Dover Environmental Solutions HEIL DuraPack 4060 Service Manual
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Dover Environmental Solutions HEIL DuraPack 4060 Service Manual

Dover Environmental Solutions HEIL DuraPack 4060 Service Manual

Split-body rear loader
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DuraPack
4060
®
SPLIT-BODY REAR LOADER
SERVICE MANUAL
ISSUED SEPTEMBER 2017
TP1D40-SM-0917
© 2017 Heil Environmental
.

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Summary of Contents for Dover Environmental Solutions HEIL DuraPack 4060

  • Page 1 DuraPack 4060 ® SPLIT-BODY REAR LOADER SERVICE MANUAL ISSUED SEPTEMBER 2017 TP1D40-SM-0917 © 2017 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

    DuraPack 4060 ® TABLE OF CONTENTS General Information Service/Parts Assistance ......................................4 Hazard Symbols and Definitions ......................................4 Lock-Out/Tag-Out Procedures ......................................8 Compressed Natural Gas (CNG) Fuel System ......................................9 Storing Refuse in Container ......................................15 Maintenance/Lubrication Information ......................................15 Grease Lubrication Recommendation ......................................15 Oil Can Lubricant Recommendation ......................................15 Hydraulic Oil Specifications ......................................16...
  • Page 4 DuraPack 4060 ® TABLE OF CONTENTS Preparing the Unit to Check the Oil Level ......................................76 Check Oil Level ......................................77 When to Change Oil Filter Element ......................................77 Change Hydraulic Oil Filter ......................................78 Drain and Clean the Hydraulic Oil Tank ......................................79 Purge the Hydraulic System ......................................81 Troubleshooting Guide ......................................82...
  • Page 5 DuraPack 4060 ® TABLE OF CONTENTS SS Proximity Switch Tailgate Harness - 263-1521-001 ......................................162 CS Proximity Switch Tailgate Harness - 263-1521-002 ......................................163 SS Tailgate Fuse Block Harness - 263-1533-003 ......................................164 CS Tailgate Fuse Block Harness - 263-1533-004 ......................................165 Bypass Filter Jumper Harness - 263-1562-060 ......................................166 OAI Pump Adapter Harness - 263-1592 ......................................167...
  • Page 6 DuraPack 4060 ® TABLE OF CONTENTS Autocar ACX Cab to Body Harness - 263-1482-006 .................................... PDF Only Am. e .. r . i . c .. a .. n . .. L .. a .f . . r a n c e. .. B .. o .. d .. y . .. H .. a .. r .. n.. e.s .. s .. . - . .2 ..6 ..3 ..-.. 1.. 4.. 8.. 2.- .. 0 .. 0 .. 7 .....................PDF Only DLB ..
  • Page 7 DuraPack 4060 ® DuraPack 4060 ® SPLIT-BODY REAR LOADER SERVICE MANUAL ISSUED SEPTEMBER 2017 TP1D40-SM-0917 Copyright 2017, Heil Environmental Issued September 2017 Printed in U.S.A.
  • Page 8 DuraPack 4060 ® NOTES Issued September 2017 Copyright 2017, Heil Environmental General Information Printed in U.S.A.

  • Page 9: Section 1 General Information

    DuraPack 4060 ® General Information SECTION 1 GENERAL INFORMATION Copyright 2017, Heil Environmental Issued September 2017 General Information Printed in U.S.A.

  • Page 10: Service/Parts Assistance

    DuraPack 4060 ® General Information SERVICE/PARTS ASSISTANCE Assistance in troubleshooting repair and service is available by contacting the authorized Heil Dealer in your area. Parts are available at your Heil Dealer or through Heil. Heil personnel are trained to give prompt, professional assistance. ALWAYS give the unit serial number in all correspondence relating to the equipment.
  • Page 11 DuraPack 4060 ® 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 12 DuraPack 4060 ® General Information WARNING Raising the body with the tailgate closed can damage the underride bumper. The under ride bumper can hit the ground when the tailgate is not fully raised before you raise the body. Death or serious injury can occur and also cause damage to the unit.
  • Page 13 DuraPack 4060 ® General Information NOTICE Do not operate the unit or perform repair or maintenance procedures on the unit until you read and understand the instructions in this manual. Failure to do so can result in damage to the unit or other property. If you do not understand a procedure or instruction, tell the owner or the designated person immediately.

  • Page 14: Lock-Out/Tag-Out Procedures

    DuraPack 4060 ® 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.

  • Page 15: Compressed Natural Gas (Cng) Fuel System

    DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM This section is for units equipped with a CNG fuel system. NOTICE For CNG units, this Service Manual should be used in conjunction with any associated CNG System Manufacturer's Operation and Maintenance Manuals.
  • Page 16 DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM (CONTINUED) CAUTION A portable fire extinguisher must be installed on the vehicle in an accessible location. B. Fill Panel The fill panel control interface is accessible by opening the fill panel access door (usually on the street side of the unit). See Figure 2.
  • Page 17 DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM (CONTINUED) C.Starting Vehicle (Continued) 1. Make sure that the system has been properly leak tested and that no leaks exist. 2. Make sure that plastic caps are installed on all exposed vent lines. For roof mounted CNG, vent lines route to both ends of the cylinders.
  • Page 18 DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM (CONTINUED) F. Defueling with a Defueling Receptacle Defueling is generally the process of removing any residual fuel from the fuel tanks and on-board fuel delivery system prior to performing any welding or a major repair. Capturing the CNG in a system that can send it back to a CNG fueling station storage facility for reuse is the most environmentally responsible method.
  • Page 19 DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM (CONTINUED) WARNING Venting does not completely empty the system of combustible gas. Never weld on a compressed natural gas vehicle unless the compressed natural gas fuel system has been purged with inert gas. See Paragraph H below. There are two methods by which to defuel a CNG vehicle using a Defueling Panel with a Defueling Receptacle.
  • Page 20 DuraPack 4060 ® General Information COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM (CONTINUED) I. Recharging the Fuel System after Purging and after Major Repairs After repairs, the inert gas must be removed from the system in a similar manner as the inert gas was introduced. Specifically, the entire system should be charged 3 times with approximately 689kPa (100 psig) of natural gas.

  • Page 21: Storing Refuse In Container

    DuraPack 4060 ® 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 22: Hydraulic Oil Specifications

    DuraPack 4060 ® General Information HYDRAULIC OIL SPECIFICATIONS Hydraulic fluid is one of the most important component in hydraulic system. It transmits power, provides lubrication and cooling function and has following features: High viscosity index Long service life Outstanding cold temperature flow properties Fast water separation Excellent anti-wear performance Long term oxidation stability...

