Dover HEIL PT1100 US Service Manual
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Dover HEIL PT1100 US Service Manual

Dover HEIL PT1100 US Service Manual

High-performance rear loader
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PT1100 ™ US
HIGH-PERFORMANCE REAR LOADER
SERVICE MANUAL
ISSUED OCTOBER 2023
TP1PT11US-SM-1023
© 2023 Heil Environmental
.

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Summary of Contents for Dover HEIL PT1100 US

  • Page 1 PT1100 ™ US HIGH-PERFORMANCE REAR LOADER SERVICE MANUAL ISSUED OCTOBER 2023 TP1PT11US-SM-1023 © 2023 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 IMPORTANT SAFETY NOTICE Proper service and repair are important to the safe, reliable operation of Heil Co.’s products.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Introduction ......................................4 Service/Parts Assistance ......................................4 Precautionary Statements ......................................5 Lock-Out/Tag-Out Procedures ......................................7 Electronic Parts Catalog (EPC) ......................................8 Storing Refuse in Container ......................................11 Maintenance/Lubrication Information ......................................11 Grease Lubrication Recommendation ......................................11 Oil Lubricant Recommendation ......................................11 Hydraulic Oil Specifications ......................................11 Proximity Switch Troubleshooting ......................................12...
  • Page 4 TABLE OF CONTENTS Control Area Network ......................................78 Body Electrical Kit ......................................81 Body Controller Software Controller Program Documentation for 109-0329 ......................................86 Controller Program Documentation for 109-0330 ......................................88 Controller Program Documentation for 109-0331 ......................................90 Controller Program Documentation for 109-0331-EXT ......................................92 Schematics Harness, Body Controller, 2020 REL - 263-1869-001 ......................................96 Harness, Body 2020 REL - 263-1869-003 ......................................97...
  • Page 5 HIGH-PERFORMANCE REAR LOADER SERVICE MANUAL ISSUED OCTOBER 2023 TP1PT11US-SM-1023 Copyright 2023, Heil Environmental Issued October 2023 Printed in the U.S.A.
  • Page 6 NOTES Issued October 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 7: Section 1 General Information

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

  • Page 8: Introduction

    General Information INTRODUCTION The following sections are guides for maintenance and service of the Heil unit. The sections cover preventive maintenance, adjustment, and troubleshooting hints. Before performing maintenance, check the work area carefully to find all the hazards present and make sure all necessary safeguards or safety devices are used to protect all persons and equipment involved.

  • Page 9: Precautionary Statements

    General Information PRECAUTIONARY STATEMENTS Listed below are the definitions for the various levels of hazards. It is important that the operators of this equipment and people who service units read and understand all warnings as they relate to this equipment operation. DANGER –...
  • Page 10 General Information DANGER Contact of the unit with overhead electric lines is dangerous. Death or serious injury can occur. Make sure there is adequate overhead clearance before you raise the container. If the unit does make contact with overhead electric lines do not touch any metal in the cab.

  • Page 11: Lock-Out/Tag-Out Procedures

    General Information LOCK-OUT/TAG-OUT PROCEDURES NOTICE Always use your employer’s Lock-Out/Tag-Out procedures. If your employer does not have Lock-Out/Tag-Out procedures, use the procedures that follow. Contact your supervisor or Heil Technical Service if you have any questions about Lock- Out/Tag-Out procedures. Put the unit in a Lock-Out/Tag-Out mode: BEFORE you enter the unit’s body BEFORE you do maintenance, repair or cleaning procedures on the unit.

  • Page 12: Electronic Parts Catalog (Epc)

    General Information ELECTRONIC PARTS CATALOG (EPC) The Parts Central EPC includes electronic versions of the Heil Parts Manuals, specific to a Customer’s truck configuration and options. After registering and logging in, the user can search by Keyword(s) or Part Number and/or Heil Body Serial Number to quickly identify a spare part or browse a custom parts catalog.
  • Page 13 General Information Search by Part Keyword(s) or Part Number in Body Serial Number After login, you will land on the User Dashboard. At the top right of the Dashboard, there will be two search fields, as shown in the image below. You can search by Keyword(s) or Part Number within a specific Heil Body Serial Number.
  • Page 14 General Information Search by Body Serial Number If you want to view an entire parts catalog for a particular Heil unit, you can search by only the Heil Body Serial Number, leaving the Keyword(s) / Part Number field blank. The search result will then be the Body Serial Number-specific parts catalog with familiar catalog sections that you can browse.

