HEIL Formula 4000 Adjustment Manual

Rear loader

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REVISION RECORD LOG

DATE

Rev.

REVISION

INSERTED

No.

NO.

The information and specifications included in this publication were in effect at the

time of approval for printing. Heil Environmental Industries Ltd., Chattanooga, TN

reserves the right, however, to discontinue or change specifications or designs at

any time without notice and without incurring any obligation whatsoever.

Printed in U.S.A.

PARTS & MAINTENANCE/ADJUSTMENT MANUAL

Formula 4000



REAR LOADER

MR-74999-404

This manual is printed

On recyclable paper

ISSUED APRIL 2004

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Summary of Contents for HEIL Formula 4000

Page 1 On recyclable paper The information and specifications included in this publication were in effect at the time of approval for printing. Heil Environmental Industries Ltd., Chattanooga, TN reserves the right, however, to discontinue or change specifications or designs at any time without notice and without incurring any obligation whatsoever.
Page 3 FORMULA 4000...
Page 4: Table Of Contents
FORMULA 4000 TABLE OF CONTENTS SECTION 3 – CONTROLS with AIR SYSTEMS (CONT’D SECTION 1 – GENERAL Neutral Switch Kits; General ..............1.1 Automatic Transmission (272-3183-01) ....3.26 Nomenclature ............1.4 Allison World Transmission and Allison VIM (272-3183-02) ............3.28 SECTION 2 –...
Page 5 FORMULA 4000 TABLE OF CONTENTS SECTION 5 – HYDRAULIC COMPONENTS (CON’T) SECTION 4 – HYDRAULIC CIRCUITS (CONT’D) Regenerative Valve (31-6285) ........ 5.40 Pump Kits; Direct Mount Pump (219-1915)......5.42 Direct Mount (272-2623)......... 4.22 Direct Mount Pump (219-1916)......5.44 PTO/Pump Drive (272-1870) ....... 4.23.2 8,000 Lb.
Page 7: Section 1 - General
FORMULA 4000 SECTION 1 – GENERAL General ................................1.1 Nomenclature ..............................1.4 Printed in U.S.A. ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 8 This catalog has been developed into nine sections for easy access and use. The first eight sections contain the replacement parts on the Formula 4000 and arranged for easy identification of Heil service parts. Section 9 contains information on maintenance/adjustment of the unit. It contains information on maintenance, adjustment, troubleshooting and hydraulic and electrical schematics.
Page 9 Order parts by description, part number and quantity desired. Give specific instructions. We want your order to reach you as quickly and economically as possible. Contact your HEIL distributor for parts and service. HEIL Environmental Ind. Ltd. Product Support Facility (Parts and Service) 4301 N.
Page 10: Nomenclature
FORMULA 4000 NOMENCLATURE ISSUED APRIL 2004 Printed in U.S.A. COPYRIGHT 2003, H.E.I.L.
Page 13: Section 2 - Body And Attaching Parts
FORMULA 4000 SECTION 2 – BODY and ATTACHING PARTS Body Assembly and Mounting Parts....................... 2.3-2.5 Tailgate Assembly and Attaching Parts......................2.7-2.9 Tailgate Step Assembly............................2.9.2 Ejector Panel and Parts ..........................2.11-2.13 Packer Blade and Slide Assembly ........................2.15 Body to Chassis Mounting Parts......................... 2.17 Hydraulic Oil Tank ...............................
Page 15 CORNERPOST ASSEMBLY – RH - 25 yd units ......1 005-3721 BRACKET, tailgate cylinder – (weldment) ........2 177-2988 REAR CROSSMEMBER – 84” wide units ........1 077-8787 REAR CROSSMEMBER – 96” wide units ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 17 FORMULA 4000 BODY and ATTACHING PARTS PART NO. DESCRIPTION REQ’D FS100932 CAPSCREW – 3/8” – 24NF x 2-1/4”..........2 040-2218 COLLAR..................2 FS240900 NUT, lock – 3/8” – 24NF............... 2 048-5482 PIN, tailgate raise cylinder............2 053-1908 HANDLE ASSEMBLY ..............2 055-0979 WASHER ...................
Page 18: Tailgate Assembly And Attaching Parts
TAILGATE and ATTACHING PARTS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 19 13/20 yd-84” wide units- ........177-3996 CROSSMEMBER, hinge- 13/20 yd-96” wide units ........177-3997 CROSSMEMBER, hinge- 25 yd-96” wide units- .......... 077-9047 KIT, tailgate prop (includes items 31 & 32)……………………….2 048-5643 PIN…………………………………………………………………1 077-9046 SUPPORT…………………………………………………………1 Printed in U.S.A. ISSUED APRIL 2004  COPYRIGHT 2004, HEIL...
Page 21 FORMULA 4000 TAILGATE and ATTACHING PARTS PART NO. DESCRIPTION REQ’D 021-3376 BAR, bearing................. 4 177-2890 CROSSMEMBER, tailgate – (84” wide units)......1 177-1336 CROSSMEMBER, tailgate (96” wide units)......... 1 070-1103 HANDLE ..................4 211-4239 BRACKET, stop light ..............1 177-3943 CROSSMEMBER, tail light (84”...
Page 22: Tailgate Step Assembly
2.9.1 TAILGATE STEP ASSEMBLY ISSUED APRIL 2000 ã COPYRIGHT 2000, H.E.I.L...
Page 23 2.9.2 FORMULA 4000 TAILGATE STEP ASSEMBLY PART NO. DESCRIPTION REQ’D 70-1722 HANDLE, grab – left hand ............1 70-1723 HANDLE, grab – right hand ............1 70-1721 ROD, spacer .................. 2 121-2106 STEP WELDMENT – left hand ............. 1 121-2107 STEP WELDMENT –...
Page 24: Ejector Panel And Parts
EJECTOR PANEL and ATTACHING PARTS 237-8162 – for 13 THRU 20 YD. 96” WIDE UNITS 2.10 237-8164– for 25 YD. 96” WIDE UNITS 237-8163 – for ALL NARROW 84” WIDE UNITS ©COPYRIGHT 2004, HEIL ISSUED APRIL 2004...
Page 25 PLATE, side – left hand..............1 237-8162-002 PLATE, side – right hand ............. 1 237-8162-008 PLATE, brace ................2 237-7369-014 BRACE, corner ................2 237-7371-001 BRACE, upper for 237-8162 ............2 Printed in U.S.A. ©COPYRIGHT 2004, HEIL ISSUED APRIL 2004...
Page 26 2.12 EJECTOR PANEL and ATTACHING PARTS 237-8162– for 13 THRU 20 YD. 96” WIDE UNITS 237-8164 – for 25 YD. 96” WIDE UNITS 237-8163 – for ALL NARROW 84” WIDE UNITS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 27 PIN, cotter – 3/16” x 3” ..............4 048-5798 PIN, ejector cylinder rod end ............1 REF. CYLINDER, ejector (see section 5) ..........1 048-5799 PIN, ejector cylinder base end ............. 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 29 FORMULA 4000 2.15 PACKER BLADE, SLIDE and ATTACHING PARTS PART NO. DESCRIPTION REQ’D 113-1674-002 BLADE, packer – (84” wide units)..........1 113-1674-001 BLADE, packer - (96” wide units)..........1 FS070940 CAPSCREW – 3/8” – 16NC x 3”..........2 048-5549 PIN, blade cylinder rod end ............2 FS230900 NUT, lock –...
Page 30: Body To Chassis Mounting Parts
2.16 BODY TO CHASSIS MOUNTING PARTS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 31 TIE DOWN ................A/R NOTE: OFFSET PLATES ARE AVAILABLE FOR THE VARIOUS COMBINATIONS OF CHASSIS RAIL WIDTHS PART NO. OFFSET 134-1744-001 1/4 Inch 134-1744-002 3/8 Inch 134-1744-003 1/2 Inch 134-1744-004 3/4 Inch Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 32: Hydraulic Oil Tank
2.18 HYDRAULIC OIL TANK 020-2010 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 33 GASKET ..................1 074-3624 FLANGE ASSEMBLY ..............1 FS540011 WASHER, lock – 1/2” ..............6 FS071120 CAPSCREW – 1/2” – 13NC x 1” ..........6 075-0570 STRAINER, suction (optional) ............1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 34 2.19.1 HYDRAULIC OIL TANK with IN-TANK FILTER 020-2326 ISSUED MARCH 2004 ã COPYRIGHT 2004,HEIL...
Page 35 FORMULA 4000 2.19.2 HYDRAULIC OIL TANK with IN-TANK FILTER 020-2326 PART NO. DESCRIPTION REQ’D 020-2284 TANK, oil (weldment) ..............1 074-3626 FLANGE ..................1 075-0724 FILTER, oil (see section 5) ............1 022-2707 SEAL ..................... 1 031-2616 VALVE, shut-off ................1 054-2988-010 ELBOW, 90 °..................
Page 36: Container Lip And Latch Kit
2.20 CONTAINER LIP and LATCH KITS 094-1504 – for CONTAINER ARM MECHANISM 094-1503 – for ALL OTHERS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 37 NUT, lock – 1/2” – 20NF ............... 4 053-1868 LATCH ASSEMBLY – for 093-1504 kit ........1 053-1871 LATCH ASSEMBLY – for 093-1504 kit ........1 064-3045 GUIDE ................... 2 211-1645 LUG ....................2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 38: Latch Kit For Winch, Roll Bar And Reeving Kit
2.21.1 LATCH KIT for WINCH, ROLL BAR OR REEVING KIT 372-2644 ISSUED FEBRUARY 2004 ã COPYRIGHT 2003, HEIL...
Page 39 CAPSCREW – 1/2” – 20NF x 2-1/2” ..........2 FS231100 NUT, lock – 1/2” – 13NC ............... 4 FS241100 NUT, lock – 1/2” – 20NF ............... 4 FS521100 WASHER, flat – 1/2” ..............8 Printed in U.S.A. ISSUED FEBRUARY 2004 ã COPYRIGHT 2003, HEIL...
Page 40: Container Arm Mechanism
2.22 CONTAINER ARM MECHANISM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 41 BRACKET, cylinder – left hand ............. 1 211-2490 BRACKET, cylinder – right hand ........... 1 111-8624 BRACKET – left hand ..............1 111-8625 BRACKET – right hand ..............1 080-1293 STOP ..................... 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 42: Roll Bar Mechanism
2.24 ROLL BAR MECHANISM 253-2095 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 43 ARM, lift – weldment – right hand ..........1 040-2071 COLLAR ..................1 207-5188 PLATE ..................1 ref. CYLINDER, roll bar (see section 5) ..........2 207-5185 PLATE ................... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 44: Winch Mechanism
2.26 WINCH MECHANISM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 45 THIMBLE – 7/16” – (for 8,000 lb. winch) ......... 1 053-1964 HOOK – with safety latch ............1 211-4322 BRACKET, rear light ..............1 211-5884 GUARD, center stop light (not shown) ......... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 46: Reeving Mechanism
2.28 REEVING MECHANISM for ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 47 NUT, lock – 5/16” – 18NC ............. 3 211-4319 BRACKET ..................1 211-4223 BRACKET – weldment – part of 211-4345) ......... 1 097-0469-003 THIMBLE ..................1 053-1963 HOOK, swivel ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 48 2.30 ROLL-BAR FLIPPER MECHANISM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 49 FS071344 CAPSCREW – 5/8” – 11NC x 3-1/2” ..........2 FS071362 CAPSCREW – 5/8” – 13NC x 5-1/4” ..........3 FS071380 CAPSCREW – 5/8” – 11NC x 7” ..........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 50 2.32 ROLL-BAR FLIPPER MECHANISM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL 253-2278...
Page 51 PIN, cotter – 5/32” x 1-1/2” ............1 QC2-FEFE-19 HOSE, hydraulic ................1 QC2-FEFE-24 HOSE, hydraulic ................1 054-3535-05 UNION, bulkhead ................2 207-5185 PLATE ................... 2 013-5195 LEVER ASSEMBLY ..............1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 52 2.34 ROLLER BAR MECHANISM with ROLLERS 272-7233 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 53 CAPSCREW – 3/8” – 24NF x 1-3/4” ..........4 014-1415 PAD ....................2 211-5385 BRACKET, pad ................2 FS510900 WASHER, flat – 3/8” ..............4 FS240900 NUT, lock – 3/8” – 24NF ............. 10 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 55 SECTION 3 SECTION 3 SECTION 3 SECTION 3 HYDRAULIC PUMPS HYDRAULIC PU HYDRAULIC PU HYDRAULIC PU SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL     2005, Heil Environmental MR-74897-105...