  • Page 23: Standard Torque Data For Nuts And Bolts

    DuraPack 4060 ® General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS The following recommended torque data is for use as a general guideline. Recommended torque, in foot pounds, for all Standard Application nuts and bolts provided in the following table. NOTICE Torque specifications on a drawing override torque values in the Standard Torque Data for Nuts and Bolts Table.
  • Page 24 DuraPack 4060 ® General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock)
  • Page 25 DuraPack 4060 ® General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock)
  • Page 26 DuraPack 4060 ® General Information STANDARD TORQUE DATA FOR NUTS AND BOLTS TABLE Heil Zinc Plated Heil Heil Thread Heil Plain Dry Fastener Lubricated Deformed Turns per Condition Torque Fastener Lock Nut Bolt Size Nut Type Inch Torque Value Value Torque Value Torque Value (STD/Lock)

  • Page 27: Bolt Type Identification Chart

    DuraPack 4060 ® General Information BOLT TYPE IDENTIFICATION CHART S.A.E. Bolt Head Description Type Grade Marking** No radial lines. 1 or 2 Low or medium carbon steel not heat treated. NOT USED, replace with same grade bolt. Three radial lines. Quenched and tempered medium carbon steel.
  • Page 28 DuraPack 4060 ® General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) 37 DEGREE FLARE (JIC) FITTINGS SET WRENCH TO NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 1/8" 6.5 ft-lbs. 80 in-lbs. 3/16" 9 ft-lbs. 110 in-lbs. 1/4" 12.5 ft-lbs.
  • Page 29 DuraPack 4060 ® General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) FROM SAE J2593 TABLE 7 (STEEL) SET WRENCH TO BOSS (ORB) NOMINAL TUBE OD TORQUE WRENCH SETTING ALTERNATE TORQUE UNITS 3/16" 9 ft-lbs. 110 in-lbs. 1/4" 16.5 ft-lbs. 200 in-lbs.
  • Page 30 DuraPack 4060 ® General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) Figure 5. Torque for Hydraulic Tubes and Fittings SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 61) SET WRENCH TO NOMINAL TUBE BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT- LBS] LBS [IN-LBS]...
  • Page 31 DuraPack 4060 ® General Information TORQUE FOR HYDRAULIC TUBES AND FITTINGS (CONTINUED) SPLIT- FLANGE (HALF CLAMP) CONNECTORS (CODE 62) SET WRENCH TO NOMINAL BOLT SIZE BOLT TORQUE [FT- BOLT TORQUE [IN-LBS] ALUMINUM FT-LBS [IN- TUBE OD LBS] LBS] 1/2" 5/16-18 x 1.25 17 ft-lbs.

  • Page 32: Cold Weather Warmup Procedure

    DuraPack 4060 ® 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

    DuraPack 4060 ® 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 34: Safety Decals On The Unit

    DuraPack 4060 ® 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 35 DuraPack 4060 ® General Information DECAL CARE (CONTINUED) Figure 6. Recommended Technique Figure 7. Incorrect Technique Copyright 2017, Heil Environmental Issued September 2017 General Information Printed in U.S.A.

  • Page 36: Hydraulic Symbols

    DuraPack 4060 ® General Information HYDRAULIC SYMBOLS Issued September 2017 Copyright 2017, Heil Environmental General Information Printed in U.S.A.
  • Page 37 DuraPack 4060 ® General Information HYDRAULIC SYMBOLS (CONTINUED) Copyright 2017, Heil Environmental Issued September 2017 General Information Printed in U.S.A.

  • Page 38: Electrical Symbols

    DuraPack 4060 ® General Information ELECTRICAL SYMBOLS Issued September 2017 Copyright 2017, Heil Environmental General Information Printed in U.S.A.

  • Page 39: Section 2 Pumps

    DuraPack 4060 ® Pumps SECTION 2 PUMPS Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.

  • Page 40: Single Gear Pump With Power Pro Drive Valve (Muncie)

    DuraPack 4060 ® Pumps SINGLE GEAR PUMP WITH POWER PRO DRY VALVE (MUNCIE) Figure 8. Single Gear Pump 9. Pump Air Logic Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.

  • Page 41: Tandem O.i.g.a.i. Pump

    DuraPack 4060 ® Pumps TANDEM O.I.G.A.I. PUMP Front Loaders, Rear Loaders, Recycle 2000, and Liberty Figure 10. Tandem O.I.G.A.I. Pump This is the Hydraulic Controls Operate-In-Gear-At-Idle (OIGAI) System. 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 shaft operates the packer and stays on at higher RPMs.

  • Page 42: Single Pump Repair Procedures

    DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES Heil has upgraded many products to a high pressure vane pump. Although ratings vary, these pumps are generally rated for higher pressure and higher duty cycles than similar size gear pumps. Because of the design of a vane pump, it is generally not necessary to replace the entire pump.
  • Page 43 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 6. Remove the zip tie from the oil shut-off valve on the hydraulic oil tank. Figure 13. 7. Turn the shut-off valve to the OFF position. Figure 14. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.
  • Page 44 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 8. Remove the grill from the chassis. The number of bolts for the grill varies with chassis brand. Figure 15. 9. Cut the zip tie around the electrical wiring that controls the pump shut-off valve solenoid. Figure 16.
  • Page 45 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 10.Disconnect the electrical wiring—the two-way Packard plug—that controls the pump shut-off valve solenoid. Figure 17. 11.Remove the one-inch hydraulic pressure hose. Figure 18. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.
  • Page 46 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 12.Remove the four suction line flange bolts. Figure 19. 13.Remove the eight bolts connecting the pump shut-off valve to the pump. There are four small bolts and four large bolts. Figure 20. Issued September 2017 Copyright 2017, Heil Environmental Pumps...
  • Page 47 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 14.Carefully, remove the shut-off valve from the pump. Figure 21. 15.Remove the four pump housing connecting bolts. Figure 22. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.
  • Page 48 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 16.Carefully remove the pump case housing. Figure 23. 17.Remove the pump cartridge by pulling it toward you. The fit might be tight. Figure 24. Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.
  • Page 49 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 18.Inspect the pump shaft, splines, and bearings for wear and damage. Check for the following: Sheared or worn shaft splines Broken bearing. Figure 25. Figure 26. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.
  • Page 50 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 19.Inspect the brass bushing on the pump cartridge for wear and damage. Figure 27. 20.Check the outer housing O-ring for wear or damage such as nicks, fraying, or cuts. Replace the o-ring if it is damaged.
  • Page 51 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 21.Place the pump cartridge back on the pump shaft. Figure 29. 22.Replace the outer pump housing and finger-tighten the four pump housing bolts. Figure 30. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.
  • Page 52 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 23.Tighten the four outer housing bolts to 138 ft. lbs. Figure 31. 24.Install the new pump shut-off valve using the new bolts included with the new valve. Figure 32. Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.
  • Page 53 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 25.Tighten the eight pump shut-off valve bolts as follows: Four small back bolts – 60 ft lb Four large front bolts – 92 ft lb Figure 33. 26.Install the suction line flange to the pump shut-off valve and tighten the four bolts on the flange. Figure 34.
  • Page 54 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 27.Install one straight connector, 054-3341-10, to the P Port on the shut-off valve. Figure 35. 28.Install one 90 degree elbow, 054-2988-10, on the straight connector. Figure 36. Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.
  • Page 55 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 29.Connect the one inch hydraulic pressure hose to the 90 degree elbow. Figure 37. 30.Install the following two-way Packard connector to the two wires coming from the solenoid on the new shut-off valve: 1 ea –...
  • Page 56 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 31.Connect the new Packard connector to the original, matching Packard connector. Secure the excess wiring harness for the solenoid to the hydraulic pressure line with a zip tie. Figure 39. 32.Attach the grill to the chassis. Figure 40.
  • Page 57 DuraPack 4060 ® Pumps SINGLE PUMP REPAIR PROCEDURES (CONTINUED) 33.On the hydraulic oil pump, move the shut-off valve to the OPEN position and secure the valve with a zip tie. Figure 41. Figure 42. Copyright 2017, Heil Environmental Issued September 2017 Pumps Printed in U.S.A.