  • Page 15: Storing Refuse In Container

    General Information STORING REFUSE IN THE BODY Heil does not recommend storing refuse in the body overnight. The different types of debris and corrosive elements usually collected can cause severe corrosion inside the body decreasing the life of your body. This corrosion can affect unloading and decrease the structural life of the body.

  • Page 16: Proximity Switch Troubleshooting

    General Information PROXIMITY SWITCH TROUBLESHOOTING When one or more of a unit’s functions do not operate properly and there are proximity switches in the circuits of the unit for these functions, refer to the following table as a guide to find the problem(s). NOTICE Heil proximity switches have a Light Emitting Diode (LED) on the switch to indicate that the switch is sensing metal.
  • Page 17 General Information PROXIMITY SWITCH TROUBLESHOOTING (CONTINUED) Copyright 2023, Heil Environmental Issued October 2023 General Information Printed in the U.S.A.

  • Page 18: Decals On The Unit

    General Information DECALS ON THE UNIT Make sure you can read all hazard and instruction decals. Clean decals if you cannot read the words. See for directions on cleaning decals. Replace any decal that is damaged, missing, or is not readable. When you replace a part that has a decal, make sure a new decal is installed on the new part.
  • Page 19 General Information DECAL CARE (CONTINUED) Figure 2. Recommended Technique Figure 3. Incorrect Technique Copyright 2023, Heil Environmental Issued October 2023 General Information Printed in the U.S.A.

  • Page 20: Hydraulic Symbols

    General Information HYDRAULIC SYMBOLS Issued October 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.
  • Page 21 General Information HYDRAULIC SYMBOLS (CONTINUED) Copyright 2023, Heil Environmental Issued October 2023 General Information Printed in the U.S.A.

  • Page 22: Electrical Symbols

    General Information ELECTRICAL SYMBOLS Issued October 2023 Copyright 2023, Heil Environmental General Information Printed in the U.S.A.

  • Page 23: Section 2 Pump

    Pump SECTION 2 PUMP Copyright 2023, Heil Environmental Issued October 2023 Pump Printed in the U.S.A.

  • Page 24: Hydraulic Pump Control

    Pump HYDRAULIC DRIVE CONTROL There are multiple hydraulic drive configurations available on the 2020 Rear End Loader. Each achieves the same goal utilizing different mechanisms and modes of operation. A. Clutch Shift PTO Listed in the display as Cab Controller Output, OUT02 p16 – PTO Sol. Not equipped Applies to Constant Drive PTO or Crankshaft Driven Front Mount Pumps.
  • Page 25 Pump HYDRAULIC DRIVE CONTROL (CONTINUED) C. Tandem Vane Pump Applies to Operate at Idle, PTO or Crankshaft driven Tandem Pumps. Listed in the display as Cab Controller Output, OUT03 p15 – Pump 1 Sol. And OUT04 p14 – Pump 2 Sol. Clutch Shift PTO Driven Option Config Clutch Shift PTO, W/Pump Manifold: [ON]...

  • Page 26: Underbody Valve Hydraulic Flow

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

  • Page 27: Section 3 Body And Tailgate

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

  • Page 28: Product Nomenclature

    Body and Tailgate PRODUCT NOMENCLATURE The figures below show the major body and tailgate components. Issued October 2023 Copyright 2023, Heil Environmental Body and Tailgate Printed in the U.S.A.
  • Page 29 Body and Tailgate PRODUCT NOMENCLATURE (CONTINUED) Copyright 2023, Heil Environmental Issued October 2023 Body and Tailgate Printed in the U.S.A.

  • Page 30: Standard Side Access Door

    Body and Tailgate SIDE ACCESS DOOR A side access door is installed on the street side of the body. This door will provide access to the hopper area for clean-out purposes. Be sure door is closed and latched properly at all times. WARNING Make sure the unit is in the Lock-Out/Tag-Out mode when you do maintenance or service procedures, when you go in the hopper, enter the side access door, or climb on the body or equipment.