Page 57: Throttle Advance Kits
FORMULA 4000 SECTION 3 – CONTROLS, THROTTLE ADVANCE AND NEUTRAL SWITCH KITS Tailgate Control Levers and Parts ....................... 3.2 Single Hydraulic Mechanism Control (winch, reeving, roll bar or arm) ............3.4 Double Hydraulic Mechanism Control (roll bar, arm or reeving) ..............3.6 Throttle Advance Kits;...
Page 58 TAILGATE CONTROLS and LINKAGE ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 59 ROD, control (84” wide units) ............1 070-1172 GRIP, handle ................. 2 027-3655 ROD, control (96” wide units) ............1 027-4835 ROD, control (84” wide units) ............1 207-2682 ACTUATOR, spool ................ 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 60 SINGLE MECHANISM CONTROL and LINKAGE for WINCH, ROLL BAR, GRAB BAR OR ARM 253-1986 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 61 BEARING ..................2 048-5581 PIN, clevis ..................1 048-3997 PIN, clevis ..................1 108-2279 SWITCH, throttle ................1 108-2280 BOOT .................... 1 027-3653 ROD, control .................. 1 070-0680 GRIP, handle ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 62 DOUBLE MECHANISM CONTROL and LINKAGE for WINCH, ROLL BAR, GRAB BAR OR ARM 253-1987 ã COPYRIGHT 2004, HEIL ISSUED APRIL 2004...
Page 63 NUT, jam – 1/2” -20NF ..............2 027-4723 ROD, control (96” wide units) ............1 027-4930 ROD, control (84” wide units) ............1 032-0991 YOKE ..................... 1 032-0991 PIN, clevis ..................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 64 MECHANICAL ACTUATED THROTTLE ADVANCE for 12v DC CHASSIS 272-1818-001 NOTE: PRESSURE INLET CONNECT TO AIR SUPPLY ASS'Y REF. P/N 272B7464 THROTTLE ADVANCE +12v GROUND AIR FROM CHASSIS N/C AIR SOLENOID (THROTTLE ADVANCE) ELECTRICAL\ PNUEMATIC DIAGRAM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 65 NUT - #8 – 32 ................2 FS420320 SCREW, machine - #8-32 x 1-1/2” ..........2 FS510300 WASHER, flat - #8 ................ 2 FS550300 WASHER, lock - #8 ............... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 66 MECHANICAL ACTUATED THROTTLE ADVANCE for 12v DC CHASSIS 272-1818-01 NOTE: PRESSURE INLET CONNECT TO AIR SUPPLY ASS'Y REF. P/N 272B7464 THROTTLE ADVANCE +12v GROUND AIR FROM CHASSIS N/C AIR SOLENOID (THROTTLE ADVANCE) ELECTRICAL\ PNUEMATIC DIAGRAM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 67 NUT - #8 – 32 ................2 FS420320 SCREW, machine - #8-32 x 1-1/2” ..........2 FS510300 WASHER, flat - #8 ................ 2 FS550300 WASHER, lock - #8 ............... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 68 3.12 MECHANICAL ACTUATED THROTTLE ADVANCE for ENGINES with PNEUMATIC ACCELERATOR 272-1818-002 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 69 PLUG, 3-way ................. 1 108-4827-011 TERMINAL, male ................2 108-4827-013 SEAL, cable ................... 2 108-5354-06 VENT, breather ................1 211-9403 BRCKET ..................1 FS270300 NUT - #8 – 32 ................2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 70 3.14 THROTTLE ADVANCE for ELECTRONIC CONTROLLED NAVISTAR ENGINE 272-1818-120 ISSUED APRIL 2004 ã COPYRIGHT 2002, HEIL...
Page 71 PLUG, cavity (not shown) ............. 1 108-5233-015 WIRE – 16 GA – (blue) ............. 18ft 108-5233-017 WIRE – 16 GA – (black) ............. 1ft 108-5233-022 WIRE – 16 GA - (white) ............. 1ft Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2002, HEIL...
Page 72 3.16 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CAT ENGINE 272-1818-121 THROTTLE ADV. PLUGGED GROUND ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 73 WIRE – 16 GA (dark blue) ............1ft 108-5233-021 WIRE – 16 GA (brown) ............... 8ft 108-5233-022 WIRE – 16 GA (white) ..............2ft 108-5233-024 WIRE – 16 GA (yellow) ............... 8ft Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2002, HEIL...
Page 74 3.18 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CUMMINS ISM ENGINE 272-1818-122 THROTTLE ADVANCE PLUGGED GROUND ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 75 WIRE – 16 GA (dark blue) ............1ft 108-5233-21 WIRE – 16 GA (brown) ............... 8ft 108-5233-22 WIRE – 16 GA (white) ..............2ft 108-5233-24 WIRE – 16 GA (yellow) ............... 8ft Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 76 3.20 THROTTLE ADVANCE for ELECTRONIC CONTROLLED VOLVO ENGINE 272-1818-127 HROTTLE ADV. UGGED UGGED ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 77 108-4827-111 TERMINAL, male ................1 108-4827-131 SEAL, cable ................... 1 108-4827-133 PLUG, cavity .................. 2 108-6718-800 WIRE – 16 GA (brown 800) ............6ft 108-7114-002 PIN, Volvo VECU ................2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 78 3.22 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CUMMINS ISB/ISC ENGINE 272-1818-128 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 79 PLUG, cavity .................. 1 108-5233-024 WIRE – 16 GA (yellow) ............... 8ft 108-6761-800 WIRE – 16 GA (brown “800”) ............. 1ft 108-6761-GND WIRE – 16 GA (white “GND”) ............. 2ft Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 80 3.24 THROTTLE ADVANCE for ELECTRONIC CONTROLLED Vmack ENGINES 272-1818-129 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 81 CONNECTOR, butt – 16-14 ............4 108-5717-003 CONNECTOR, butt – 12-10 ............6 108-6718-800 WIRE – 18 GA (brown “800”) ............. 3ft 108-3647 CONNECTOR, closed end ............1 108-7114-03 PIN, Mack VECU ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 82 3.26 NEUTRAL SWITCH KIT for AUTOMATIC TRANSMISSION (NON-ELECTRONIC) 272-3183-001 TO CHASSIS STARTER SOLENOID CIRCUIT TRANSMISSION NEUTRAL SWITCH HARNESS, REF. TRANSMISSION NEUTRAL SWITCH, REF. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 83 SEAL, cable ................. 11 108-4476 LOOM ..................1ft 108-6752 RELAY ................... 1 FS070715 CAPSCREW – 1/4” – 20NC x 3/4” ..........1 FS230700 NUT, lock – 1/4” –20NC ..............1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 84 3.28 NEUTRAL SWITCH KIT with ALLISON WORLD TRANSMISSION & ALLISON VIM 272-3183-002 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 85 CONNECTOR, 2-way female ............1 108-4827-011 TERMINAL, male ................2 108-4827-012 TERMINAL, female ............... 2 108-4827-013 SEAL, cable ................... 4 108-5717-002 CONNECTOR, butt ............... 2 108-6362 WIRE, VIM connector ..............2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 86 3.30 NEUTRAL SWITCH KIT for 320 PETERBILT CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-003 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 87 NEUTRAL SWITCH KIT for 320 PETERBILT CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-003 PART NO. DESCRIPTION REQ’D 108-4827-006 CONNECTOR, 3-way female ............1 108-4827-012 TERMINAL, female ............... 2 108-4827-013 SEAL, cable ................... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 88 FREIGHTLINER FUSE PANEL LOCATED UNDER CURB SIDE DASH C B A CONNECT +12v DC 15 AMP FROM HEIL CONTROLS TO PIN OUT "F" CONNECT HEIL NEUTRAL SIGNAL WIRE TO PIN OUT "E" FOR + 12v OUTPUT NOTE: INSERT TERMINAL INTO REAR OF CONNECTOR.
Page 89 3.33 FORMULA 4000 NEUTRAL SWITCH KIT for FREIGHTLINER CHASSIS and ALLISON WORLD TRANSMISSION 272-3183-005 PART NO. DESCRIPTION REQ’D 108-6783 TERMINAL, packard ..............2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 90: With Allison World Transmission (272-7738-02)
3.34 NEUTRAL SWITCH KIT for FORD LOUISVILLE with ALLISON WORLD TRANSMISSION 272-3183-006 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 91 POWERTRAK 1000 NEUTRAL SWITCH KIT for FORD LOUISVILLE with ALLISON WORLD TRANSMISSION 272-3183-006 PART NO. DESCRIPTION REQ’D 108-6784 PLUG, deutsch ................1 108-6031-012 SOCKET ..................2 108-6785-003 PLUG, sealing ................21 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 92 3.36 NEUTRAL SWITCH KIT for MANUAL TRANSMISSION 272-3183-007 N.C. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 93 REQ’D 054-7350 TUBING, shrink ................2” 054-8881-003 FITTING, reducer – brass ............. 1 108-4943-003 TERMINAL, ring ................2 108-5617 SWITCH, pressure – N.C............. 1 354-0202-006 TEE, male ..................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 94 3.38 NEUTRAL SWITCH KIT for NAVISTAR CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-008 NEUTRAL RELAY NEUT. RELAY ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 95 TEK SCREW ................. 1 108-2648 DIODE ................... 1 108-4470 LOOM, electrical ................3ft 108-5233-022 WIRE – 16 GA (white) ..............3ft 108-5717-022 CONNECTOR, butt ............... 3 108-6363 TUBING, shrink ................3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 96 3.40 NEUTRAL SWITCH KIT for STERLING 1999 CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-009 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 97 NEUTRAL SWITCH KIT for STERLING 1999 CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-009 PART NO. DESCRIPTION REQ’D 108-4815-004 PLUG, deutsch ................1 108-4815-111 SOCKET, deutsch ................. 2 108-4815-114 PLUG, sealing ................29 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 98: Chassis (272-7738-03)
AIR SUPPLY PARTS for 272-7464-001 AIR FROM CHASSIS NOTE: ADJUST REGULATOR NOTE: ADJUST REGULATOR TO 80 PSI TO 100 PSI PNEUMATIC DIAGRAM PRESSURE OUTLET PRESSURE INLET CONNECT TO UNIT CONTROLS CONNECT TO CHASSIS SYSTEM PRESSURE ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 99 FORMULA 4000 3.43 AIR SUPPLY PARTS for 272-7464-001 PART NO. DESCRIPTION REQ’D 031-1909 VALVE, pressure protection ............1 036-1115 CLAMP, strap................30 047-2151-011 SCREW, tek – 1/4”................2 054-5449 TUBE – 1/4”................20ft 054-8468-003 CONNECTOR – 1/8” pipe x 1/4” tube..........1 054-8468-004 CONNECTOR – 1/4” pipe x 1/4” tube..........1 054-8470-004 ELBOW, 90°...
Page 100: Pneumatic Diagram
3.44 AIR SUPPLY PARTS for 272-7464-002 NOTE: ADJUST REGULATOR TO 80 PSI PRESSURE PRESSURE AIR FROM INLET OUTLET CHASSIS PNEUMATIC DIAGRAM CONNECT TO UNIT CONTROLS CONNECT TO CHASSIS SYSTEM PRESSURE ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 101 FORMULA 4000 3.45 AIR SUPPLY PARTS for 272-7464-002 PART NO. DESCRIPTION REQ’D 036-1115 CLAMP, strap................30 047-2151-011 SCREW, tek – 1/4”................2 054-5449 TUBE – 1/4”................20ft 054-8468-003 CONNECTOR – 1/8” pipe x 1/4” tube..........1 054-8468-004 CONNECTOR – 1/4” pipe x 1/4” tube..........1 054-8470-004 ELBOW, 90°...