  • Page 58: 219-2303 Pump Configuration Installed On Another Chassis

    DuraPack 4060 ® Pumps 219-2303 PUMP CONFIGURATION INSTALLED ON ANOTHER CHASSIS Figure 44. Figure 43. Figure 45. Figure 46. Figure 47. Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.

  • Page 59: Troubleshoot Pump 219-2303 With 031-6427

    DuraPack 4060 ® Pumps TROUBLESHOOT PUMP 219-2303 WITH 031-6427 In 2007, Heil changed the pump control valve to a design that easily allows testing the pump and the pump control valve functions on the vehicle. A. Hydraulic functions do not operate. 1.
  • Page 60 DuraPack 4060 ® Pumps TROUBLESHOOT PUMP 219-2303 WITH 031-6427 (CONTINUED) C.Remove the unloading cartridge. Temporarily set aside in a clean location. Figure 49. D.Remove test plug located in the side of the pump control valve. E. Insert plug in the port where the unload cartridge was removed. There are threads for it at the bottom of the cavity.
  • Page 61 DuraPack 4060 ® Pumps TROUBLESHOOT PUMP 219-2303 WITH 031-6427 (CONTINUED) F. Reinsert the unload cartridge. Figure 51. G.Start the truck and test all functions. 1. If the system now works correctly the problem is in the pump control valve. 2. If the system still does not function correctly the pump cartridge need to be replaced. H.Remove the unload cartridge.

  • Page 62: Tandem Vane Pump O.i.g.a.i. Hydraulic System Troubleshooting

    DuraPack 4060 ® 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 63: Mount Pump Monoblock To Tandem Pump

    DuraPack 4060 ® Pumps TANDEM VANE PUMP O.I.G.A.I. HYDRAULIC SYSTEM TROUBLESHOOTING (CONTINUED) Figure 52. 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 64 DuraPack 4060 ® Pumps Figure 53. Issued September 2017 Copyright 2017, Heil Environmental Pumps Printed in U.S.A.

  • Page 65: Section 3 Body And Tailgate

    DuraPack 4060 ® Body and Tailgate SECTION 3 BODY AND TAILGATE Copyright 2017, Heil Environmental Issued September 2017 Body and Tailgate Printed in U.S.A.

  • Page 66: Body And Tailgate Nomenclature

    DuraPack 4060 ® Body and Tailgate BODY AND TAILGATE NOMENCLATURE Figure 54. Body and Tailgate Nomenclature Issued September 2017 Copyright 2017, Heil Environmental Body and Tailgate Printed in U.S.A.

  • Page 67: Specifications

    DuraPack 4060 ® Body and Tailgate SPECIFICATIONS Hydraulic Oil Tank ................................ 54 Gal. Hydraulic In-Tank Oil Filter ......................... 3-Micron Absolute Hydraulic Oil Tank Suction Strainer ......................100 Mesh Screen Hydraulic Pump ..................Per Pump – 25 Gal/Min @ 1200 RPM @ 2500 PSI Main System Relief Pressure Setting ........................

  • Page 68: Tailgate Lock And Unlock Inspections

    DuraPack 4060 ® Body and Tailgate TAILGATE LOCK AND UNLOCK INSPECTIONS Listed are the steps required to ensure the tailgate is locked on the unit. A. Pre-Trip Inspection 1. RED indicator arrows are aligned on the locking arm and the body anchor. 2.
  • Page 69 DuraPack 4060 ® Body and Tailgate TAILGATE LOCK AND UNLOCK INSPECTIONS (CONTINUED) Figure 56. Tailgate Unlocked Figure 57. Tailgate Locked Copyright 2017, Heil Environmental Issued September 2017 Body and Tailgate Printed in U.S.A.

  • Page 70: Auxillary Quick Disconnect Hook-Up

    DuraPack 4060 ® Body and Tailgate AUXILIARY QUICK DISCONNECT HOOK-UP If the unit has hydraulic system trouble and is unable to use the hydraulic system, either body can be emptied of refuse by hooking up an auxiliary pump system to the quick disconnect on the unit. The suction line disconnect is located at the back of the oil tank.

  • Page 71: Welding And Electronic Devices / Electrical Lubricants

    DuraPack 4060 ® Body and Tailgate WELDING AND ELECTRONIC DEVICES / ELECTRICAL LUBRICANTS 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. See Service Manual Section 1. Disconnect all battery connections.
  • Page 72 DuraPack 4060 ® NOTES Issued September 2017 Copyright 2017, Heil Environmental Maintenance and Adjustment Printed in U.S.A.

  • Page 73: Section 4 Maintenance And Adjustment

    DuraPack 4060 ® Maintenance and Adjustment SECTION 4 MAINTENANCE AND ADJUSTMENT Copyright 2017, Heil Environmental Issued September 2017 Maintenance and Adjustment Printed in U.S.A.

  • Page 74: Body Daily Checklist

    DuraPack 4060 ® 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 75: Body Preventive Maintenance Chart

    DuraPack 4060 ® 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 76 DuraPack 4060 ® Maintenance and Adjustment BODY PREVENTIVE MAINTENANCE CHART *HOURS OF OPERATION COMPONENT/SYSTEM 1000 2000 CHECK/SERVICE Grease Fittings Lubricate as shown on Body Lube Chart. Body Undercoating Inspect body undercoating and repair as necessary. Inspect Tailgate Shoes Wear Pads When a Shoe Wear Pad is worn down for Wear (both Tailgates) to 0.125 inch thickness, rotate the top...

