Having taken the decision to build the former Gar Wood LP-900 rear loader under license, Heil not only had to prepare all-new tooling, but also needed to establish brand identity for the packer which was distinctly Heil. The name Formula 5000 was chosen, which reflected the high level of engineering that had gone into designing the body. It would be the first Heil rear loader since 1953 that did not bear the Colectomatic moniker. A media campaign was launched in late 1979 to announce the 5000, which was technically a 1980 model, and the Heil name was emblazoned vertically in large letters set against a stripe on the sides of early versions. This "Formula" appearance theme also appeared on other Heil refuse bodies during the early 1980s.
Though built with all-new tooling at Fort Payne, the tailgate, packer and ejector panel on early-production 5000s were virtually identical to those of the Gar Wood LP-900. A single lever controlled the packing mechanism, and the bore and stroke of the cylinders remained the same. While Gar Wood had bought their cylinders from outside vendors, the 5000 would use Heil-built cylinders, except for the telescopic ejector, which was supplied by Great Bend on early models. The nylon bushings in the packer support links were replaced by greaseable bearings, in response to LP-900 customer feedback. The body was the part that received a subtle yet distinct change, with straight vertical posts, replacing the slanted pillars of the 900. During its long life, the 5000 has been built in 18,20,25,27 and 32-cubic yard sizes. A 16-cubic yard body is listed in early parts manuals, but does not appear in the sales literature and presumably was short-lived.
As originally designed in the 1970s, the LP-900 packer went through the complete cycle automatically, without any operator attention. By the 1980s however, the "split-cycle" was the new safety standard for rear loaders. This mandated that the mechanism stopped halfway through the cycle, with a gap of approximately 7" between the blade edge and hopper sill to prevent limbs from being accidentally crushed. To complete the remainder of the cycle required the operator to activate the packer controls a second time. Meeting this standard proved troublesome for the Formula 5000, since the lower packer panel did not open far enough and created a pinch point at the hopper sill at the mid-point of the cycle. Initially, this was solved by replacing single lever control with the dual-lever system (as used on the Mark IV and Mark V), and modifying the linkage to stop the descent of the upper panel before it reached the pinch point.
A better solution to the pinch point issue was built into units after serial number 2740 (late 1984 or 1985), which had a completely revised sweep panel which opened wide enough to leave a gap at the mid-point of the cycle. As an added benefit, the 5000 gained a larger bite, which helped in dealing with bulk items. Sweep cylinders were bumped up to a 5.5 inch bore with increased stroke, and a greatly improved, ergonomic two-handled control was introduced around the same time. The tailgate has remained virtually unchanged ever since. In 1987, self-cleaning catcher troughs were added to collect small bits of refuse which escaped the sidewall slots, a minor nuisance going back to the Gar Wood era.
Building upon the Gar Wood 900's reputation, and Heil's legacy of quality workmanship, the Formula 5000 soon became a mainstay of large refuse collection fleets. It could handle virtually any type of refuse with ease, and weighed a full 500 pounds less than any competitive unit. It had excellent forward weight distribution and minimal tailgate overhang for a packer of its size. The hopper is deceptively cavernous, owing to the trough-like shape, originally rated at three cubic yards (now advertised as 3.94 yards). No less than five types of container hoists would be optional for the 5000: Chain and cable, arm-type, roll-bar, overhead winch and hydraulic reeving. The only area where it could not truly compete with the 2-R Leach was in the heavy demolition sector of the market; its narrow throat design was not well suited to eating steady loads of dense construction debris. However, this was a very narrow segment of the market, concentrated primarily in the northeast, and was more than made up for by increased sales to national accounts.
National collection companies such as Browning Ferris Industries (BFI) and Waste Management Inc. (BFI) appreciated the efficiency of the 5000, and Heil's ability to deliver the body in quantity. Large regional haulers also became a mainstay, such as AAA Disposal of Fairfax, Virginia, which had upwards of 50,000 customers in the D.C. suburbs. AAA had owned Gar Wood 900s since the 1970s, and stayed with the 5000 in the early 1980s. The New York City Department of Sanitation (DSNY) had only recently come back to Heil in 1968, buying the Mark III, and later the Mark IV body. The City soon became Heil's biggest municipal customer when the Department standardized their fleet with the Formula 5000. Heil built special versions with extra lighting and dual-side packer controls, and the DSNY is still a customer to this day. Independent haulers also appreciated the 5000, which could typically outlive several truck chassis. It is also one of the few high-compaction rear loaders available with an 18-yard body.