Page 102 AIR SUPPLY PARTS for 272-7464-03 NOTE: ADJUST REGULATOR TO NOTE: ADJUST REGULATOR TO 80 PSI 100 PSI. AIR FROM CHASSIS PRESSURE OUTLET PNEUMATIC DIAGRAM PRESSURE INLET CONNECT TO UNIT CONTROLS CONNECT TO CHASSIS SYSTEM PRESSURE ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 103 3.47 FORMULA 4000 AIR SUPPLY PARTS for 272-7464-03 PART NO. DESCRIPTION REQ’D 031-1909 VALVE, pressure protection ............1 036-1115 CLAMP, strap................30 047-2151-011 SCREW, tek – 1/4”................2 054-5449 TUBE – 1/4”................20ft 054-8468-003 CONNECTOR – 1/8” pipe x 1/4” tube..........1 054-8468-004 CONNECTOR – 1/4” pipe x 1/4” tube..........1 054-8470-004 ELBOW, 90°...
Page 105 3.49 FORMULA 4000 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for UNITS WITHOUT ALLISON TRANSMISSION 272-7738-001 PART NO. DESCRIPTION REQ’D 047-2151-011 TEK SCREW – 1/4” ..............2 108-4545-001 CABLE ..................1 108-4545-002 SWITCH, eos................1 108-4827-009 CONNECTOR, 6-way male ............1 108-4827-010 CONNECTOR, 6-way female ............
Page 106 3.50 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for UNITS with ALLISON TRANSMISSION 272-7738-02 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 107 CONNECTOR, 2-way female ............1 108-4827-111 TERMINAL, male ................2 108-4827-121 TERMINAL, female ............... 2 108-4827-131 SEAL, cable ................... 4 108-5717-002 CONNECTOR, butt ............... 3 108-6362 WIRE, VIM connection ..............2 Printed in U.S.A. ISSUED APRIL2004 ã COPYRIGHT 2004, HEIL...
Page 108 3.52 (EOS) ELECTRONIC OVERPEED SWITCH KIT for ALLISON WORLD TRANSMISSION/ PETERBILT 320 272-7738-003 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 109 PART NO. DESCRIPTION REQ’D 054-7350 TUBING, shrink ................2” 108-4827-006 CONNECTOR, 3-way female ............1 108-4827-121 TERMINAL, female ............... 2 108-4827-131 SEAL, cable ................... 2 108-5717-002 CONNECTOR, butt ............... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 110: Allison World Transmission And 24V Dc (272-7738-124)
3.54 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and 24v DC 272-7738-124 PUMP SW. OUTPUT YELLOW "R" STATOR TO HEIL CONTROLS GREEN PUMP SOLENOID BLACK GROUND WHITE ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 111 DESCRIPTION REQ’D 047-2151-011 TEK SCREW ................. 2 054-7350 TUBING, shrink ................8” 108-3647 CAP, wire ..................1 108-4887 SWITCH, electronic overspeed – 24v .......... 1 108-5717-002 CONNECTOR, butt ............... 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 112: Allison World Transmission And Freightliner Chassis (272-7738-05)
272-7738-005 FREIGHTLINER FUSE PANEL LOCATED UNDER CURB SIDE DASH CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUT "2" D E F CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUT "F" CONNECT HEIL PUMP SOLENOID WIRE TO PIN OUT "E".
Page 113 3.57 FORMULA 4000 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION AND FREIGHTLINER CHASSIS 272-7738-005 PART NO. DESCRIPTION REQ’D 108-6783 TERMINAL ..................2 108-5587 TERMINAL, amp ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 114: Allison World Transmission And Ford Louisville Chassis (272-7738-06)
V.I.M. NOTE: INSERT DEUTSCH SOCKETS (ITEM 1) INTO MIDDLE CONNECTOR IN HEIL NEUTRAL KIT CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUTS "V" & "B". CONNECT HEIL PUMP SOLENOID WIRE TO PIN OUT "T" . VIEW "A"...
Page 115 3.59 FORMULA 4000 (EOS) ELCTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and FORD LOUISVILLE CHASSIS 272-7738-006 PART NO. DESCRIPTION REQ’D 108-4815-111 SOCKET ..................3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 116 3.60 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and NAVISTAR 1998 MODEL and AFTER 272-7738-008 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 117 KIT, micro relay (see section 6) ............ 1 047-2151-001 TEK SCREW ................. 1 108-4470 LOOM – 3/8” ................3ft 108-5233-017 WIRE – 16 GA – (black) ............. 3ft 108-5233-022 WIRE – 16 GA – (white) .............. 3ft Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 118 3.62 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and STERLING CHASSIS 272-7738-009 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 119: Allison World Transmission And Sterling Chassis (272-7738-09)
3.63 FORMULA 4000 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and STERLING CHASSIS 272-7738-009 PART NO. DESCRIPTION REQ’D 108-4815-111 SOCKET ..................3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 121: Hydraulics
Electric/Air Shift Kit with Overspeed (108-5354) .....................4.60 Electric/Air Shift Kit without Overspeed (108-5355)..................4.62 Pressure Test Gauge Kit (272-6347)......................... 4.64 PTO Mount Tandem Vane Pump Installation (372-2280) ................4.66 Front Mount Tandem Vane Pump Installation (372-2281)................4.68 Printed in U.S.A. ISSUED APRIL 2005 ©COPYRIGHT 2005, Heil Environmental...
Page 122: Tailgate Valve With Fittings
TAILGATE VALVE with FITTINGS...
Page 123 ELBOW, 90 ° swivel ............... 2 058-3205-019 CONNECTOR, reducing ............... 2 FS071124 CAPSCREW – 1/2” – 13NC x 1-1/2” (valve mounting) ....4 FS231100 NUT, lock – 1/2” – 13NC ............... 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 124 OIL TANK and FILTER HYDRAULICS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 125 NUT, lock – 5/16” – 24NF ............. 4 058-3248-003 FITTING, swivel ................1 057-2183-072 HOSE, low pressure ..............1 FS743000 ELBOW, 90 ° - 2” ................1 272-4016 SUCTION LINE SHUT-OFF VALVE KIT ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 127: Body
TUBE, hydraulic (11 thru 20 yd units) ........... 1 054-9326 TUBE, hydraulic (25 yd units) ............1 054-7482 TUBE, hydraulic ................1 054-7485 TUBE, hydraulic ................1 054-3185-010 ELBOW, 90 °.................. 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 129 FORMULA 4000 4.7.2 BODY HYDRAULICS PART NO. DESCRIPTION REQ’D 054-3185-008 ELBOW, 90 °.................. 1 057-2181-028 HOSE, hydraulic ................1 057-2182-038 HOSE, hydraulic ................1 211-4644 BRACKET, bulkhead ..............1 054-3237-013 ELBOW, 90 ° reducing ..............2 054-2988-010 ELBOW, 90 °.................. 1 054-3341-008 CONNECTOR, straight ..............
Page 130: Underbody Valve With Fittings
UNDERBODY VALVE with FITTINGS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 131 ELBOW, 90 ° reducing ..............2 054-2988-010 ELBOW, 90 ° swivel ............... 1 054-3341-008 CONNECTOR, straight ..............1 054-3341-007 CONNECTOR, straight ..............1 031-5601-003 DISCONNECT, quick – with cap ..........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 132 4.10 TAILGATE HYDRAULICS for UNITS WITHOUT REGENERATIVE VALVE ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 133 HOSE, hydraulic ................1 054-5470 TUBE, hydraulic ................1 054-3526-019 CONNECTOR ................2 031-3305 VALVE, check ................1 054-3340-003 ELBOW, 90 °.................. 1 054-5409 TUBE, hydraulic ................1 036-1295-005 CLAMP, tube ................. 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 134 4.12 TAILGATE HYDRAULIC for UNITS WITH REGENERATIVE VALVE ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 135 CONNECTOR ................2 FS071124 CAPSCREW – 1/2” – 13NC x 1-1/2” ..........2 FS231100 NUT, lock – 1/2” – 13NC ............... 2 REF. VALVE, tailgate control (see section 5) ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 136: Tailgate Control Valve
4.14 TAILGATE CONTROL VALVE HYDRAULICS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 137 TUBE, hydraulic ................1 036-1295-002 CLAMP, tube ................A/R FS070920 CAPSCREW – 3/8” – 16NC x 1” ..........A/R FS230900 NUT, lock – 3/8” – 16NC ............A/R 054-3340-010 ELBOW, 90 °.................. 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 138 4.16 WINCH MECHANISM HYDRAULICS 253-1981 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 139: Winch
WINCH MECHANISM HYDRAULICS PART NO. DESCRIPTION REQ’D 054-3237-019 ELBOW, 90 °.................. 2 057-1509-034 HOSE, hydraulic ................2 REF. WINCH ASSEMBLY – (See Section 5) ........1 058-3205-019 ADAPTER ..................2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 140: Arm Or Roll Bar Mechanism
4.18 ARM OR ROLL BAR MECHANISM HYDRAULICS ISSUED APRIL 2002 ãCOPYRIGHT 2002, H.E.I.L...
Page 141 TUBE, hydraulic ................1 354-2056 TUBE, hydraulic ................2 354-2057 TUBE, hydraulic ................2 354-2058 TUBE, hydraulic ................1 FS070815 CAPSCREW, hex. 5/16”-18NC x 3/4” .......... 7 FS230800 NUT, lock 5/16”-18NC ..............7 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 142 4.20 GRAB BAR FLIPPER MECHANISM HYDRAULICS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 143: Grab-Bar Flipper
CAPSCREW – 1/4” – 20NF x 1” ........... 2 FS230700 NUT, lock – 1/4” – 20NF ............... 2 FS100913 CAPSCREW – 3/8” – 24NF x 5/8” ..........6 FS540900 WASHER, lock – 3/8” ..............6 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 144 4.22 DIRECT MOUNT PUMP KIT 272-2623 OIL TANK ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 145 4.23 FORMULA 4000 DIRECT MOUNT PUMP KIT 272-2623 PART NO. DESCRIPTION REQ’D 035-2727 GUARD, fiber ................14ft 036-1295-007 CLAMP – 2-7/16” ................4 036-1478 CLAMP ..................7 036-1499 CLAMP, bandit................2 054-3237-007 ELBOW, 90° reducing..............1 054-4194-010 ADAPTER, female ................1 057-1719-005 HOSE, hydraulic – w/reuseable ends ..........1 057-1719-010 FITTING, hose ................2...