  • Page 77: Body Lubrication Guide

    DuraPack 4060 ® Maintenance and Adjustment 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. See the figure below.

  • Page 78: Pack/Eject Cylinders Maintenance

    DuraPack 4060 ® Maintenance and Adjustment PACK/EJECT CYLINDERS MAINTENANCE Heil Environmental recommends completing the following tasks to make sure the pack/eject cylinders are working properly and not damaged. WARNING Make sure that the unit is in Lock-Out/Tag-Out mode before you perform maintenance/service procedures, or when you enter or climb on the hopper/body/related assemblies.

  • Page 79: Cold Weather Warmup Procedure

    DuraPack 4060 ® 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 80: Preparing The Unit To Check The Oil Level

    DuraPack 4060 ® 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 –...

  • Page 81: Preparing The Unit To Check The Oil Level

    DuraPack 4060 ® 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 –...

  • Page 82: Preparing The Unit To Check The Oil Level

    DuraPack 4060 ® 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 –...

  • Page 83: Check Oil Level

    DuraPack 4060 ® 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 84: Change Hydraulic Oil Filter

    DuraPack 4060 ® Maintenance and Adjustment CHANGE HYDRAULIC OIL FILTER ELEMENT To change the hydraulic oil filter, refer to the figure below and follow these steps: 1. Remove nuts and filter cover. 2. Remove the filter element with the by-pass assembly and discard as required. 3.

  • Page 85: Drain And Clean The Hydraulic Oil Tank

    DuraPack 4060 ® 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 86 DuraPack 4060 ® 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 87: Purge The Hydraulic System

    DuraPack 4060 ® 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: Troubleshooting Guide

    DuraPack 4060 ® Maintenance and Adjustment TROUBLESHOOTING GUIDE Problem Problem Cause Remedy 1. Raise main relief setting. Ejector panel set higher than Ejector Panel will not relieve. Main relief. 2. Lower ejector relief setting. 1. Lower main relief setting. Ejector relief set too low. 2.

  • Page 89: Underbody Valve With Resitance Relief

    DuraPack 4060 ® Maintenance and Adjustment UNDERBODY VALVE WITH RESISTANCE RELIEF The resistance valve is located in the ejector section of the underbody valve and preset at 2250 PSI. See Figure 5. A. Resistance Relief 1. When the upper panel moves refuse from the hopper into the body, resistance will begin to increase. 2.
  • Page 90 DuraPack 4060 ® Maintenance and Adjustment UNDERBODY VALVE WITH RESISTANCE RELIEF (CONTINUED) 4. If ejector panel stalled before reaching the front of the body, turn adjusting screw out (counter clockwise) 1/8 turn. 5. Repeat steps 1 thru 4 to increase or decrease resistance as necessary to get desired payloads. See Figures below: Figure 63.
  • Page 91 DuraPack 4060 ® Maintenance and Adjustment UNDERBODY VALVE WITH RESISTANCE RELIEF (CONTINUED) Figure 64. Underbody Valve: Return Hose and Power Beyond Sleeve Figure 65. Underbody Valve: Main Relief Valve, Pressure Gauge Port and Resistance Valve Copyright 2017, Heil Environmental Issued September 2017 Maintenance and Adjustment Printed in U.S.A.

  • Page 92: Pressure Adjustment Procedures

    DuraPack 4060 ® Maintenance and Adjustment PRESSURE ADJUSTMENT PROCEDURES 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 93 DuraPack 4060 ® Maintenance and Adjustment PRESSURE ADJUSTMENT PROCEDURES (CONTINUED) (4) Turn engine ignition OFF, remove keys and follow the Lock-Out/Tag-Out procedure in Service Manual Section 1. (5) All mechanical linkage must be free of any binding. Move blade spool by hand in either direction if needed. (6) REMOVE any dirt or grease around the underbody valve main relief.

  • Page 94: Blade Back-Off Relief Valve

    DuraPack 4060 ® Maintenance and Adjustment (21) If Slide detents: (a) Manually shift control mechanism to disengage blade function. (b) Adjust Main Relief adjusting screw out (counter-clockwise) 1 additional turn. (22) Repeat steps (19) and (20). (23) Slowly turn main relief adjusting screw IN to increase pressure. Watch the pressure gauge to see what the pressure is when the spool kicks out of detent (returns to neutral).

  • Page 95: Tailgate Control Lever Alignment

    DuraPack 4060 ® Maintenance and Adjustment TAILGATE CONTROL LEVER ALIGNMENT The tailgate control handles should be in line when in the neutral position. Adjustments can only be made to blade control rod. See Figure Tailgate Control Levers below. If Handle is Out of Align: 1.

  • Page 96: Proximity Switch Adjustments

    DuraPack 4060 ® Maintenance and Adjustment PROXIMITY SWITCH ADJUSTMENTS A. Throttle Advance Switch Adjustment 1. With the blade and slide spools in neutral position, proximity switch striker should be centered directly in front of and 3/16” away from the face of the proximity switch. See Figure 9. 2.
  • Page 97 DuraPack 4060 ® Maintenance and Adjustment PROXIMITY SWITCH ADJUSTMENTS (CONTINUED) Figure 67. Slide Panel Figure 68. Slide Retract Proximity Switch Copyright 2017, Heil Environmental Issued September 2017 Maintenance and Adjustment Printed in U.S.A.

  • Page 98: Cracked Weld Joints

    DuraPack 4060 ® 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. Issued September 2017 Copyright 2017, Heil Environmental Maintenance and Adjustment Printed in U.S.A.

  • Page 99: Oil Lubrication Recommendation

    DuraPack 4060 ® Maintenance and Adjustment 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. Always wipe off excess. GREASE LUBRICANT RECOMMENDATION Use a grease gun.

  • Page 100: Clean And Inspect The Tailgate Seal

    DuraPack 4060 ® 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 70.

  • Page 101: Section 5 Body Controller Hardware

    DuraPack 4060 ® Body Controller Hardware SECTION 5 BODY CONTROLLER HARDWARE Copyright 2017, Heil Environmental Issued September 2017 Body Controller Hardware Printed in U.S.A.

  • Page 102: Plc Assembly In Enclosure And Cover Removed Views

    DuraPack 4060 ® Body Controller Hardware PLC ASSEMBLY IN ENCLOSURE AND COVER REMOVED VIEWS Issued September 2017 Copyright 2017, Heil Environmental Body Controller Hardware Printed in U.S.A.

  • Page 103: Terminals And Peripheral Port

    DuraPack 4060 ® Body Controller Hardware TERMINALS AND PERIPHERAL PORT Copyright 2017, Heil Environmental Issued September 2017 Body Controller Hardware Printed in U.S.A.