After twenty years of production, the 5000 was fitted with the advanced DuraPak body in 1999, a curved-side shell that was invented by Fred Smith and had first appeared on the 1978 Gar Wood LP-10 00. Single steel sheets form the sides, arranged so the load forces pack with the grain of the steel for longer life. It came with a new ejector panel using a floor-mounted, angled cylinder. By this time, the Mark V was a distant memory at Chattanooga, and the 5000 was recognized by many as the best rear loader in its class. It undoubtedly has helped make the company one of the top refuse body producers in America. Over 20,000 Formula 5000s have been produced since 1980, and there is no end in sight for this great packer. Additionally, there have been countless other non-Heil versions produced by Gar Wood, Scapa, KSG, Fuji, FAUN, and Ochsner which have seen service around the globe.
Early-production Formula 5000 with single-lever packer control; the tailgate was almost identical to the Gar Wood LP-900
Packer cylinder and outer link are connected to upper panel through slots in the tailgate walls
FORMULA 5000 PACKING MECHANISM DEMONSTRATED
The heil Formula 5000 uses a packer mechanism designed by Fred T. Smith and patented in 1972 for Sargent Industries. It is a swing-link type packer in which the entire mechanism is carried by eight bearings and four links. Upper panel cylinders and main link arms are mounted outside the tailgate, and connect to the panel through slots in the sidewalls. Upper stabilizer links are mounted high in the inside of the tailgate. The video below shows the packer in action and its working parts:
Video courtesy of FormerWMDriver, with special thanks to Trucks & Parts of Tampa
Below is an animated graphic showing the inside of a FAUN Powerpess, which is German-built body based on the same Smith patent as the Formula 5000. This cutaway view shows the operation of all of the links, the curvature of the panels and the 'tortured path' the refuse takes within the structure:
Video courtesy of Faun Umwelttechnik GmbH & Co. KG
The first version dual-handle controls appeared in the early 1980s. Rearmost handle controls the lower panel, while front handle controls the upper panel
Interior shot of the packer; refuse follows a 'tortured path', through a progressively narrowed throat formed by the curvature of
the upper packer panel and the hopper front wall. The upper (fixed) partition is also slightly curved and aids compaction
The back of the sweep panel has angular ribs which strengthen, as well as imparting compaction force at right angles to the blade face.
The LP-900/F5000 is perhaps the most meticulously engineered rear loader ever created
Looking at ejector through tailgate; twin curved panels form the assembly, which is guided by tracks and shoes
Ejector panel is unobtrusive and compact, and remained unchanged from 1979-1999
The 5000 received a redesigned sweep panel beginning with serial number 2740, circa 1985. It opened further, eliminating the pinch point
and giving the 5000 a bigger bite. New cylinders for the sweep panel had a larger bore and longer stroke.
Viewed in profile, the 1985 & up models are almost identical to the earlier versions
Later models also got an ergonomically-designed two lever control. A wider riding step now wrapped slightly around the rear of the hopper,
and rear grab handles were added to the ends of the side walls. High-mounted stop lights (above hopper opening) were soon added as well.
LEFT: 1979-1984 sweep panel was nearly identical to Gar Wood 900, with fine ribs and 5" x 20" cylinders
RIGHT: 1985 & up sweep panel was redesigned with shorter crank arms, wide upper rib, 5.5" x 24" cylinders
LEFT: Maximum open position of sweep panel for Gar Wood 900 and Formula 5000 from 1979-1984
RIGHT: Maximum open position was increased for Formula 5000, serial #2740 & up
LEFT: Blade up/slide down position for Gar Wood 900 and Formula 5000 from 1979-1984 created pinch point at hopper sill
RIGHT: Later model 5000 with wide-opening blade eliminated the pinch point for compliance with ANSI standards
Household refuse is mangled by the intense pressures within the Formula 5000
Optional slot covers that travel with the packer blade helped minimize spillage of shredded refuse on to riding steps.
These were replaced by catch basins which empty themselves when the tailgate is raised (right photo)
Big 32-yard body is the largest Heil rear loader ever built
DSNY 27-yard body has many special features such as dual-side packer controls and hazard light array.
Wheel wells are cut into body to accommodate low-entry chassis, and riding steps are eliminated
The best got better in 1999: The curved-shell Formula 5000 DPF (DuraPack Family)
The DuraPack body can trace its lineage to the 1978 Gar Wood LP-10 00
DPF 5000 got a new ejector with floor-mounted high-angle cylinder
FOR MORE INFORMATION ON THE HISTORY OF THE LP-900 PACKER:
