/21...
  • Page 226 SLIDE OUT □ GRIP CYLINDER DUMP CYLINDER ARM RAISE CYLINDER IN - UT CYLINDER BODY DUMP CYLINDER TAILGATE CYLINDERS PACKER CYLINDERS r::::I 2200PSI --r----- --r----- --r----- r--7 ® -� ---7----r----- 235� PSI hfi-,' 2200PSI SOLENOID (BLOCKER) ·---- --------- - -- -- - --- ----- -- --- - ----- -·...
  • Page 236 Rapid Rail Schematics Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.
  • Page 238 Rapid Rail NOTES Issued September 2024 Copyright 2024, The Heil Co. Schematics Printed in the U.S.A.
  • Page 239 Rapid Rail INDEX hazard symbols and definitions hydraulic oil specifications 263-0942 hydraulic symbols 263-1436-014 InSight™ CAN programming cable battery disconnect switch InSight™ standard diagnostic display body daily checklist InSight™ standard diagnostic display cable body lubrication guide inspect proximity switches body preventive maintenance chart introduction body props body/tailgate/packer valve...
  • Page 240 Rapid Rail INDEX Rapid Rail and STARR System Cortex Controller Program 109-0283 repairing cracked weld joints service/parts assistance specifications standard torque data for nuts and bolts standard torque data for nuts and bolts table storing refuse in the body tailgate lubrication tailgate support props tandem vane pump O.I.G.A.I.
  • Page 241 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 242 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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