  • Page 104: Port Covers Opened And Terminal Covers Removed

    DuraPack 4060 ® Body Controller Hardware PORT COVERS OPENED AND TERMINAL COVERS REMOVED Various vehicle applications use the Mini PLC. These applications require two (2) Electronic Over Speeds (EOS). These applications generally use a tandem pump. The EOS set points are part of the PLC program, therefore you do not need the EOS screws.

  • Page 105: Hand Held Loader Programmer

    DuraPack 4060 ® Body Controller Hardware HAND HELD LOADER PROGRAMMER Copyright 2017, Heil Environmental Issued September 2017 Body Controller Hardware Printed in U.S.A.

  • Page 106: Hand Held Loader Programming Procedures

    DuraPack 4060 ® Body Controller Hardware HAND HELD LOADER PROGRAMMING PROCEDURES Downloading Program to PLC Use the instructions that follow to download a program from an EEPROM in the Hand held Loader (loader) into the PLC's memory. 1. Make sure you have an EEPROM (PN 108-7715-EEP) with the correct program, 2.

  • Page 107: Diagnostic Link

    DuraPack 4060 ® Body Controller Hardware DIAGNOSTIC LINK The Diagnostic Link (PN 108-7715-DIS) is a hand-held tool that connects to the PLC's Peripheral Port with a Communication Cable (PN 108-7715-CAB). Refer to the applicable Body Controller Software manual for the specific instructions for a PLC program. You use the Diagnostic Link to: Perform the calibration setup for a newly installed PLC (password required) Monitor input status...
  • Page 108 DuraPack 4060 ® NOTES Issued September 2017 Copyright 2017, Heil Environmental Body Controller Software Printed in U.S.A.

  • Page 109: Section 6 Body Controller Software

    DuraPack 4060 ® Body Controller Software SECTION 6 BODY CONTROLLER SOFTWARE Copyright 2017, Heil Environmental Issued September 2017 Body Controller Software Printed in U.S.A.

  • Page 110: Body Controller Software

    DuraPack 4060 ® Body Controller Software Section 1: PLC Hardware 1.01: P LC Indica tor Lights Loca te d on the fa ce of the P LC a re the P WR, RUN, COMM, a nd ERR indica tor lights . The P WR indica tor s hould light whe n the P LC ha s powe r.
  • Page 111 DuraPack 4060 ® Body Controller Software 1.06: Circuit Identification The input and output circuits are identified by there point of origin at the PLC. Each connector on the PLC assembly is assigned a number P1 and P2. Each wire is also assigned a number representing the connector and pin number of its origin. Example, the wire exiting connector P1 on pin #10 will be identified “P1-10”.
  • Page 112 DuraPack 4060 ® Body Controller Software I/O Listing PROGRAM NUMBER 109-0246 RELEASE LEVEL: ND RAPID RAIL STARR PROGRAM NUMBER: 109-0236 STANDARD O.I.N. O.I.G.A.I. IN-CAB INPUT FUNCTIONS CHASSIS SERVICE BRAKE SIGNAL P1-08 (01.04) P1-08 (01.04) TRANS. TEMP. CIRCUIT P1-26 (02.04) P1-26 (02.04) SYSTEM POWER SWITCH P1-16 (02.02) P1-16 (02.02)
  • Page 113 DuraPack 4060 ® Body Controller Software PACK RIGHT INDICATOR P1-12 (11.07) P1-12 (11.07) BODY/TAILGATE INDICATOR P1-11 (12.05) P1-11 (12.05) PACKER PRESSURE SWITCH INDICATOR P1-15 (10.04) P1-15 (10.04) CHIME P1-25 (10.01) P1-25 (10.01) TRANS TEMP INDICATOR P1-32 (12.07) P1-32 (12.07) BODY INPUT FUNCTIONS BODY/TAILGATE RAISED ALARM P2-07 (00.09) P2-07 (00.09)
  • Page 114 DuraPack 4060 ® Body Controller Software NONE NONE NONE OPTION BODY INPUT FUNCTIONS LOW ENGINE TORQUE PRESSURE SWITCH P2-16 (01.05) P2-16 (01.05) FIFTH WHEEL PROX P2-36 (01.09) OPEN BODY OUTPUT SPARE BODY OUTPUT P1-03 (11.05) P1-03 (11.05) OPEN BODY INPUTS SPARE BODY INPUT P2-36 (01.09) SPARE BODY INPUT...
  • Page 115 DuraPack 4060 ® Body Controller Software 1.07: PLC Fusing The PLC is equipped with multiple fuses located on circuit boards in the PLC enclosure. These fuses are detailed in the chart below as well as on the fuse decal inside the lid of the PLC enclosure. The fuse numbers are etched into the printed circuit board at each fuse location.
  • Page 116 DuraPack 4060 ® Body Controller Software Section 2: PLC Calibration Setup When installing a PLC it will be necessary to complete the calibration setup procedure, detailed in this section. 2.01: Engine Idle Calibration The engine idle calibration can be performed by two methods. The first method is through the diagnostic link.

  • Page 117: Section 3: Default Parameters

    DuraPack 4060 ® Body Controller Software Section 3: Default Parameters 3.01 Program 109-0236 Parameter Defaults Parameter Default Setting A. Max Engage Speed (Pump 1, Loader)- 800 RPM B. Max Operating Speed (Pump 1)------- 900 RPM C. Max Engage Speed (Pump 2, Body)-- 1700 RPM D.