Page 146 4.23.1 PTO – PUMP DRIVE KIT 272-1870 OIL TANK ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 147 WASHER, lock – 5/8” ..............2 FS853024 ELBOW, 90 ° reducing street ............1 FS882400 NIPPLE, close – 1-1/2” ..............1 FS933024 REDUCER, bell – 2” x 1-1/2” ............1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 148 4.24 PUMP MOUNT KIT for FORD L SERIES CHASSIS 272-5859 SECTION A-A ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 149 NUT, lock – 1/2” – 13NC ............12 FS511000 WASHER, flat – 1/2” ..............12 047-1794 CAPSCREW – 7/16” – 20NC x 1” ..........4 FS551000 WASHER, lock - 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 150 4.26 PUMP MOUNT KIT for FORD LOUISVILLE CHASSIS 272-8418 VIEW A-A ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 151 SETSCREW .................. 2 177-2070 CHANNEL, pump support ............. 1 211-3298 BRACKET, pump ................1 263-0042 WIE, lock ..................1 311-0210 BRACKET, pump ................2 FS511000 WASHER, lock – 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 152 4.28 PUMP MOUNT KIT for CRANE CARRIER CHASSIS 272-5860 SECTION A-A ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 153 CAPSCREW – 1/2” – 13NC x 1-1/4” ..........8 FS231100 NUT, lock – 1/2” – 13NC ............. 12 FS511100 WASHER, flat – 1/2” ..............8 FS551000 WASHER, lock – 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 154 4.30 PUMP MOUNT KIT for WX VOLVO CHASSIS 272-5090 – WITHOUT PUMP COVER 272-5090-01 – WITH PUMP COVER ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 155 DRIVE LINE .................. 1 047-2193 SETSCREW .................. 2 263-0042 WIRE, lock ..................1 047-1794 BOLT, drive line ................4 FS551000 WASHER, lock – 7/16” ..............4 FS190400 FITTING, grease ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 156 4.32 FRONT MOUNT KIT for WXLL VOLVO CHASSIS 272-8016 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 157 CAPSCREW – 5/8” – 11NC x 2-1/4” ..........4 FS231100 NUT, lock – 1/2” – 13NC ............... 4 FS231300 NUT, lock – 5/8” – 11NC ............... 4 FS551000 WASHER, lock – 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 158 4.34 FRONT MOUNT KIT for WG VOLVO CHASSIS 272-8024 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 159 CAPSCREW – 5/8” – 11NC x 2-1/2” ..........6 FS231100 NUT, lock – 1/2” – 13NC ............... 4 FS231300 NUT, lock – 5/8” – 11NC ............... 6 FS551000 WASHER, lock – 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 160 4.36 PUMP MOUNT KIT for MR MACK CHASSIS 272-3460 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 161 NUT, lock – 1/2” – 13NC ............A/R FS551000 WASHER, lock – 7/16” ..............4 211-6917 COVER, pump ................1 112-9882 PANEL, cover ................1 177-3999 SUPPORT, bracket ............... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 162 4.38 MOUNT KIT for KENWORTH/PETERBILT CHASSIS 272-6486 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 163 CAPSCREW – 7/16” – 20NF x 1” ..........4 047-2193 SETSCREW .................. 2 030-0705-006 DRIVE LINE .................. 1 263-0042 WIRE, lock ..................1 FS551000 WASHER, lock – 7/16” ..............4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 164 4.40 PUMP MOUNT KIT for NAVISTAR CHASSIS 272-8040 – WITHOUT EXT. BUMPER 272-8040-001 – WITH EXT. BUMPER ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 165 NUT, lock – 1/2” – 13NC ............. 10 FS241100 NUT, lock – 1/2” – 20NF ............... 4 FS551000 WASHER, lock – 7/16” ..............4 311-0107 BRACKET, bumper extension (for 272-8040-01 kit) ....2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 166: Plumbing Diagram
FRONT MOUNT PUMP KIT with OVERSPEED 272-5855 TO TANK CONNECT TO PORT PUMP MARKED "T" CROSS OVER PROVIDED WITH PUMP POWER PRO VALVE 3/8" LINE TO VALVE 2" SUCTION LINE PUMP PLUMBING DIAGRAM ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 167 HOSE KIT (see page 4.45) ............1 108-4545 CONTROLLER, overspeed ............1 FS071126 CAPSCREW – 1/2” – 13NC x 1-3/4” ..........4 FS231100 NUT, lock – 1/2” – 13NC ............... 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 168 4.44 FRONT MOUNT PUMP HOSE KIT 272-5630 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 169 ELBOW, 45 ° (check pump kit for correct elbow) ......1 074-4487-008 ELBOW, 90 ° (check pump kit for correct elbow) ......1 074-4498-032 CLAMP, suction hose ..............4 211-9851 BRACKET, hose support .............. 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 170 4.46 FRONT MOUNT PUMP INSTALLATION for STERLING ACTERRA CHASSIS 372-0355 DETAIL A-A ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 171 NUT, lock – 1/2” – 13NC ............... 6 FS551000 WASHER, lock – 7/16” ..............4 FS071124 CAPSCREW – 1/2” – 13NC x 1-1/2” ..........4 FS021134 BOLT, carriage – 1/2” – 13NC x 2-1/2” ......... 4 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 172 4.48 FLOW CONTROL KIT 272-5859 INSTALL IN PORT STAMPED TO TANK "BP" ON FRONT OF FLOW CONT. VALVE. TANK ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 173 CAPSCREW – 3/8” – 16NC x 1” ..........4 FS131042 CAPSCREW, socket head – 7/16” – 14nc x 3-1/4” ..... 4 FS230900 NUT, lock – 3/8” – 16NC ............... 4 FS510900 WASHER, flat – 3/8” ..............8 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 174 4.50 FRONT MOUNT PUMP KIT with FLOW CONTROL 272-8460 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 175 FS071126 CAPSCREW – 1/2” – 13NC x 1-3/4” ..........4 FS081050 CAPSCREW – 7/16” – 14NC x 4” ..........4 272-8459 HOSE KIT, front mount (see page 4.53) ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 176 4.52 FRONT MOUNT PUMP HOSE KIT 272-8459 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 177 CLAMP, suction hose ..............4 211-9851 BRACKET, hose support .............. 6 FS070920 CAPSCREW – 3/8” – 16NC x 1” ..........10 FS230900 NUT, lock – 3/8” – 16NC ............. 20 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 178 4.54 FRONT MOUNT PUMP KIT 272-7153 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 179 ELBOW, 45 ° - 2” SAE ..............1 054-8668-001 ELBOW, 90 ° - 2” SAE ..............1 FS071126 CAPSCREW – 1/2” – 13NC x 1-3/4” ..........4 FS231100 NUT, lock – 1/2” – 13NC ............... 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 180 4.56 FRONT MOUNT HOSE KIT 272-8423 REF. PUMP KIT TO CONTROL VALVE ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 181 CLAMP, suction hose ..............4 211-9851 SUPPORT ..................8 QD2-FEFE-025 HOSE, hydraulic ................1 FS070920 CAPSCREW – 3/8” – 16NC x 1” ..........14 FS230900 NUT, lock – 3/8” – 16NC ............. 14 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 182 4.58 PUMP AIR SHIFT KIT 272-7973 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 183 NUT, hex - #8 – 32 ................ 2 FS420320 SCREW, machine - #8 – 32 x 1-1/2” ..........2 FS510300 WASHER, flat - #8 ................ 2 FS550300 WASHER, lock - #8 ............... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 184 4.60 ELECTRIC/AIR SHIFT KIT with OVERSPEED 108-5354 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 185 108-5354-004 WIRE ..................... 1 108-4176-010 TUBING, air ................30ft 108-4176-013 CONNECTOR, female spade ............5 108-5354-005 SWITCH, pressure ................ 1 108-4545 SWITCH, electronic overspeed ............ 1 108-5354-06 BREATHER ................... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 186 4.62 ELECTRIC/AIR SHIFT KIT without OVERSPEED 108-5355 ISSUED MAY 1999 ã COPYRIGHT 2004, HEIL ISSUED APRIL 2004...
Page 187 CLIP, terminal ................2 108-4176-008 TERMINAL, ring ................2 108-5354-004 WIRE ..................... 1 108-4176-010 TUBING, air ................30ft 108-4176-013 CONNECTOR, female spade ............5 108-5354-005 SWITCH, pressure ................ 1 108-5354-006 BREATHER ................... 2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 188 4.64 PRESSURE TEST GAUGE KIT 272-6347 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 189 DISCONNECT, quick – male ............1 031-5601-002 DISCONNECT, quick – female ............. 1 054-3526-004 CONNECTOR ................1 QZ1-FCFC-017 HOSE, hydraulic ................1 054-3532-014 CONNECTOR ................1 067-0640 GAUGE, pressure – 0-5000 PSI ........... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 191 FS230900 NUT, lock – 3/8” – 16NC ............14 263-0042 WIRE, lock ..................2 055-1391-007 WASHER, hardened – 5/8” ............8 FS071330 CAPSCREW – 5/8” – 11NC x 2”..........4 ISSUED OCTOBER 2004 Printed in U.S.A. © COPYRIGHT 2004, HEIL...
Page 193 CAPSCREW – 3/8” – 16NC x 1”..........14 FS230900 NUT, lock – 3/8” – 16NC ............14 372-3003 SWITCH KIT, pressure..............1 ISSUED OCTOBER 2004 ISSUED OCTOBER 2004 Printed in U.S.A. Printed in U.S.A. © COPYRIGHT 2004, HEIL © COPYRIGHT 2004, HEIL...
Page 195: Section 5 - Hydraulic Components
PTO Mount Hydraulic Pump (219-1738/219-1748) ..................5.58 Hydraulic Pump (219-1870-01) ........................5.60 Dry Valve (31-3230)............................5.62 Optional Hydraulic Oil Filter (75-0724)......................5.64 Powr-Pro Valve for 219-1893 Pump........................5.66 Tandem Vane Hydraulic Pump Assembly (219-2272/219-2273)..............5.68 Tandem Vane Hydraulic Pump Only (219-2272-001/2273-001)..............5.70 Printed in U.S.A. ISSUED APRIL 2005 ©COPYRIGHT 2005, Heil Environmental...
Page 196 EJECTOR CYLINDER 001-6222 – STD. 13 YD & NARROW 11YD UNITS 001-6223 – STD. 16 YD & NARROW 14 YD UNITS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 197 FORMULA 4000 EJECTOR CYLINDER 001-6222 – STD. 13 YD & NARROW 11YD UNITS 001-6223 – STD. 16 YD & NARROW 14 YD UNITS PART NO. DESCRIPTION REQ’D 001-6223-001 BARREL ASSEMBLY ..............1 001-4881-019 RING, wear ..................1 001-4881-002 RING, piston .................. 1 001-6223-002 SLEEVE ASSEMBLY –...
Page 198 EJECTOR CYLINDER 001-6224 – STD. 18 YD AND NARROW 16 YD UNITS 001-6225 – STD. 20 YD AND NARROW 18 YD UNITS 001-6226 – STD. 25 YD UNITS ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 199 001-4881-025 WIPER ................... 1 001-4261-003 SEAL, lip (u-cup) ................1 001-6223-006 GLAND, retaining ................1 001-4881-017 RING, wear ..................1 Printed in U.S.A. Printed in U.S.A. ISSUED MARCH 2002 ISSUED MARCH 2004 ã COPYRIGHT 2002, H.E.I.L ã COPYRIGHT 2004, HEIL...
Page 200 EJECTOR CYLINDER 001-6224 – STD. 18 YD AND NARROW 16 YD UNITS 001-6225 – STD. 20 YD AND NARROW 18 YD UNITS 001-6226 – STD. 25 YD UNITS ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 201 SLUG, nylon .................. 4 272-4884 KIT, rebuild (consists of items 2, 3, 6 thru 10, 12, 13, 16 thru 20, 22, 26 thru 30, 32, 33, 36 thru 40, 43) ..... 1 Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 203 CAPSCREW – 1/4” – 20NC x 1/2” ..........1 053-1581 BAR, lock ..................1 272-0956 KIT, seal (consists of items 7 thru 10, 13, 14, 15, 20 thru 22) ..1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 205 5.11 FORMULA 4000 ISSUED APRIL 2004 Printed in U.S.A. COPYRIHGT 2004, HEIL...
Page 206 5.12 TAILGATE RAISE CYLINDER 001-4070 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 207 RING, retaining ................1 022-3379 V-PACKING ASSEMBLY .............. 1 023-0636 GLAND, packing ................1 026-3707-010 RING, wiper ................... 1 272-0937 KIT, seal (consists of items 2, 3, 5, 6, 8) ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 208 5.14 CONTAINER ARM MECHANISM CYLINDER 001-4283 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 209 RING, back-up ................2 FS440707 SETSCREW .................. 1 27-4199 ROD ASSEMBLY ................1 272-0966 SEAL KIT – consists of items 3, 4, 6, 7, 8, 11 thru 13) .... A/R Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 210 5.16 ROLL-BAR FLIPPER CYLINDER 001-5069 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 211 O-RING ..................1 026-4186-016 RING, back-up ................1 001-5069-002 ROD ASSEMBLY ................1 272-0958 SEAL KIT, repair (consists of items 3, 4, 6, 7, 9, 10 12, 14, 15) .................. 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 212 5.18 ROLL BAR MECHANISM CYLINDER 001-4105 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 213 ROD ASSEMBLY ................1 FS440909 SETSCREW – 3/8” ............... 1 047-1520 SLUG, nylon .................. 1 272-0958 SEAL KIT – (consists of items 3, 4, 5, 7 thru 12) ..... A/R Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 214 5.20 REEVING CYLINDER 001-6061 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 215 SLUG, nylon .................. 1 FS440909 SETSCREW – 3/8” ............... 2 026-4265 RING, buffer .................. 1 272-0989 SEAL KIT – (consists of items 2, 3, 5, 6, 7, 10, 11) ....A/R Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 216 5.22 UNDERBODY CONTROL VALVE for EJECTOR & TAILGATE FUNCTIONS 031-3374 LOW SETTING @ 500 PSI ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 217 SEAL KIT (consists of items 11, 12, 13,14 (2 each) ....1 031-3285-006 STUD KIT (consists of items 9 & 10) ..........1 Printed in U.S.A. Printed in U.S.A. ISSUED MARCH 2002 ISSUED APRIL 2004 ã COPYRIGHT 2002, H.E.I.L ã COPYRIGHT 2004, HEIL...
Page 218 5.24 INLET and OUTLET SECTIONS 031-3285-001 AND 031-3285-003 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 219 SEAL, o-ring .................. 1 031-3285-056 SEAL, o-ring .................. 1 031-3285-057 RING, back-up ................1 011-5093 SEAL, o-ring .................. 1 207-6103 SEAL KIT – (consists of items 3 thru 6) ........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 220 5.26 WORKING VALVE SECTION for EJECTOR FUNCTION 031-3285-002 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 221 SEAL KIT (consists of items 3, 4) ..........A/R 031-2940-006 SEAL KIT (consists of items 30 thru 34) ........A/R 031-3285-026 SEAL KIT (consists of items 23 thru 27) ........A/R Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 222 5.28 WORKING VALVE SECTION for TAILGATE FUNCTION 031-3374-001 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 223 SEAL KIT (consists of items 3, 4) ..........A/R 031-2940-006 SEAL KIT (consists of items 30, 32 thru 35) ......A/R 031-3285-026 SEAL KIT (consists of items 23 thru 27) ........A/R Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 224 SET @ 3900 PSI PORT RELIEF CARTRIDGE * 031-3245-008 SET @ 1400 PSI (031-3242) * RELIEF IS NOT (WINCH HAS 2 PORT RELIEFS, ONE NOT INCLUDED W/VALVE SHOWN IS ON OPPOSITE SIDE OF SECTION) ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 225 TAILGATE (SECONDARY) VALVE FORMULA 4000 5.31 031-6268-002, -003, -004 TAILGATE (SECONDARY) VALVE 031-6268-002, -003, -004 PART NO. DESCRIPTION REQ’D 031-3245-009 SECTION, outlet (see page 5.33) ..........1 031-3245-005 SECTION, inlet (see page 5.33) ..........1 031-3544-005 SECTION, working (see page 5.35) ..........1 031-3544-006 SECTION, working (see page 5.37) ..........
Page 226 5.32 INLET SECTION with PLUGS and TIE RODS 31-3245-05 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 227 3-spool valve ..1 (includes rods and nuts) 27-4679 TIE ROD ASSEMBLY for 4-spool valve ..1 (includes rods and nuts) OUTLET SECTION 31-3245-09 PART NO. DESCRIPTION REQ’D 31-3245-09 OUTLET SECTION ............... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 228 5.34 TAILGATE VALVE WORKING SECTION for SLIDE FUNCTION 031-3544-005 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEL...
Page 229 O-RING ..................1 031-3245-016 POPPET ..................1 031-3245-014 SPRING ..................1 031-2909-001 SLEEVE, detent ................1 272-3861 KIT, spool (consists of items 5 thru 11, 14 thru 25, 30) ....1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 230 5.36 TAILGATE VALVE WORKING SECTION for BLADE FUNCTION 031-3544-006 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 231 VALVE, relief (set @ 2900 PSI) (ORDER SEPERATELY – ................ 1 NOT PART OF VALVE 272-3861 KIT, spool (consists of items 5 thru 11, 14 thru 25, 30) ....1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 204, HEIL...
Page 233 5.39 FORMULA 4000 TAILGATE VALVE WORKING SECTION for ARM, WINCH, ROLL BAR or REEVING MECHANISM 031-6267 PART NO. DESCRIPTION REQ’D BODY .................... 1 031-2012-003 CAP, spool ..................1 031-2012-005 CAPSCREW ................. 2 SPOOL (see kit)................1 031-2018-013 END, spool..................1 031-2018-004 O-RING ..................
Page 234 5.40 REGENERATIVE VALVE 031-6285 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 235 SPRING ..................1 031-6272-002 PLUG ..................... 2 031-6285-004 SPRING ..................1 031-6285-005 PLUG ..................... 1 031-2685-006 PLUG ..................... 1 031-6285-007 PLUG ASSEMBLY, retaining ............1 PLUG ..................1 031-6285-009 O-RING ..................1 Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 236 5.42 HYDRAULICE PUMP – DIRECT MOUNT 219-1915 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 237 GEARS – matched set ..............1 219-0915-008 SEAL, gasket ................. 2 219-1915-002 HOUSING, gear ................1 219-1705-010 PIN, dowel ..................4 219-1915-003 COVER, port end ................1 219-1683-007 WASHER ..................4 219-0915-011 CAPSCREW ................. 4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 239 5.45 FORMULA 4000 HYDRAULIC PUMP – DIRECT MOUNT 219-1916 PART NO. DESCRIPTION REQ’D 219-0915-04 SEAL, lip ..................1 219-1915-01 COVER, shaft end ................ 1 219-1473-01 CHECK ASSEMBLY ..............2 219-0915-03 SEAL, ring..................1 219-0915-02 BEARING, roller................4 219-0915-07 SEAL, pocket ................12 219-0915-06 PLATE, thrust................
Page 240 5.46 8,000 LB. WINCH ASSEMBLY 253-2291 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 241 CAPSCREW – 1/2” – 20NC x 1-3/4” grade 8 ....... 2 253-2291-046 NUT, jam – 1/2” – 20NC ............... 2 253-2291-001 SEAL KIT (consists of items 12, 25, 27, 28, 30, 34, 43) ....1 Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 242 5.48 12,000 LB. WINCH ASSEMBLY 253-1472 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 243 KEY ....................1 253-1472-038 PLUG, pipe ..................1 253-1472-039 WASHER, lock ................6 253-1472-040 CAPSCREW ................. 6 253-1472-041 STRAP ................... 1 253-1472-042 CLAMP, cable ................1 253-1472-043 SCREW ..................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 244 5.50 8,000 LB. WINCH MOTOR 219-1878 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 245 219-1878-018 BEARING (“DU”) ................1 219-1878-012 KEY ....................1 219-1878-020 PACK, grease (not shown) ............1 219-1878-020 SEAL KIT (consists of items 3, 4, 5, 11, 13, 21) ......1 Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 246 5.52 12,000 LB. WINCH MOTOR 219-1879 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 247 BEARING, “DU” ................1 219-1878-012 KEY ....................1 219-1878-020 PACK, grease – (not shown) ............1 219-1878-021 SEAL KIT – (consists of items 3, 4, 5,11, 13, 21) ......1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 248: Hydraulic Oil Filter
5.54 HYDRAULIC OIL FILTER 075-0585 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 249 5.55 FORMULA 4000 HYDRAULIC OIL FILTER 075-0585 PART NO. DESCRIPTION REQ’D 075-0587 HEAD, oil filter ................1 075-0425-001 ELEMENT, spin-on oil – (10 micron) ..........1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 250 5.56 FRONT MOUNT PUMP 219-1893 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 251 219-1684-011 PIN, dowel ..................4 219-1684-002 COVER, rear ................. 1 219-1473-021 WASHER, lock ................8 219-1684-013 CAPSCREW ................. 8 219-1684-010 PLUG ..................... 2 SEE PAGE 5.66 FOR POWR PRO VALVE Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 252 5.58 PTO MOUNT HYDRAULIC PUMP 219-1738 and 219-1748 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 253 CAPSCREW – for 219-1738 pump ..........2 219-1474-003 CAPSCREW – for 219-1748 pump ..........2 219-1738-002 CAPSCREW – for 219-1738 pump ..........2 219-1748-001 CAPSCREW – for 219-1748 pump ..........2 Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 254: Hydraulic Pump
5.60 HYDRAULIC PUMP 219-1870-001 PUMP & DRY VALVE (31-3230) MAKE 219-1870 PUMP ASSEMBLY ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 255 GEARS ..................1 219-1473-011 SEAL, gasket ................. 2 219-1870-004 HOUSING, gear ................1 219-1870-008 COVER, port end ................1 219-1473-021 WASHER ..................8 219-1742-004 CAPSCREW ................. 8 219-1870-009 PLUG ..................... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 257 031-3230-008 SEAL, o-ring .................. 4 031-3230-009 O-RING ..................1 031-3230-010 VENT, air ..................2 HOUSING ..................1 031-3230-011 SPRING ..................1 031-3230-012 CAPSCREW ................. 4 031-3230-013 WASHER, lock ................4 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 258 5.64 IN-TANK OIL FILTER ASSEMBLY 075-0724 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 259 INCLUDES AN ELEMENT (75-0724-01) AND A SLEEVE (75-0724-02). AFTER INSTALLING 75-0724-03 ACCORDING TO THE INSTRUCTIONS WITH THE ASSEMBLY, THE ELEMENT (75-0724-01) CAN BE USED FOR FUTURE FILTER CHANGES IN THE 75-0711 HOUSING. Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 260 5.66 POWR-PRO VALVE for 219-1893 PUMP 031-5736-050 ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 261 PIN, dowel – (short) ............... 1 031-5736-003 SPOOL ..................1 031-5736-016 SCREW ..................2 031-5736-002 PLUG ..................... 1 031-5736-021 KIT, seal – (consists of items 1, 10, 6, 12, 16)………………..A/R Printed in U.S.A. ISSUED MARCH 2004 ã COPYRIGHT 2004, HEIL...
Page 263 ADAPTER .................. 1 031-6375-007 O-RING (block to pump)............1 031-2256-010 CAPSCREW – 3/8” – 16NC x 2-1/2” ........4 031-2256-011 WASHER, lock – 3/8” ..............4 219-2288-001 TUBE, bypass................1 ISSUED OCTOBER 2004 Printed in U.S.A. © COPYRIGHT 2004, HEIL...
Page 264 TANDEM VANE HYDRAULIC PUMP ONLY (Keyed Shaft) 219-2272-001 - FRONT MOUNT - (LH rotation) 219-2273-001 – PTO MOUNT – (RH Rotation) TORQUE TO 45 FT. LBS TORQUE TO 117 FT. LBS P2 IS FOR PACKER P1 IS FOR LOADER © COPYRIGHT 2004, HEIL ISSUED OCTOBER 2004...
Page 265 (for 219-2272 pump) 219-2256-100 REPAIR KIT (cartridge and plate assembly) (for 219-2273 pump) 219-2076-055 SEAL KIT ..................1 219-2076-056 SHAFT & BEARING KIT .............. 1 219-2076-057 REAR PORT PLATE & BUSHING..........1 ISSUED OCTOBER 2004 Printed in U.S.A. © COPYRIGHT 2004, HEIL...
Page 267: Section 6 - Electrical