  • Page 31: Tailgate Support Props

    Body and Tailgate TAILGATE SUPPORT PROPS Two support props are on the unit and must be used whenever the tailgate is opened for service or maintenance. Both props must be used. DANGER Do not walk under or go between the body and the tailgate when the tailgate is in motion, while you prop the tailgate or while the tailgate is propped.
  • Page 32 Body and Tailgate TAILGATE SUPPORT PROPS (CONTINUED) CAUTION Do not proceed to lower the tailgate until both props are in place. 4. Slowly LOWER tailgate until props mate with the tailgate Stop. Figure 7. Tailgate Lowered onto Both Streetside and Curbside Props 5.

  • Page 33: Section 4 Maintenance And Adjustment

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

  • Page 34: Body Daily Checklist

    Maintenance and Adjustment BODY DAILY CHECKLIST Make sure you perform a daily check of the unit. Refer to the Operator’s Manual for the Daily Checklist. Many checks in the Daily Checklist are maintenance related, such as checking tire pressures and hoses for wear and damage. DAILY CHECKLIST MAINTENANCE ITEMS ITEM REQUIRED ACTION...

  • Page 35: Body Preventive Maintenance Chart

    Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART Preventive maintenance must be performed to ensure the safe and reliable operation of your unit. Use the chart below as a guideline for when essential items should checked and serviced. Severe use or adverse conditions may require more frequent maintenance.
  • Page 36 Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE spline PTOs such as the Chelsea 890/897 series. Lubricate as shown on Body Lube Grease Fittings Chart. Inspect body undercoating and repair Body Undercoating as necessary. Tailgate Seal Integrity Packer/Ejector Cylinder Preventive See Packer/Ejector Cylinder...

  • Page 37: Pto Inspection And Preventive Maintenance

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

  • Page 38: Packer/Ejector Cylinder Preventive Maintenance

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

  • Page 39: Lubrication Guide

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

  • Page 40: Cold Weather Warmup Procedure

    Maintenance and Adjustment 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 41: Preparing The Unit To Check The Oil Level

    Maintenance and Adjustment PREPARING THE UNIT TO CHECK THE OIL LEVEL Before checking the oil level or adding oil, make sure the unit is in the following position with all cylinders collapsed: Truck – on level ground Tailgate and Body – fully down and locked Ejector Panel –...

  • Page 42: Check Oil Level

    Maintenance and Adjustment CHECK OIL LEVEL Check the hydraulic oil level (after warning up the oil) daily or every eight (8) hours, whichever comes first. Fill as necessary. Important: Contamination is a hydraulic system’s worst enemy. Do not let dirt enter the system. Use a clean rag and remove dirt or other contamination around any system component before you disconnect or remove it.

  • Page 43: Drain And Clean The Hydraulic Oil Tank

    Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK Change the hydraulic oil at least annually or every 2000 hours of operating time, whichever comes first. Remember that almost all hydraulic system malfunctions can be traced to dirt in the fluid. When working with the hydraulic system, the hands, tools, working area and parts must be as clean as possible.

  • Page 44: Purge The Hydraulic System

    Maintenance and Adjustment DRAIN AND CLEAN THE HYDRAULIC OIL TANK (CONTINUED) NOTICE Before filling the tank be sure the funnel is clean and 200 mesh (or finer) screen is used to strain the hydraulic oil. 13.Fill tank with recommended oil, checking the sight gauge as you fill. Refer to Hydraulic Oil Specifications 14.Check the entire system to make sure all connections are tight and no leaks are found.

  • Page 45: Pressure Adjustment Settings

    Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS DANGER Stand clear when packing mechanism is in motion. Standing close to the unit when it is in motion or operation may result in injury or death. DANGER Do not stand in the hopper or on the hopper sill while adjustments are being made on the packing mechanism with the unit running.
  • Page 46 Maintenance and Adjustment PRESSURE ADJUSTMENT SETTINGS (CONTINUED) C.Valve Locations The hydraulic control valves are located on the front head (street side) of the body and on the rear of the body above the hopper. D.Pressures and Cycle Times MODEL MAIN EJECTOR TAILGATE TAILGATE...

  • Page 47: Slide Wear Strips

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

  • Page 48: Troubleshooting

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

  • Page 49: Double Acting Telescopic Hydraulic Cylinder Disassembly And Assembly

    Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY Step 1 The cylinder is best serviced when mounted in the vertical position, for both disassembly and assembly. Also, it is best located where a hoist can be used directly overhead of the cylinder for removing the plungers if complete disassembly is required.
  • Page 50 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 3 - Head Nuts After the set screws have been loosened, tap head nut gently around its circumference and unscrew the head nut with a chain wrench, or an equivalent tool. Do not use a chisel, punch or weld any studs to the head nut to remove.
  • Page 51 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 5 – Packing To remove packing, pull the plunger up about one foot. Add tape to a clean area as shown in Figure 20. Push the plunger down past the packing then pull the plunger up. The packing will stick to the tape and be pulled out with the plunger.
  • Page 52 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 7 - Retainer Rings Using a tool shown in Figure 22, insert the hooked end into the retaining ring slot. Force the retaining ring out of the groove and lift ring out of plunger. Figure 18.
  • Page 53 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 9 – Second Retaining Ring and Plunger Stop Repeat Step 6 to remove second retaining ring. The plunger is now free to lift out. The plunger stop will come out with the plunger.
  • Page 54 Maintenance and Adjustment DOUBLE ACTING TELESCOPIC HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY (CONTINUED) Step 10 - Setting Head Nuts Remove the small slug located opposite the set screw. Using an allen wrench (Figure 17), tighten the head-nut down until the hex wrench bottoms out on the top of the plunger. Remove the hex wrench and replace the slug. Install the set screw using a nylon slug to protect the threads.

  • Page 55: Clean And Inspect The Tailgate Seal

    Maintenance and Adjustment CLEAN AND INSPECT THE TAILGATE SEAL Periodically check the tailgate seal to make sure it mates properly with the body and inspect for possible wear, damage or leaking. Replace the seal as necessary. See the figure below. Figure 22.
  • Page 56 NOTES Issued October 2023 Copyright 2023, Heil Environmental Body Controller Hardware Printed in the U.S.A.

  • Page 57: Section 5 Body Controller Hardware

    Body Controller Hardware SECTION 5 BODY CONTROLLER HARDWARE Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.

  • Page 58: In-Cab Display

    Body Controller Hardware IN-CAB DISPLAY The display also allows a qualified and authorized Service Technician to see detailed system information and make configuration changes based on option configuration. Status LED The Status LED on the bottom-right corner of the display indicates status of the display as described below. GREEN, 2Hz Flash –...
  • Page 59 Body Controller Hardware CAB CONTROLLER INPUTS SCREEN This Cab Controller Inputs screen displays the status of Cab Controller inputs and parameters. INPUT PIN # DESCRIPTION FUNCTION IN00 PTO Pressure Sw. ON with PTO engaged IN01 Low Torque PSW. ON with O.A.I. LTPSW IN02 Trans Temp.
  • Page 60 Body Controller Hardware BODY CONTROLLER INPUTS SCREEN This Body Controller Inputs screen displays the status of Body Controller inputs and parameters. INPUT PIN# DESCRIPTION FUNCTION IN00 Hyd. Press #1 Main body valve inlet pressure IN01 Hyd. Press #2 CV valve pressure IN02 Hyd.
  • Page 61 Body Controller Hardware INPUT PIN# DESCRIPTION FUNCTION Enable PB System Enable PB TG Open PB TG Close PB Ejector Ext PB Ejector Ret PB TG Unlock PB TG Lock PB Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.
  • Page 62 Body Controller Hardware TAILGATE CONTROLLER INPUTS SCREEN This Tailgate Controller Inputs screen displays the status of Tailgate Controller inputs and parameters. INPUT PIN# DESCRIPTION FUNCTION IN00 Tipper Curb Side ON with cart tipper activated, curb side IN01 Tipper Street Side ON with cart tipper activated, street side IN02 Spare In...
  • Page 63 Body Controller Hardware TAILGATE HYDRAULIC CONTROL INPUTS SCREEN This Tailgate Hydraulic Control Inputs screen (for units with electrically controlled tailgate valves) displays the status of Tailgate Ext. Controller inputs and parameters. INPUT PIN# DESCRIPTION FUNCTION IN00 Tailgate Hyd. Press. #1 Main tailgate valve inlet pressure (Not Currently Used) IN01 Tailgate Hyd.
  • Page 64 Body Controller Hardware INPUT PIN# DESCRIPTION FUNCTION SWITCH BANK controller Tipper #1 UP ON with button pressed Tipper #1 DWN ON with button pressed Roll Bar UP ON with button pressed Roll Bar DWN ON with button pressed Winch/Rev Mech. UP ON with button pressed Winch/Rev Mech.
  • Page 65 Body Controller Hardware CHASSIS VARIABLES (J1939) SCREEN This screen displays chassis variables which are received from the chassis J1939. Some variables are not available on all chassis, in which case the variable status will not update. On chassis where J1939 is not available, Engine RPM is derived from the alternator R Stator or tach.
  • Page 66 Body Controller Hardware CAB CONTROLLER OUTPUTS SCREEN This Cab Controller Outputs screen displays the status of Cab Controller outputs. State of each output in brackets [ ]. All Outputs [ON] - Output is On. [OFF] - Output is Off. Diagnostic features outputs 00 thru 07 [Disabled] - Output is disabled by option set or spare.
  • Page 67 Body Controller Hardware BODY CONTROLLER OUTPUTS SCREEN This Body Controller Outputs screen displays the status of Body Controller outputs. OUTPUT PIN# DESCRIPTION FUNCTION OUT00 Right Turn Light NOT USED, Power to mid body RH Turn lamp OUT01 Left Turn Light NOT USED, Power to mid body LH Turn lamp OUT02 Option Output 1...
  • Page 68 Body Controller Hardware TAILGATE CONTROLLER OUTPUTS SCREEN This Tailgate Controller Outputs screen displays the status of Tailgate Controller outputs. OUTPUT PIN# DESCRIPTION FUNCTION OUT00 Right Turn Light RH Multi-Function Strobe OUT01 Left Turn Light LH Multi-Function Strobe OUT02 Stop Light NOT USED, Power to Stop lamps OUT03 Back Up Light/Alarm...

  • Page 69: Fault Screens

    Body Controller Hardware FAULT SCREENS Access fault screens from the Home screen by using the UP directional arrow. CRITICAL FAULTS SCREEN Critical faults result in disabled functions, allowing limited to no operation. These faults are displayed in the Home Screen Message Banner, which allows one message at a time based upon order of importance.
  • Page 70 Body Controller Hardware SYSTEM FAULTS SCREEN Access this screen from the Critical Fault screen by using the LEFT directional arrow. System faults occur with the loss of a signal or, when a signal is out of the normal operating range. These faults are retained through a power cycle and once active will remain active until reset.
  • Page 71 Body Controller Hardware CONTROLLER FAULTS SCREEN Access this screen from the Critical Fault screen by using the RIGHT directional arrow. Controller faults occur with the following: Supply voltage to a controller is lost or low. A controller output has an error, short or open circuit etc. Loss of communications with or between two controllers.
  • Page 72 Body Controller Hardware FAULT CAUSE Body, Output Error Error diagnostic on one or more outputs 00 thru 07 Body, Lost Comms w/ Controller lost comms with in-cab display. Display Body, Lost Comms w/ Controller lost comms with Body controller. Body Body, Lost Comms w/ Controller lost comms with Tailgate controller.

  • Page 73: Password Protected Screens

    Body Controller Hardware PASSWORD PROTECTED SCREENS To access password protected screens press and hold the OK button for 3 seconds. This will switch the view to the password screen. Enter the password and press OK. PASSWORD PROTECTED SCREEN PASSWORD Maintenance 4321 Option Config 123412...
  • Page 74 Body Controller Hardware OPTION CONFIG SCREEN The Option Config screen is used to configure the system. Press the OK button to turn the functions ON/OFF. Press ESC to exit screen. Clutch Shift PTO ON, enables the PTO Solenoid output and should be used when a Clutch shift PTO in installed. Additionally, the hydraulic pump may or may not be configured with a solenoid controlled manifold block.
  • Page 75 Body Controller Hardware OPTION CONFIG SCREEN (CONTINUED) Multi-Function Strobe ON, enables a secondary use of the tailgate turn lamps. When not in use as turn signals, the lamps can be used as alternating strobe lights. Option Switches ON, enables two multiplexed body controller outputs to be used for optional functions. Blunt cut wires RED "OPTION-02"...

  • Page 76: Maintenance Screen

    Body Controller Hardware MAINTENANCE SCREEN Filter Change Reset, press OK button to reset Oil Change Reset, press OK button to reset Service Mode, press OK button to activate. Service mode is strictly intended to allow pump operation while servicing or troubleshooting the unit.

  • Page 77: Programmable Controllers

    Body Controller Hardware PROGRAMMABLE CONTROLLERS Cortex Controllers There are three 32 I/O Cortex Controllers in this system: Cab, Body and Tailgate. Each has a unique program with I/O shared between the three controllers and the In-Cab display. Each controller is equipped with an LED Status indicator. If communications between the three controllers and the In-Cab display are communicating as expected a solid green LED will be displayed.
  • Page 78 Body Controller Hardware PROGRAMMABLE CONTROLLERS (CONTINUED) Cab Controller Typically mounted inside the cab, on a conventional cab this controller will be behind or under the seat. On a cab over engine it will be under the dog house cover. This controller manages most of the unit functionality, this includes: Chassis interface, including J1939 comms Hydraulic Pump Controls Option Configuration...
  • Page 79 Body Controller Hardware PROGRAMMABLE CONTROLLERS (CONTINUED) Tailgate Controller Mounted in the upper portion of the tailgate this controller manages circuits local to the tailgate, including: Strobe Lights Work Lights Tailgate controls PT 1100 US Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.

  • Page 80: Control Fusing

    Body Controller Hardware CONTROL FUSING Control Fuses The 2020 REL control system utilizes two fuses. Fuse #1 (F1) is powered by chassis ignition. Fuse #2 (F2) is battery powered by the cold side of the battery disconnect. Fusing for RP170 Compliant Chassis The below fuse holder is typically located within 8”...
  • Page 81 Body Controller Hardware CONTROL FUSING (CONTINUED) Fusing for NON RP170 Compliant Chassis Non RP170 chassis uses a Power Relay Module, pictured below, with two build-in 20-amp fuses. This module is typically located near the chassis battery disconnect switch. SOURCE FUSE CIRCUIT Ignition Power F1 (20amp)

  • Page 82: Control Area Network

    Body Controller Hardware CONTROL AREA NETWORK The control system for the 2020 Rear End Loader has multiple components that communicate over Control Area Networks or CAN. a. In-Cab Display b. Cab Controller (32 I/O Cortex Control Module) c. Body Controller (32 I/O Cortex Control Module) d.
  • Page 83 Body Controller Hardware CONTROL AREA NETWORK (CONTINUED) Network Schematic Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.
  • Page 84 Body Controller Hardware CONTROL AREA NETWORK (CONTINUED) System Architecture Issued October 2023 Copyright 2023, Heil Environmental Body Controller Hardware Printed in the U.S.A.

  • Page 85: Body Electrical Kit

    Body Controller Hardware BODY ELECTRICAL KIT Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.
  • Page 86 Body Controller Hardware BODY HARNESS ROUTING Issued October 2023 Copyright 2023, Heil Environmental Body Controller Hardware Printed in the U.S.A.

  • Page 87: Pneumatic Diagram

    Body Controller Hardware PNEUMATIC DIAGRAM Copyright 2023, Heil Environmental Issued October 2023 Body Controller Hardware Printed in the U.S.A.
  • Page 88 NOTES Issued October 2023 Copyright 2023, Heil Environmental Body Controller Software Printed in the U.S.A.

  • Page 89: Section 6 Body Controller Software

    Body Controller Software SECTION 6 BODY CONTROLLER SOFTWARE Copyright 2023, Heil Environmental Issued October 2023 Body Controller Software Printed in the U.S.A.