  • Page 118: Section 4: I/O Functions

    DuraPack 4060 ® Body Controller Software Section 4: I/O Functions The following sheets detail the functionality as well as provide circuit diagrams for each of the input and output function provided through the PLC. 4.01: Standard In-Cab Input Functions A01 Input Function – Chassis Service Brake (In Cab Input 01.04) This circuit monitors the on/off status of the chassis service brake.
  • Page 119 DuraPack 4060 ® Body Controller Software A05 Input Function – Chassis Alternator Signal (In Cab Input 00.00) This circuit monitors the signal generated by the alternator “R” Stator. This signal is typically a -1.4V to +15V square wave, of which the frequency varies relative to engine speed. The PLC uses the Engine Idle, “Tach.
  • Page 120 DuraPack 4060 ® Body Controller Software A09 Input Function – Lift Coordinated Mode Button (In Cab Input 01.06) This circuit monitors the on/off status of the Lift Coordinated Mode Button. Function Logic Input Device Channel LED Lamp LED Status A. Lift Coordinated Mode Button Note: Reference functions D01, D02, D03, D04, D05, D06, D07, and D09 for LED Status conditions during system operation.
  • Page 121 DuraPack 4060 ® Body Controller Software A14 Input Function – Loader Out Push Button (In Cab Input 00.02) This circuit monitors the on/off status of the Loader Out push button. Function Logic Input Device Channel LED Lamp LED Status A. Loader Out Button (momentary) Note: Reference functions D04 for LED Status conditions during lift operation.
  • Page 122 DuraPack 4060 ® Body Controller Software 4.02: Standard In-Cab Output Functions B01 Output Function -- Filter Bypass Indicator (In Cab Output 12.04) 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 123 DuraPack 4060 ® Body Controller Software B03 Output Function – Hydraulic Pump, Loader – P1 (In Cab Output 11.02) This output function controls the hydraulic pump for the loader. Circuit will engage the pump upon activation of the chassis service brake or transmission neutral signal or upon pressing the Grabber Open push button.
  • Page 124 DuraPack 4060 ® Body Controller Software B06 Output Function – Packer Right Indicator (In Cab Output 11.07) This output function controls the indicator lamp for the Pack Right function. Default Parameters Default Setting A. None -------------------------------------- N/A Conditions Necessary to activate the circuit Function or Component Channel LED Lamp...
  • Page 125 DuraPack 4060 ® Body Controller Software B09 Output Function – In-Cab Chime (In Cab Output 10.01) This output function controls In-Cab Chime. Default Parameters Default Setting None ------------------------------------------------- Conditions Necessary to activate the circuit Function or Component Channel LED Lamp LED Status A.
  • Page 126 DuraPack 4060 ® Body Controller Software 4.03: Standard Body Input Functions C01 Input Function – Body/Tailgate Raised Alarm Proximity Switch (Body Input 00.09) This circuit monitors the on/off status of the Body/Tailgate Raised proximity switch. Function Logic Input Device Channel LED Lamp LED Status A.
  • Page 127 DuraPack 4060 ® Body Controller Software C06 Input Function – Packer Proximity Switch (Body Input 02.01) This circuit monitors the on/off status of the Packer proximity switch. Function Logic Input Device Channel LED Lamp LED Status A. Packer Proximity Switch See Note Note: Reference functions D09 and D10 for LED Status conditions during operation.
  • Page 128 DuraPack 4060 ® Body Controller Software C11 Input Function – Coordinated In Proximity Switch - STARR (Body Input 01.11) This circuit monitors the on/off status of the coordinated in proximity switch. Function Logic Input Device Channel LED Lamp LED Status A.
  • Page 129 DuraPack 4060 ® Body Controller Software 4.04: Standard Body Output Functions D01 Output Function – Grabber Close Output (Body Output 10.07) This output function controls the Grabber Close Output. This output will close the grabbers by activating either a solenoid or a relay depending on the control package ordered.
  • Page 130 DuraPack 4060 ® Body Controller Software D03 Output Function -- Loader In Output (Body Output 12.06) This output function controls the Loader In output. This output will retract the loader by activating either a solenoid or a relay depending on the control package ordered. Default Parameters Default Setting A.
  • Page 131 DuraPack 4060 ® Body Controller Software D05 Output Function -- Loader Up Output (Body Output 12.03) This output function controls the Loader Up output. This output will raise the loader by activating either a solenoid or a relay depending on the control package ordered. Default Parameters Default Setting A.
  • Page 132 DuraPack 4060 ® Body Controller Software D07 Output Function -- Loader Dump Output (Body Output 11.06) This output function controls the Loader Dump output. This output will dump the grabbers by activating either a solenoid or a relay depending on the control package ordered. Default Parameters Default Setting A.
  • Page 133 DuraPack 4060 ® Body Controller Software D09 Output Function – Pack Right Solenoid (Body Output 12.02) This output function controls the Pack Right solenoid. Default Parameters Default Setting A. Packer Reverse Delay ------------------ 0.5 Sec. B. Packer Startup Time -------------------- 5.0 Sec. Conditions Necessary to activate the circuit Function or Component Channel...
  • Page 134 DuraPack 4060 ® Body Controller Software D11 Output Function – Loader Latch Solenoid (Body Output 10.06) This output function controls the Loader Latch solenoid. Default Parameters Default Setting A. None -------------------------------------- N/A Conditions Necessary to activate the circuit Function or Component Channel LED Lamp LED Status...
  • Page 135 DuraPack 4060 ® Body Controller Software 4.05: Optional In-Cab Input Functions Not Applicable. 4.06: Optional In-Cab Output Functions Not Applicable. 4.07: Optional Body Input Functions G01 Input Function – Low Engine Torque Pressure Switch (Body Input 01.05) This circuit monitors the on/off status of the low engine torque pressure switch. Function Logic Input Device Channel...
  • Page 136 DuraPack 4060 ® Body Controller Software 4.08: Optional Body Output Functions Not Applicable. Issued September 2017 Copyright 2017, Heil Environmental Body Controller Software Printed in U.S.A.

  • Page 137: Section 5: Special Features

    DuraPack 4060 ® Body Controller Software Section 5: Special Features 5.01: Auto/Manual Pack Mode Auto/Manual Pack Mode is a standard feature on all PLC 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 138: Section 6: Diagnostics

    DuraPack 4060 ® 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 devices, the amperage required to light and incandescent tester may exceed the maximum output of the device.
  • Page 139 DuraPack 4060 ® Body Controller Software 6.06: 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 140 DuraPack 4060 ® Body Controller Software Issued September 2017 Copyright 2017, Heil Environmental Body Controller Software Printed in U.S.A.
  • Page 141 DuraPack 4060 ® Body Controller Software Fault #43- Loss of Engine Tach. Calibration The Tach. Hz./2 at Engine Idle has been erased from PLC memory. Indication: A. Engine speed needs to be calibrated. B. Internal data storage device has malfunction. Replace PLC 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 142 DuraPack 4060 ® Body Controller Software 6.07: System Faults Fault #54- Filter Bypass Switch Fault _ The PLC 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 143: Schematics

    DuraPack 4060 ® Schematics SECTION 8 SCHEMATICS Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 144: Packard Connection Kit, 108-4827

    DuraPack 4060 ® Schematics PACKARD CONNECTION KIT, 108-4827 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 145 DuraPack 4060 ® Schematics PACKARD CONNECTION KIT, 108-4827 ITEM PART NO. DESCRIPTION 108-4827 KIT, Packard connection ..............- ..REF 108-4827-001 CONNECTION, 1-Way Male ............- .... 20 108-4827-002 CONNECTION, 1-Way Female ............- .... 20 108-4827-003 CONNECTION, 2-Way Male ............- .... 20 108-4827-004 CONNECTION, 2-Way Female ............