FORMULA 4000 SECTION 6 – ELECTRICAL Tailgate Wiring, Lights and Parts........................6.3 Body Wiring, Lights and Parts.......................... 6.5 Cab Electrical ..............................6.7 Packard Connector Kit (108-4827)........................6.9 Deutsch Connection Kit (108-6461) ....................... 6.11 Deutsch Plugs, Pins and Accessories......................6.13 Micro Relay Kit (069-0032) ..........................6.15 Printed in U.S.A.
Page 268 TAILGATE WIRING AND PARTS TAILGATE WIRING AND PARTS 18 19 20 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL 372-1524...
Page 269 WASHER, lock - #8 ............... 1 025-0473-003 PLUG – 1/2” .................. 2 036-1122-008 CLAMP ..................5 FS070920 CAPSCREW – 3/8” – 16 ............... 5 FS230900 NUT, lock – 3/8” – 16NC ............... 5 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 270 BODY WIRING and PARTS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL 372-1468...
Page 271 COVER ..................1 REF. DECAL, throttle ................1 311-3158 BRACKET, harness ..............1 115-0782 LIGHT, mid-body turn signal ............2 FS070920 CAPSCREW – 3/8” – 16NC x 1” ..........3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 273: Cab Electrical
CONNECTOR, 6-way male ............2 108-4827-008 CONNECTOR, 4-way female ............1 108-4827-130 SEAL, cable ................. 19 108-4827-134 PLUG, cavity .................. 1 108-7114-010 FEMALE QDC ................6 108-5717-003 CONNECTOR, butt ............... 6 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 274 FORMULA 4000 PACKARD CONNECTION KIT 108-4827 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 275 SEAL, 1-way female connection ..........A/R 108-4827-015 SEAL, 2-way female connection ..........A/R 108-4827-016 SEAL, 3-way female connection ..........A/R 108-4827-017 SEAL, 4-way female connection ..........A/R 108-4827-018 SEAL, 6-way female connection ..........A/R Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 277 WEDGE, 12-way recepticle ............3 108-6461-100 PLUG, sealing ................25 108-6461-101 PIN, gold plated ................. 200 108-6461-102 SOCKET, gold plated ..............200 108-6461-201 CRIMPER ..................1 108-6461-202 TOOL, removal ................1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 279 6.13 FORMULA 4000 CONNECTORS, PLUGS, PINS and ACCESSORIES for DEUTSCH ELECTRICAL PARTS 108-4815 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 280 6.14 FORMULA 4000 MICRO RELAY KIT 069-0032 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 281 MICRO RELAY KIT 069-0032 PART NO. DESCRIPTION REQ’D 069-0032-001 RELAY – 12V ................1 069-0032-002 CONNECTOR ................1 069-0032-003 TERMINAL – 1/4” ................2 069-0032-004 TERMINAL – 3/16” ................ 3 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 283 6.17 FORMULA 4000 RELAY 108-6752 PART NO. DESCRIPTION REQ’D 108-6752-001 RELAY ................... 1 108-6752-002 CONNECTOR ................1 108-6752-003 TERMINAL ..................4 108-6752-004 PLUG ..................... 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 285: Section 7 - Optional Parts
POWERTRAK 1000 SECTION 7 – OPTIONAL PARTS Washout Tank and Parts (020-1251)........................7.3 Buzzer Kit (108-3993) ............................7.5 Tool Box Kit (272-8560)............................7.7 High Pressure Filter Kit (272-3284) ........................7.9 High Pressure Oil Filter (075-0705) ........................7.11 Safety Mirror Kit – Cab Over (372-0300) ......................7.13 Safety Mirror Kit –...
Page 286 WASHOUT TANK and PARTS 020-1251 DETAIL "B" DETAIL "A" CHASSIS TANK ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 287 ELBOW, street - 90 ° x 1/4” ............1 FS880700 NIPPLE, close ................5 FS883000 NIPPLE, close ................1 FS600907 BUSHING, reducer ................ 1 FS591507 BUSHING, reducer – 3/4” x 1/4” ........... 1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 289 NUT - #8 – 32NC ............... 1 FS420313 SCREW - #8 – 32NC x 5/8” ............1 FS500715 SCREW, tek – 1/4” x 3/4” ............2 FS550300 WASHER, lock - #8 ..............1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 290 TOOL BOX KIT 272-8560-024 - 24” BOX 272-8560-036 - 36” BOX ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 291 272-8560-024 - 24” BOX 272-8560-036 - 36” BOX PART NO. DESCRIPTION REQ’D 151-1336-024 BOX, tool – 24” box ............... 1 151-1336-036 BOX, tool – 36” box ............... 1 311-0461 BRACKET ..................2 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 292 HIGH PRESSURE FILTER KIT 272-3284 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 293 ELBOW, 90 °.................. 1 057-1719-001 HOSE, high pressure ..............1 311-0912 BRACKET, filter ................1 FS070915 CAPSCREW – 3/8” – 16NC x 3/4” ..........4 054-4739 ELBOW, 90 °.................. 1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 294 7.10 HIGH-PRESSURE HYDRAULIC OIL FILTER 075-0705 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 295 075-0705-004 SCREW, drive ................2 075-0705-005 SPRING ..................1 075-0705-006 O-RING, bowl ................1 075-0705-007 BOWL, filter ................... 1 075-0705-008 PLUG, drain w/plug ............... 1 075-0705-009 KIT, indicator ................. 1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 296 7.12 SAFETY MIRROR KIT – CAB OVER 372-0300-001 – SINGLE 372-0300-002 - DUAL DUAL ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 297 CABLE, 3-conductor ..............A/R 212-2615 DECAL, heated mirror ..............1 003-3379 GROMMET, rubber ............... 1 108-6461-002 PLUG – for dual kit only ..............1 108-6461-003 PLUG – for dual kit only ..............1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 298 7.14 SAFETY MIRROR KIT – CONVENTIONAL CAB 372-0301-001 – SINGLE 372-0301-002 - DUAL DUAL ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 299 CABLE, 3-conductor ..............A/R 212-2615 DECAL, heated mirror ..............1 003-3379 GROMMET, rubber ............... 1 108-6461-002 PLUG – for dual kit only ..............1 108-6461-003 PLUG – for dual kit only ..............1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 300 7.16 TAILGATE SUMP KIT 272-4972 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 301 7.17 FORMULA 4000 TAILGATE SUMP KIT 272-4972 PART NO. DESCRIPTION REQ’D 272-4972-001 PANEL, side .................. 2 272-4972-002 SUMP .................... 1 042-1353 CAP, drain ..................2 112-8045 SCREEN ..................2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 302 7.18 REAR VISION KITS 372-1001 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 303: Camera Systems
MONITOR .................. 1 161-0384-003 CABLE ..................1 372-1001-001 ECCO K5010 CAMERA with MONITOR 161-0371-001 CAMERA ..................1 161-0371-002 MONITOR .................. 1 161-0371-003 CABLE ..................1 161-0371-004 CABLE, extension ..............1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 304 7.20 FIRE EXTINGUISHER BRACKET 372-0266 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 305 FORMULA 4000 7.21 FIRE EXTINGUISHER BRACKET PART NO. DESCRIPTION REQ’D 311-1571 HANGER, fire extinguisher ............1 161-0345 EXTINGUISHER, fire – 20 Lb. (not shown) ........1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 306 7.22 RETURN LINE SHUT-OFF VALVE KIT 272-9179 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 307 7.23 FORMULA 4000 RETURN LINE SHUT-OFF VALVE KIT 272-9179 PART NO. DESCRIPTION REQ’D 031-5788-001 VALVE, shut-off – 1” ..............2 058-8519-003 NIPPLE, hex – 1” ................2 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 308 7.23.1 FORMULA 4000 CALIFORNIA BACK-UP ALARM 272-6409 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 309 FUSE & HOLDER – (20 amp) ............1 108-5034-001 LOOM, convoluted – 1/4” x 40ft ........... 1 108-5233-017 WIRE – 16GA – white ............... 20ft 108-5233-023 WIRE – 16GA – pink ..............20ft Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 310 7.24 HOPPER FLOOD LIGHT KIT 372-1572-001 – SINGLE 372-1572-002 – DUAL ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 311 108-6752-001 RELAY ................... 1 108-4867-005 BREAKER, circuit – 10 amp ............1 108-4943-003 TERMINAL, ring - #10 ..............3 054-7350 TUBE, shrink ................1 ft. 108-7114-010 TERMINAL, female ..............2 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 312 7.26 SMART LAMP KIT 372-2913 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 313 GROMMET, rubber ..............1 115-1269-002 LIGHT ASSEMBLY, smart – left hand .......... 2 115-1269-LFT LIGHT – 4” amber ..............1 115-0742-002 GROMMET, rubber ..............1 263-1238 HARNESS, wire ................1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 314 7.28 HOPPER FLOOD LIGHT KIT (SWITCH IN CAB) 372-1842-001 – SINGLE LIGHT KIT 372-1842-002 – DUAL LIGHT KIT ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 315 SWITCH, toggle ................1 108-2750-006 WIRE – 12 GA – white ............6 inch. 108-4867-005 BREAKER, circuit – 10 amp ............1 108-7114-010 TERMINAL, female QDC .............. 2 108-7149-006 TERMINAL, male ................2 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 316 7.30 SINGLE BEACON LIGHT on TAILGATE 372-2191-001 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 317 BRACKET, light ................1 115-0868 LIGHT, beacon – amber ............... 1 FS240241 SCREW, machine - #10 32 x 1” ........... 3 FS270440 NUT, hex - #10 – 32 ..............3 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 318 7.32 FRONT BEACON LIGHT INSTALLATION KIT 372-2195-001 WIRING ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 319 WIRE – RED (633) ..............3 ft. 108-6716-GND WIRE – WHITE (GND) ............. 3 ft. 108-5717-002 CONNECTOR, butt ............... 4 054-7350 TUBE, shrink ................2 ft. 108-4476 LOOM ..................6 ft. Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 320 7.34 SIDE MOUNTED FLOOD LIGHT 372-2100-001 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 321 LAMP, trapezoidal with connector ..........2 115-0916 LIGHT ..................1 108-6461-012 RECEPTICLE, 2-pin ..............1 108-7336-002 LOOM ..................1 ft 311-0655 BRACKET, side light ..............2 108-4867-005 BREAKER, circuit – 10 amp ............1 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 322 7.36 MUNICIPAL LIGHT KIT 372-2409 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 323 SCREW, machine - #8 – 32 x 3/4” ..........2 FS280300 NUT, hex - #8 - 32 ................. 2 115-1262 LIGHT, flood .................. 1 115-1282-001 BULB ..................1 035-3354 GUARD, light ................. 1 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 324 7.38 SINGLE STROBE LIGHT KIT 372-2092-001 PLUG INTO CONNECTOR T3 IN TAILGATE HARNESS ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 325 115-1232-001 LIGHT ..................1 115-1232-002 GUARD, light ................1 FS240411 SCREW - #10 – 32 x 1” (light mounting) ........3 FS270440 NUT, hex - #10 – 32 ..............3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 326 7.40 DUAL STROBE LIGHT KIT 372-2092-002 ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 327 115-1232-001 LIGHT ..................1 115-1232-002 GUARD, light ................1 FS240411 SCREW - #10 – 32 x 1” (light mounting) ........3 FS270440 NUT, hex - #10 – 32 ..............3 Printed in U.S.A. ISSUED APRIL 2004 ã COPYRIGHT 2004, HEIL...