  • Page 90: Controller Program Documentation For 109-0329

    Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0329 PROGRAM: 109-0329 REVISION: 20201102 ADDRES SIGNAL PIN # CONTROLLER FUNCTION DESCRIPTION REL-CAB (CR2530) INPUT FUNCTIONS BINARY Activated by a Clutch Shift PTO pressure switch. ON indicates A01 PTO Pressure Sw. IN00 ACTIVE PTO engaged.
  • Page 91 Body Controller Software CORTEX CONTROLLER PROGRAM DOCUMENTATION FOR 109-0329 (CONTINUED) OUTPUT FUNCTIONS Spare Out OUT00 Spare Out OUT01 ON engages Clutch Shift PTO. Must be enabled in Option PTO Sol. OUT02 BINARY ACTIVE HIGH Configuration. Controls Pump Solenoid (P1). See Pump Control Pump 1 Sol.

  • Page 92: Controller Program Documentation For 109-0330

    Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0330 PROGRAM: 109-0330 REVISION: 20201102 I/O ADDRESS SIGNAL PIN # CONTROLLER FUNCTION DESCRIPTION REL-BODY (CR2530) INPUT FUNCTIONS Hyd. Pressure Transducer. Main body valve inlet pressure. C01 Hyd. Pressure #1 IN00 ANALOG (0.50-4.50 VDC) = (0-3000 PSI) Hyd.
  • Page 93 Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0330 (CONTINUED) OUTPUT FUNCTIONS Actuates Tailgate lock Cylinder, for Pneumatically controlled D01 Tailgate Lock Sol OUT00 BINARY ACTIVE HIGH Body Valve with independent tailgate lock cylinders only. Actuates Tailgate unlock Cylinder, for Pneumatically Tailgate Unlock OUT01 BINARY ACTIVE HIGH...

  • Page 94: Controller Program Documentation For 109-0331

    Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0331 PROGRAM: 109-0331 REVISION: 20201102 SIGNAL PIN # ADDRESS CONTROLLER FUNCTION DESCRIPTION REL-TAILGATE (CR2530) INPUT FUNCTIONS BINARY ACTIVE Used to sense Tipper activation E01 Curb Side Tipper IN00 HIGH BINARY ACTIVE Used to sense Tipper activation E02 Street Side Tipper IN01 HIGH...
  • Page 95 Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0331 (CONTINUED) OUTPUT FUNCTIONS F01 Right Turn Sig. OUT00 BINARY ACTIVE HIGH NOT USED F02 Left Turn Sig. OUT01 BINARY ACTIVE HIGH NOT USED F03 Stop Lights OUT02 BINARY ACTIVE HIGH NOT USED Back-Up Light/ NOT USED OUT03...

  • Page 96: Controller Program Documentation For 109-0331-Ext

    Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0331-EXT PROGRAM: 109-0331-EXT REVISION: 20201102 SIGNAL PIN # CONTROLLER FUNCTION DESCRIPTION ADDRESS REL-TAILGATE-EXT (HYD) (CR2530 EXT) INPUT FUNCTIONS Hyd. Pressure Transducer. Main body valve inlet pressure. G01 Tailgate Hyd. Press. #1 IN00 ANALOG (0.50-4.50 VDC) = (0-3000 PSI) Hyd.
  • Page 97 Body Controller Software CONTROLLER PROGRAM DOCUMENTATION FOR 109-0331-EXT (CONTINUED) OUTPUT FUNCTIONS H01 Slide Up Sol. OUT00 Moves Tailgate Packer Side Up Slide Down Moves Tailgate Packer Side Down OUT01 Sol. H03 Blade In Sol. OUT02 Rotates Tailgate Packer Blade In Blade Out Rotates Packer Blade Out OUT03...
  • Page 98 NOTES Issued October 2023 Copyright 2023, Heil Environmental Schematics Printed in the U.S.A.

  • Page 99: Schematics

    Schematics SECTION 7 SCHEMATICS Copyright 2023, Heil Environmental Issued October 2023 Schematics Printed in the U.S.A.

  • Page 100: Harness, Body Controller, 2020 Rel - 263-1869-001

    TANK ANTI PSI#2 PSI#1 FMVSS FMVSS TAPE THIS JUMPER TO TRUNK OF HARNESS TEMP CAN1 CAN1 CAN1 TWISTED PAIR TWISTED PAIR TEMP TEMP LOWER SOL BODY CONTROL SWITCH RAISE SOL EJECTOR RET. SOL EJECTOR EXT. SOL HARNESS, BODY CONTROLLER 2020 REL 263-1869-001 REV: C2 03/01/19...