  • Page 146: Connectors, Plugs, Pins And Accessories For Deutsch Electrical Parts - 108-4815

    DuraPack 4060 ® Schematics CONNECTORS, PLUGS, PINS AND ACCESSORIES FOR DEUTSCH ELECTRICAL PARTS, 108-4815 PINS AND SOCKETS 108-4815-101 PIN (6 GA) 108-4815-102 SOCKET (6 GA) 108-4815-103 SEALING PLUG (6 GA) 108-4815-104 PIN (8-10 GA) 108-4815-105 SOCKET (8-10 GA) 108-4815-106 SEALING PLUG (8-10 GA) 108-4815-107 PIN (12-14 GA) 108-4815-108...
  • Page 147 DuraPack 4060 ® Schematics PLASTIC CONNECTOR SHELLS 108-4815-018 8 (Socket) PLUG (12 GA) 108-4815-020 21-PIN RECEPTACLE 108-4815-021 21-PIN SOCKET 108-4815-022 19-PIN RECEPTACLE 108-4815-023 19-PIN SOCKET 108-4815-024 23-PIN RECEPTACLE 108-4815-025 23-PIN SOCKET 108-4815-030 31 PIN RECEPTACLE 108-4815-031 31 SOCKET PLUG 108-4815-032 16 PIN PLUG 108-4815-033 16 SOCKET RECEPTACLE...
  • Page 148 DuraPack 4060 ® Schematics ACCESSORIES 108-4815-150 PANEL NUT, 24 SHELL 108-4815-151 LOCKWASHER, 24 SHELL 108-4815-152 STRAIN RELIEF STRAIGHT 24 108-4815-153 STRAIN RELIEF 90° 24 108-4815-154 PANEL NUT, 18 SHELL 108-4815-155 LOCKWASHER, 18 SHELL 108-4815-156 STRAIN RELIEF STRAIGHT 18 108-4815-157 STRAIN RELIEF 90° 18 108-4815-158 REMOVAL TOOL (6 GA) 108-4815-159...

  • Page 149: Deutsch Dt Series Connector Kits, 108-8411

    DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS, 108-8411 ITEM PART NO. DESCRIPTION 108-8411 KITS, Deutsch Connector, DT Series ..........- ..REF 108-8411-001 KIT, Deutsch Connector, DT Series ..........- ..REF 108-8411-02R RECEPTACLE, 2-Way ..............- ....1 108-4815-401 PIN, Gold 12 AWG ...............

  • Page 150: Deutsch Dt Series Connector Kits - 108-6461

    DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS - BOOT, 108-6461 ITEM PART NO. DESCRIPTION 108-6461 KITS, Deutsch Connection, DT Series ..........- ..REF 108-6461-3PB BOOT, 3-Way Plug ................- ..A/R 108-6461-3RB BOOT, 3-Way Receptacle ............... - ..A/R 108-6461-4PB BOOT, 4-Way Plug ................
  • Page 151 DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS - STRAIGHT, 108-6461 ITEM PART NO. DESCRIPTION 108-6461 KITS, Deutsch Connection, DT Series ..........- ..REF 108-6461-001 KIT, Deutsch Connector, DT Series, Straight ........- ..REF 108-6461-311 PLUG, 3-Way ................- ....1 108-6461-319 PLUG, 3-Way Wedge ..............
  • Page 152 DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS - STRAIGHT - 108-6461, CONTINUED ITEM PART NO. DESCRIPTION 108-6461 KITS, Deutsch Connection, DT Series ..........- ..REF 108-6461-008 KIT, Deutsch Connector, DT Series, Straight ........- ..REF 108-6461-801 RECEPTACLE, 8-Way ..............
  • Page 153 DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS - 90° - 108-6461, CONTINUED ITEM PART NO. DESCRIPTION 108-6461 KITS, Deutsch Connection, DT Series ..........- ..REF 108-6461-041 KIT, Deutsch Connector, DT Series, 90º ......... - ..REF 108-6461-03P PLUG, 3-Way ................
  • Page 154 DuraPack 4060 ® Schematics DEUTSCH DT SERIES CONNECTOR KITS - 90° - 108-6461, CONTINUED ITEM PART NO. DESCRIPTION 108-6461 KITS, Deutsch Connection, DT Series ..........- ..REF 108-6461-048 KIT, Deutsch Connector, DT Series, 90º ......... - ..REF 108-6461-08R RECEPTACLE, 8-Way ..............

  • Page 155: Deutsch Connection Kit, 108-6461-Pc

    DuraPack 4060 ® Schematics DEUTSCH CONNECTION KIT, 108-6461-PC ITEM PART NO. DESCRIPTION 108-6461-PC KIT, Deutsch Connection ..............- ..REF 108-6461-003P PLUG, 3-Way ................... - .... 15 108-6461-003PW WEDGE, 3-Way Plug ............... - .... 15 108-6461-003PB BOOT, 3-Way Plug ................- .... 15 108-6461-003R RECEPTACLE, 3-Way ..............

  • Page 156: Solenoid Valve Schematic Assembly - 108-8503-Sch

    DuraPack 4060 ® Schematics SOLENOID VALVE SCHEMATIC ASSEMBLY – 108-8503-SCH Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 157: Intec Power System Connection Harness - 161-0420-003

    DuraPack 4060 ® Schematics INTEC POWER SYSTEM CONNECTION HARNESS – 161-0420-003 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 158: Alarm Adapter Harness, 263-1309-004

    DuraPack 4060 ® Schematics ALARM ADAPTER HARNESS, 263-1309-004 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 159: Outside Work Light Harness - 263-1489

    DuraPack 4060 ® Schematics Outside Work Light Harness - 263-1489 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 160: Mini Plc Harness - 263-1490

    DuraPack 4060 ® Schematics Mini PLC Harness - 263-1490 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 161: Tandem Pump Pressure Switch Harness - 263-1491

    DuraPack 4060 ® Schematics Tandem Pump Pressure Switch Harness - 263-1491 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 162: Transmission Temperature Relay Harness - 263-1492

    DuraPack 4060 ® Schematics TRANSMISSION TEMPERATURE RELAY HARNESS - 263-1492 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 163: Neutral Relay Harness - 263-1493

    DuraPack 4060 ® Schematics Neutral Relay Harness - 263-1493 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 164: Battery Connection Harness Units, 263-1506

    DuraPack 4060 ® Schematics BATTERY CONNECTION HARNESS UNITS, 263-1506 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 165: Battery Connection Harness Units, 263-1506-001

    DuraPack 4060 ® Schematics BATTERY CONNECTION HARNESS UNITS, 263-1506-001 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 166: Battery Connection Harness - 263-1506-002

    DuraPack 4060 ® Schematics BATTERY CONNECTION HARNESS – 263-1506-002 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 167: Reverse Connection Battery Harness - 263-1506-100

    DuraPack 4060 ® Schematics REVERSE CONNECTION BATTERY HARNESS - 263-1506-100 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 168: Ss Proximity Switch Tailgate Harness - 263-1521-001