Page 328 7.42 SINGLE STROBE KIT (IGN Power) 372-2092-011 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 329 SCREW - #10 – 32 x 1” (light mounting) ........3 FS270440 NUT, hex - #10 – 32 ..............3 Printed in U.S.A. Printed in U.S.A. ISSUED APRIL 2004 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL ã COPYRIGHT 2004, HEIL...
Page 330 7.44 DUAL STROBE LIGHT KIT (IGN POWER) 372-2092-012 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 331 115-1232-001 LIGHT ..................1 115-1232-002 GUARD, light ................1 FS240411 SCREW - #10 – 32 x 1” (light mounting) ........6 FS270440 NUT, hex - #10 – 32 ..............6 Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 332 7.46 LEFT FRONT STROBE KIT 372-2092-100 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 333 SCREW - #10 – 32 x 1” (light mounting) ........3 FS270440 NUT, hex - #10 – 32 ..............3 Printed in U.S.A. Printed in U.S.A. ISSUED APRIL 2004 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL ã COPYRIGHT 2004, HEIL...
Page 334 7.48 STROBE LIGHT KIT (FRONT LEFT & REAR LEFT) 372-2092-200 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 335 SCREW - #10 – 32 x 1” (light mounting) ........6 FS270440 NUT, hex - #10 – 32 ..............6 311-4344 BRACKET, strobe – front .............. 1 Printed in U.S.A. Printed in U.S.A. ISSUED APRIL 2004 ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL ã COPYRIGHT 2004, HEIL...
Page 337 FORMULA 4000 SECTION 9 - GENERAL CONTENTS SECTION 1 – GENERAL ..............MR-74892-1002 SECTION 3 – PUMPS...............MR-74897-608 SECTION 4 – CONTROLS (includes electrical) .......MR-75018-404 SECTION 5 – BODY .................MR-75019-404 SECTION 6 – TAILGATE ..............MR-75020-404 Printed in U.S.A. ISSUED APRIL 2004 ©COPYRIGHT 2004, HEIL...
Page 339: General Information
SECTION 1 SECTION 1 SECTION 1 SECTION 1 GENERAL GENERAL GENERAL GENERAL INFORMATION INFORMATION INFORMATION INFORMATION 2002 UNITS 2002 UNITS 2002 UNITS 2002 UNITS DOVER COMPANY     2002, Heil Environmental MR-74892-1002 Industries Ltd.
Page 341: Section 1 - Table Of Contents
Pump Flanges ............................. 1.13 Average Density of Materials Chart......................1.14 Conversion Tables ............................1.15 Cold Weather Warm Up Procedure ......................1.16 Battery Disconnect Switch .......................... 1.17 Peterson Smart Lamp Light System ....................1.18, 1.19 Printed in U.S.A. ISSUED APRIL 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 343: Safety Symbols And Definitions
SAFETY SYMBOLS and DEFINITIONS Listed below are the definitions for the various levels of safety hazards. It is important that the operator’s of this equipment read and understand safety messages as they relate to this equipment operation. 1. DANGER – indicates an imminently hazardous situation, which if not avoided WILL result in DEATH or SERIOUS INJURY if you don’t follow proper instructions.
Page 347: Lubrication Information
INTRODUCTION SERVICE/PARTS ASSISTANCE The following sections are a guide for maintenance Assistance in troubleshooting repair and service of this and adjustment of the HEIL unit. It covers preventive equipment obtained by contacting maintenance, adjustment and trouble shooting hints. authorized HEIL distributor in your area. HEIL...
Page 349: Parts Ordering
PARTS ORDERING TECHNICAL & SUPPORT INQUIRIES & WARRANTY CLAIMS Contact your Local HEIL Distributor or 1-800-251-7258 Service Center WEBSITE : www.heil.com...
Page 350 1.10...
Page 351 1.11 DIAMETERS and CORRESPONDING CROSS-SECTIONAL AREAS Printed in U.S.A. ISSUED OCTOBER 2000 COPYRIGHT 2000, H.E.I.L.
Page 352 1.12 SIZING A GEAR PUMP (based on existing pump) Printed in U.S.A. ISSUED OCTOBER 2000 COPYRIGHT 2000, H.E.I.L.
Page 353 1.13 PUMP FLANGES ISSUED OCTOBER 2000 Printed in U.S.A. COPYRIGHT 2000, H.E.I.L.
Page 358 Peterson Smart Lamp Light Systems 1.18 Heil has used two different versions of the Peterson Smart Lamp Systems in the past years. Both of the Peterson Smart Lamp lighting systems use LED lights that function as strobe lights and turn signals.
Page 359 This system provides for a total of four strobe lights that are all synchronized to strobe in the same pattern sequence. VERSION - 4 - LIGHT SYSTEM Printed in U.S.A. ISSUED APRIL 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 361 SECTION 3 SECTION 3 HYDRAULIC PU HYDRAULIC PUMPS HYDRAULIC PU HYDRAULIC PU SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL 2002 UNITS 2002 UNITS 2002 UNITS 2002 UNITS DOVER COMPANY     2004, Heil Environmental MR-74897-904 Industries Ltd.
Page 363: Section 3 - Pump Section
Low Torque Engine Electronic Pressure Switch Kit.....................3.19 Pressure Switch Kit - Low Torque Engines - Drawing..................3.19.1 Electronic Pressure Switch ..........................3.19.1.1 Non Electronic Pressure Switch ........................3.19.2 Pump Cavitation ..............................3.20 Drive Shaft Mfg. Specifications ..........................3.21 Printed in U.S.A. ISSUED JUNE 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 365 FRONT MOUNT PUMP with DRY VALVE (Commercial) LOOP LINE HYDRAULIC PUMP DRY VALVE AIR PRESSURE PORT “A” PRESSURE HOSE See air logic INLET HOSE SEE PUMP SPECIFICATIONS FOR CIRCUIT GPM AND PSI This pump set up does not require a constant flow valve in the off mode.
Page 366 OCCURS WHEN THE PRESSURE DROP ACROSS THE FLOW CONTROL ORIFICE REACHES 50 PSI. RESTORE POWER HYDRAULIC SYSTEM, THE OPERATOR MUST LOWER THE ENGINE SPEED 300 TO 400 RPM BELOW THE HOC SPEED SETTING Printed in U.S.A. ISSUED JUNE 2004 COPYRIGHT 200, HEIL...
Page 367 COMMERCIAL HOC MAIN CONTROL VALVE – (FEL) MAIN SYSTEM PUMP SHUT OFF VALVE PRESSURE HOC SIGNAL LINE FROM FLOW CONTROL THE NORMALLY OPEN PUMP SHUT OFF VALVE IS ENERGIZED BY THE PLC MAIN PUMP OUTPUT. THIS HYDRAULIC SYSTEM IS PROTECTED BY THE HOC SYSTEM AND DOES NOT USE THE PLC ELECTRONIC OVERSPEED.
Page 368 SYSTEM THE OPERATOR MUST LOWER THE ENGINE SPEED 300 TO 400 RPM BELOW THE HOC SPEED SETTING. SOLENOID ‘A’ IS LOCATED ON THE LIFT CONTROL VALVE – SEE LIFT SECTION. Printed in U.S.A. ISSUED APRIL 2005 ©COPYRIGHT 2005, Heil Environmental...
Page 369 ON, IN PACK MODE AND LESS THAN EOS SETTING THE HOC SYSTEM IS DESIGNED TO LIMIT THE HYDRAULIC SYSTEM PUMP FLOW TO 55 GPM. SOLENOID ‘A’ IS LOCATED ON THE LIFT CONTROL VALVE – SEE LIFT SECTION. Printed in U.S.A. ISSUED APRIL 2005 ©COPYRIGHT 2005, Heil Environmental...
Page 371 PUMP SHUT-OFF VALVE 31-5796 USED WITH COMMERCIAL HOC SYSTEM 12 VOLT DC COIL INLET PORT # 2 - must be plumbed for fluid entering the valve. OUTLET PORT # 1 – must be plumbed for fluid leaving the valve This style of pump shut off valve is normally open and closes when the coil is activated. The valve does not have a plumbing schematic on it but must be plumped one way to function properly.
Page 372 FLOW CONTROL VALVE TESTING for HOC PUMP Follow these steps for testing. FLOW CONTROL LEAKAGE TEST 1. Warm hydraulic system temperature to 120°F. Check valve spool leakage by running 5 GPM less than the actual flow of 55 GPM through the valve with BYPASS and BINDING TEST 1100 PSI on the flow control valve outlet.
Page 373 MUNCIE MLS LIVE – PACK PUMP Pump by pass hose Pump Inlet returns to tank Signal relief valve preset to 3100 psi. Main system pressure connects to control valve Normally open pump solenoid MLS Live-Pack flow control system The internal by-pass poppet is open whenever the pump is turning and the pump solenoid is open to unload the system internal...
Page 374 AUTOMATED O.I.G.A.I. FRONT MOUNT TANDEM GEAR PUMP (TYRONE) SOLENOID CARTRIDGE 2-WAY N.O. DISCHARGE W/COIL MANIFOLD This gear pump uses two normally open directional control valves to engage each pump section. In the off mode oil is diverted back to the inlet side of the pump.
Page 375 SINGLE GEAR PUMP WITH POWER PRO DRY VALVE (Muncie) Return line to tank Pressure outlet to system Pump inlet Air shift cylinder Air pressure port # 2 See air logic Loop line Air pressure port # 1 See air logic This pump set up does not require a constant flow valve in the off mode.
Page 376 Pump ON – Apply air pressure to port # 1 and release air from port # 2 Pump Off – Release air pressure from port #1 and apply air pressure to port #2 Printed in U.S.A. ISSUED AUGUST 2005 ©COPYRIGHT 2005, Heil Environmental...
Page 378 3.10 TYRONE 257 SERIES PUMP Air Chamber Top Port # 1 Case Drain Line Bottom Port # 2 Flow Control Inlet Line Pressure Line The Tyrone 257 series gear pump uses a flow control that diverts excess oil back to the inlet side of the pump through an internal loop passage.
Page 379 3.11 Denison Operate-In-Gear-at-Idle Pump - DPF 7000 with Hydraulic Controls Pressure Blocks Pump 1- closest to Pressure Blocks the drive shaft Pump 2 – farthest from the drive shaft Unloader Valve Coil By Pass Tube This is the Hydraulic Controls Operate In Gear At Idle Hydraulic system.
Page 380 Denison Operate-In-Gear-at-Idle Pump 3.12 – Raid Rail with Hydraulic Controls Pressure Blocks Pump 1- closest to Pressure Blocks the drive shaft Pump 2 – farthest from the drive shaft Unloader Valve Coil By Pass Tube This is the Hydraulic Controls Operate In Gear At Idle Hydraulic system.
Page 381 3.13 Denison Tandem Vane Pump with Oasis Control Manifolds (F7000/DPF7000) Unloader Valve Cartridge Assembly Pressure Block Manifold Combiner Block Manifold Pressure Block Manifold By Pass Tube This Denison pump set up uses three manifolds to direct the flow of oil away from the pump to the system pressure circuit.
Page 382 3.14 Denison Tandem Vane Pump with Hydraulic Controls Manifold Block (CP Python) Unloader Cartridge Assembly Pressure Manifold Block Pressure Line to Lift Valve By Pass Tube This Denison pump set up can be used on the CP Python with the Commercial HOC inlet unloader valve section.
Page 383 3.14.1 DENISON TANDEM VANE PUMP with OASIS CONTROL MANIFOLDS (Rear Loader) Electronic Pressure Switch Pressure Block Manifolds Inlet Line Unloader Valve Cartridge Assembly This Denison pump set up uses three manifolds to direct the flow of oil away from the pump to the system pressure circuit. The two pressure block manifolds each contain an unloader valve cartridge and coil assembly to activate the system and an...
Page 384 The pump closest to the input shaft shuts off first at lower RPM`s while the pump farthest from the input shaft stays on at higher RPM`s. Printed in U.S.A. ISSUED AUGUST 2004 COPYRIGHT 2004, HEIL...
Page 385 3.14.3 Tandem Vane Pump with Oasis Monoblock (Rapid Rail / Starr) Bypass tube to inlet P1 to lift valve Unloader valves P2 to body valve Bypass to tank This is the Oasis Mono Block Operate In Gear At Idle Hydraulic system. The pump section (Pump 1) closest to the input shaft operates the lift and shuts off first.