  • Page 101: Harness, Body 2020 Rel - 263-1869-003

    HARNESS, BODY, 2020 REL 263-1869-003 REV: A3 RELEASE DATE: 04/09/20...

  • Page 102: Harness, Body Bulkhead - 263-1869-004

    HARNESS, BODY BULKHEAD 263-1869-004 REV: A RELEASE DATE: 04/27/20...

  • Page 103: Harness, Mid Tailgate Light Cluster - 263-1869-211

    HARNESS, MID TAILGATE LIGHT CLUSTER 263-1869-211 REV: C2 RELEASE DATE: 05/11/20...

  • Page 104: Harness, Tailgate Hydraulic Valve Control - 263-1869-212

    HARNESS, TAILGATE, HYD VALVE CONTROL 263-1869-212 REV: - RELEASE DATE: 05/12/20...

  • Page 105: Harness, Battery Power Relay, Non-Rp170 - 263-1880-001

    HARNESS, BATTERY POWER RELAY, NON-RP170 263-1880-001 REV: - RELEASE DATE: 02/20/19...

  • Page 106: Harness, Battery Relay, Non-Rp170 - 263-1880-002

    HARNESS, BATTERY RELAY, NON-RP170 263-1880-002 REV: - RELEASE DATE: 09/24/19...

  • Page 116: Pt1100-Us Unit Packer Extention 701-9342-003

    SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...

  • Page 117: Pt1100-Us Unit Packer Retracting 701-9342-004

    SYSTEM AT IDLE SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 118: Pt1100-Us Unit Tailgate Open 701-9342-005

    PUM- ON SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 119: Pt1100-Us Unit Tailgate Close 701-9342-006

    PACKER EXTENDING SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 120: Pt1100-Us Unit Tailgate Function Ready 701-9342-007

    PACKER RETRACTING SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 121: Pt1100-Us Unit Blade-Down 701-9342-008

    TAILGATE OPEN SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 122: Pt1100-Us Unit Blade-Up 701-9342-009

    TAILGATE CLOSE SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 123: Pt1100-Us Unit Slide Down (Regen) 701-9342-010

    TAILGATE FUNCTION READY SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 124: Pt1100-Us Unit Slide-Up 701-9342-011

    BLADE-DOWN SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...

  • Page 125: Pt1100-Us Unit Blade-Up And Packer Retract 701-9342-012

    BLADE-UP SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...

  • Page 126: Pt1100-Us Unit Slide-Up And Packer Retract 701-9342-013

    SLIDE - DOWN (REGEN) SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi...

  • Page 127: Pt1100-Us Unit Roll-Bar-Up 701-9342-014

    SLIDE - UP SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 128: Pt1100-Us Unit Roll-Bar-Down 701-9342-015

    BLADE-UP AND PACKER-RETRACT SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi...

  • Page 129: Pt1100-Us Unit Tipper-Up 701-9342-016

    SLIDE - UP AND PACKER - RETRACT SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi...

  • Page 130: Pt1100-Us Unit Tipper-Down 701-9342-017

    ROLL-BAR-UP SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...
  • Page 131 ROLL-BAR-DOWN SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...
  • Page 132 TIPPER-UP SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...
  • Page 133 TIPPER-DOWN SLIDE CYL. ROLL BAR CYL. TIPPER ASSEMBLY REEVING CYL. QUICK-TIP CYL. (OPTION) (OPTION) (OPTION) BLADE CYL. (OPTION) TAILGATE OPEN CYL. PACKER CYL. Basic Tailgate Valve Assembly 3900 psi 1500 psi 2000 psi 2500 psi 1850 psi 1500 psi 2000 psi 2500 psi 1850 psi Utility Section...

  • Page 134: Index

    INDEX body daily checklist in-cab display body electrical kit introduction body harness routing pneumatic diagram body preventive maintenance chart lock-out/tag-out procedures lock-out tags lubrication guide caution change hydrualic oil filter element check oil level maintenance/lubrication information clean and inspect the tailgate seal control area network control fusing notice...
  • Page 135 INDEX warning when to change oil filter element Issued October 2023 Printed in the U.S.A. Index Copyright 2023, Heil Environmental...
  • Page 136 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 137 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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