    DuraPack 4060 ® Schematics SS PROXIMITY SWITCH TAILGATE HARNESS – 263-1521-001 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 169: Cs Proximity Switch Tailgate Harness - 263-1521-002

    DuraPack 4060 ® Schematics CS PROXIMITY SWITCH TAILGATE HARNESS – 263-1521-002 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 170: Ss Tailgate Fuse Block Harness - 263-1533-003

    DuraPack 4060 ® Schematics SS TAILGATE FUSE BLOCK HARNESS – 263-1533-003 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 171: Cs Tailgate Fuse Block Harness - 263-1533-004

    DuraPack 4060 ® Schematics CS TAILGATE FUSE BLOCK HARNESS – 263-1533-004 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 172: Bypass Filter Jumper Harness, 263-1562-060

    DuraPack 4060 ® Schematics BYPASS FILTER JUMPER HARNESS, 263-1562-060 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 173: Oai Pump Adapter Harness - 263-1592

    DuraPack 4060 ® Schematics OAI PUMP ADAPTER HARNESS - 263-1592 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 174: Main Body Assembly Harness - 263-1616-001

    DuraPack 4060 ® Schematics MAIN BODY ASSEMBLY HARNESS – 263-1616-001 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 175: Ss Tailgate Assembly Harness - 263-1616-002

    DuraPack 4060 ® Schematics SS TAILGATE ASSEMBLY HARNESS – 263-1616-002 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 176: Cs Tailgate Assembly Harness - 263-1616-003

    DuraPack 4060 ® Schematics CS TAILGATE ASSEMBLY HARNESS – 263-1616-003 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 177: Ss Tailgate Light Box Assembly Harness - 263-1616-004

    DuraPack 4060 ® Schematics SS TAILGATE LIGHT BOX ASSEMBLY HARNESS – 263-1616-004 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 178: Cs Tailgate Light Box Assembly Harness - 263-1616-005

    DuraPack 4060 ® Schematics CS TAILGATE LIGHT BOX ASSEMBLY HARNESS – 263-1616-005 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 179: E-Stop Relay Harness - 263-1704

    DuraPack 4060 ® Schematics E-STOP RELAY HARNESS – 263-1704 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 180 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 181: Mini-Plc Kits - 372-1828-009, 372-1828-010

    DuraPack 4060 ® Schematics MINI-PLC KIT - 372-1828-009 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 182 DuraPack 4060 ® Schematics MINI-PLC KIT - 372-1828-010 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 183: Hopper Tail/Reverse Light Activated Schematic - 701-8872-002

    DuraPack 4060 ® Schematics HOPPER TAIL/REVERSE LIGHT ACTIVATED SCHEMATIC - 701-8872-002 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 184: Hopper Light In Cab Switch Activated Schematic - 701-8872-003

    DuraPack 4060 ® Schematics HOPPER LIGHT IN CAB SWITCH ACTIVATED SCHEMATIC - 701-8872-003 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 185: Ls Active Input Neutral Schematic - 701-8872-007

    DuraPack 4060 ® Schematics LS ACTIVE INPUT NEUTRAL SCHEMATIC - 701-8872-007 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 186: Hs Active Input Neutral Schematic - 701-8872-008

    DuraPack 4060 ® Schematics HS ACTIVE INPUT NEUTRAL SCHEMATIC - 701-8872-008 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 187: Allison Eos Gen. Iv 1000/2000 Schematic - 701-8872-009

    DuraPack 4060 ® Schematics ALLISON EOS GEN. IV 1000/2000 SCHEMATIC - 701-8872-009 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 188: Allison Eos Gen. Iv 3000/4000 Schematic - 701-8872-010

    DuraPack 4060 ® Schematics ALLISON EOS GEN. IV 3000/4000 SCHEMATIC - 701-8872-010 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 189: Throttle Advance Schematic - 701-8872-011

    DuraPack 4060 ® Schematics THROTTLE ADVANCE SCHEMATIC - 701-8872-011 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 190: In Cab Switch Activated Outside Work Tailgate Schematic - 701-8872-013

    DuraPack 4060 ® Schematics IN CAB SWITCH ACTIVATED OUTSIDE WORK TAILGATE SCHEMATIC - 701-8872- Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 191: Mack Body Link And Body Builder Wire Connection Harness - 42005023-001

    DuraPack 4060 ® Schematics MACK BODY LINK AND BODY BUILDER WIRE CONNECTION HARNESS - 42005023-001 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 192: Switch Overlay Panel Harness - 263-1831-001

    DuraPack 4060 ® Schematics SWITCH OVERLAY PANEL HARNESS - 263-1831-001 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.

  • Page 193: Cab To Body Overlay Harness - 263-1831-002

    DuraPack 4060 ® Schematics CAB TO BODY OVERLAY HARNESS - 263-1831-002 Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.

  • Page 194: Organic Bin Clearance Lights Harness - 263-1831-004

    DuraPack 4060 ® Schematics ORGANIC BIN CLEARANCE LIGHTS HARNESS - 263-1831-004 Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 231 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 232 DuraPack 4060 ® Schematics Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 233 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 234 DuraPack 4060 ® Schematics Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 235 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 236 DuraPack 4060 ® Schematics Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 237 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 238 DuraPack 4060 ® Schematics Copyright 2017, Heil Environmental Issued September 2017 Schematics Printed in U.S.A.
  • Page 239 DuraPack 4060 ® Schematics Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 240 DuraPack 4060 ® INDEX hydraulic oil tank with sight gauge hydraulic symbols access doors auxiliary quick disconnect inspect proximity switches battery disconnect switch body daily checklist lock-out/tag-out procedures body nomenclature lock-out tags body preventive maintenance chart lubrication guide bolt type identification chart maintenance/lubrication information caution mount pump monoblock to tandem pump...
  • Page 241 DuraPack 4060 ® INDEX specifications standard torque data for nuts and bolts standard torque data for nuts and bolts table storing refuse in container tailgate blade shoe wear tailgate control lever alignment tailgate lock and unlock inspections tailgate lubrication tailgate nomenclature tailgate support props tandem O.I.G.A.I.

  • Page 242: Unit Serial Number

    DuraPack 4060 ® MANUAL ORDER FORM To purchase a printed copy of the Parts Manual or complete Parts and Service Manual, fax or make a PDF copy of this form and send to your local Heil dealer. Do you want a Parts Section ONLY? _____________ Yes or No Do you want the complete Parts and Service Manual? _________ Yes or No The order number for the Parts Manual ONLY is: TP1D40-PM-0917...
  • Page 243 DuraPack 4060 ® NOTES Issued September 2017 Copyright 2017, Heil Environmental Schematics Printed in U.S.A.
  • Page 244 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 245 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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