Page 386 3.14.4 Tandem Vane Pump with Oasis Monoblock (Python and 7000) Bypass tube to inlet P1 to lift valve Unloader valves Bypass to tank P2 to lift valve This is the Oasis Monoblock Operate In Gear At Idle Hydraulic system. The pump section (Pump 1) closest to the input shaft shuts off first at a lower RPM.
Page 387 .030 When the pump solenoid is in the off mode oil is allowed to circulate back to the inlet. The maximum pump speed is controlled by .500 the PCL. Printed in U.S.A. ISSUED AUGUST 2007 ©COPYRIGHT 2007, Heil Environmental...
Page 388 Cut the zip tie around the electrical wiring that controls the the grill varies with chassis brand. pump shut-off valve solenoid. (Figure 4) Figure 4 Cut zip tie around wiring Figure 3 Remove grill Printed in U.S.A. ISSUED MAY 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 389 11. Carefully remove the pump case housing. (Figure 11) 12. Remove the pump cartridge by pulling it toward you. (Figure 12) The fit may be tight. Figure 11 Remove housing Figure 12 Remove pump cartridge Printed in U.S.A. ISSUED MAY 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 390 (Figure 20) • Four small back bolts – 60# • Four large front bolts – 92# Figure 20 Install new shut-off valve Figure 21 Torque shut-off valves Printed in U.S.A. ISSUED MAY 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 391 28. On the hydraulic oil pump, move the shut-off valve to the open position and secure the valve with a zip tie. (Figure 29 and 30) Figure 30 Secure valve Figure 29 Open valve Figure 28 Reattach grill Printed in U.S.A. ISSUED MAY 2008 ©COPYRIGHT 2008, Heil Environmental...
Page 393 The Oasis pressure block manifolds contain two unloader valve and coil assemblies used to activate each respective pumping section and control the flow of oil directed to the hydraulic system. Printed in U.S.A. ISSUED AUGUST 2007 ©COPYRIGHT 2007, Heil Environmental...
Page 394 We need to shut the smaller P2 (38 GPM pump farthest from input shaft) off at idle to prevent engine stall. A pressure switch that is plumbed or wired incorrectly may cause hydraulic system chatter. Printed in U.S.A. ISSUED AUGUST 2007 ©COPYRIGHT 2007, Heil Environmental...
Page 395: Suction Line
3.15 VELJAN TANDEM VANE HYDRAULIC PUMP Primary pump solenoid shuts off first 1” IN- LINE CHECK VALVE Secondary pump solenoid shuts off last Low torque engine pressure switch # 2 set @ 2000 psi. Inlet / pressure manifold Low torque engine pressure switch # 1 set @ 1500 psi.
Page 396: Troubleshooting
3.16 DENISON TANDEM VANE PUMP with Hydraulic Controls Pressure Blocks OR Oasis Pressure Blocks OPERATE IN GEAR AT IDLE HYDRAULIC SYSTEM TROUBLESHOOTING DESCRIPTION The Operate in Gear system is designed to perform the side loading operations at standard idle speed. It is comprised of two major components, the Denison T6CC series vane pump and attached unloader valve assemblies.
Page 397 3.17 DENISON TANDEM VANE PUMP with Hydraulic Controls Pressure Blocks, Oasis Double Pressure Blocks, or Oasis Monoblock OPERATE IN GEAR AT IDLE HYDRAULIC SYSTEM TROUBLESHOOTING ELIMINATE THE UNLOADER VALVE FROM THE CIRCUIT With the engine shut down, remove the bypass line from the pressure block port marked “bypass”.
Page 398 3.18 DENISON TANDEM VANE PUMP with Hydraulic Controls Double Pressure Blocks, Oasis Double Pressure Blocks, or Oasis Monoblock OPERATE IN GEAR AT IDLE HYDRAULIC SYSTEM TROUBLESHOOTING CHECKING UNLOADER VALVE PUMP 2 3) REPLACE PUMP ASSEMBLY If problem still persists, an internal failure of the pump is indicated. Replace the pump assembly. If the pump is a remote mount type (drive shaft driven), care must be taken to maintain correct “phasing"...
Page 399 3.18.1 DENISON PUMP TROUBLESHOOTING Pressure Ports on opposite side Oasis Monoblock Unloader valves Test Cap Test Plug Bypass to Tank Bypass to Inlet Troubleshooting Tandem Vane Pump Pressure Manifolds - This Procedure Covers Hydraulic Controls Double Block Configuration, Oasis Double Block Configuration, and Oasis Monoblock Configuration On front mount tandem vane pump applications the pump is always rotating and always producing flow.
Page 400 T7DD pump – 45 ft. lbs. Torque unloader valve cartridge to monoblock to 110 ft. lbs. Torque front mounting cap bolts T6CC pump – 117 ft. lbs. T7DD pump – 140 ft. lbs ISSUED JANUARY 2005 Printed in U.S.A. COPYRIGHT 2005, Heil Environmental...
Page 401 3.19 LOW TORQUE ENGINE ELECTRONIC PRESSURE SWITCH KIT 372-2260 The optional electronic pressure switch kit is used on low torque engine applications with O-I-G-A-I tandem vane pump to prevent engine stall during high torque demands. 063-0114 354-2522 ADAPTER 054-3526-004 057-1959 PRESSURE SWITCH BSP to NPTF CONNECTOR –...
Page 403 The electronic pressure switch is very versatile and can be used in any Heil pressure switch application. It is typically used in a low torque engine with a tandem pump application to prevent engine stall at low RPM. The electronic pressure switch can be programmed to shut off one of the tandem pumps when a predetermined system pressure is reached.
Page 404 Therefore the final adjustment to the pressure switch must always be made by increasing the switch setting against the spring force. ISSUED AUGUST 2004 Printed in U.S.A. COPYRIGHT 2004, HEIL...
Page 406 3.20 Cavitation Cavitation is caused by vacuum or the absence of atmospheric pressure that extracts air molecules from the fluid in the form of tiny air bubbles. When these air bubbles see pressure greater than 20 psi. They collapse or implode. Bubbles that implode next to the gear housing or gear surface take metal particles with them causing pitting and pump damage.
Page 407 DRIVE SHAFT MFG. SPECIFICATIONS:...
Page 409: Section 4 Controls
CONTROLS CONTROLS CONTROLS CONTROLS (& Electrical) (& Electrical) (& Electrical) (& Electrical) SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL 2002 UNITS 2002 UNITS 2002 UNITS 2002 UNITS DOVER COMPANY     2004, Heil Environmental MR-75018-404 Industries Ltd.
Page 411: Section 4 - Controls/Electrical
Pneumatic and Mechanical Throttle Advance....................4.7 Electronic Controlled Throttle Advance ..................4.8 thru 4.13 Neutral Switch Kits ........................4.14 thru 4.20 EOS Electronic Overspeed Kits....................4.21 thru 4.29 Air Shift Kit ..............................4.30 Printed in U.S.A. ISSUED MAY 2004 ãCOPYRIGHT 2004, HEIL...
Page 413 F4000 ELECTRICAL SCHEMATIC 701-8465...
Page 414 CAB ELECTRICAL 372-1523...
Page 418 1. A 3/8” female stud type connector and 2. A molded pin plug. Dipit is recommended for use on the stud type and an antioxidant grease is recommended fro the plug type connection. Printed in U.S.A. ISSUED JULY 2004 COPYRIGHT 2004, HEIL...
Page 419 PNEUMATIC and MECHANICAL THROTTLE ADVANCE 272-1818-01 MECHANICAL LINKAGE ACCELERATOR 272-1818-02 PNEUMATIC ACCELERATOR 272-1818-24 THROTTLE ADVANCE +12v GROUND AIR FROM CHASSIS N/C AIR SOLENOID (THROTTLE ADVANCE) MECHANICAL LINKAGE ACCELERATOR – 24v DC CHASSIS Printed in U.S.A. ISSUED MAY 2004 ã COPYRIGHT 2004, HEIL...
Page 420 FORMULA 4000 THROTTLE ADVANCE for ELECTRONIC CONTROLLED NAVISTAR ENGINE 272-1818-120 ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 421 FORMULA 4000 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CAT ENGINE 272-1818-121 THROTTLE ADV. PLUGGED GROUND Printed in U.S.A. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 422 4.10 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CUMMINS ISM ENGINE 272-1818-122 THROTTLE ADVANCE PLUGGED GROUND ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 423 4.11 FORMULA 4000 THROTTLE ADVANCE for ELECTRONIC CONTROLLED VOLVO ENGINE 272-1818-127 THROTTLE ADV. PLUGGED PLUGGED Printed in U.S.A. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEILL...
Page 424 4.12 FORMULA 4000 THROTTLE ADVANCE for ELECTRONIC CONTROLLED CUMMINS ISB/ISC ENGINE 272-1818-128 ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 425 4.13 THROTTLE ADVANCE for ELECTRONIC CONTROLLED Vmack ENGINES 272-1818-129 Printed in U.S.A. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 426 4.14 NEUTRAL SWITCH KIT for AUTOMATIC TRANSMISSION (NON-ELECTRONIC) 272-3183-01 TO CHASSIS STARTER SOLENOID CIRCUIT TRANSMISSION NEUTRAL SWITCH HARNESS, REF. TRANSMISSION NEUTRAL SWITCH, REF. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 427 4.15 NEUTRAL SWITCH KIT for NAVISTAR CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-08 NEUTRAL RELAY NEUT. RELAY Printed in U.S.A. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 428 4.16 NEUTRAL SWITCH KIT for 320 PTERBILT CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-03 ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 429 FREIGHTLINER FUSE PANEL LOCATED UNDER CURB SIDE DASH C B A CONNECT +12v DC 15 AMP FROM HEIL CONTROLS TO PIN OUT "F" CONNECT HEIL NEUTRAL SIGNAL WIRE TO PIN OUT "E" FOR + 12v OUTPUT NOTE: INSERT TERMINAL INTO REAR OF CONNECTOR.
Page 430 4.18 NEUTRAL SWITCH KIT for FORD LOUISVILLE with ALLISON WORLD TRANSMISSION 272-3183-06 ISSUED AUGUST 2004 ã COPYRIGHT 2004, HEIL...
Page 431 4.19 NEUTRAL SWITCH KIT for MANUAL TRANSMISSION 272-3183-07 N.C. Printed in U.S.A. ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 432 4.20 NEUTRAL SWITCH KIT for STERLING 1999 CHASSIS with ALLISON WORLD TRANSMISSION 272-3183-09 ISSUED JUNE 2004 ã COPYRIGHT 2004, HEIL...
Page 433 4.21 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for UNITS WITHOUT ALLISON TRANSMISSION 272-7738-01 YELLOW GREEN WHITE BLACK Printed in U.S.A. ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 434 4.22 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for UNITS with ALLISON TRANSMISSION 272-7738-02 ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 435 4.23 (EOS) ELECTRONIC OVERPEED SWITCH KIT for ALLISON WORLD TRANSMISSION/ PETERBILT 320 272-7738-03 Printed in U.S.A. ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 436 4.24 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and 24v DC 272-7738-124 PUMP SW. OUTPUT YELLOW "R" STATOR TO HEIL CONTROLS GREEN PUMP SOLENOID BLACK GROUND WHITE ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 437 272-7738-05 FREIGHTLINER FUSE PANEL LOCATED UNDER CURB SIDE DASH CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUT "2" D E F CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUT "F" CONNECT HEIL PUMP SOLENOID WIRE TO PIN OUT "E".
Page 438 V.I.M. NOTE: INSERT DEUTSCH SOCKETS (ITEM 1) INTO MIDDLE CONNECTOR IN HEIL NEUTRAL KIT CONNECT +12v DC FROM HEIL CONTROLS PUMP SWITCH OUTPUT TO PIN OUTS "V" & "B". CONNECT HEIL PUMP SOLENOID WIRE TO PIN OUT "T" . VIEW "A"...
Page 439 4.27 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and NAVISTAR 1998 MODEL and AFTER 272-7738-08 Printed in U.S.A. ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 440 4.28 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and STERLING CHASSIS 272-7738-09 ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 441 4.29 (EOS) ELECTRONIC OVERSPEED SWITCH KIT for ALLISON WORLD TRANSMISSION and 24v DC 272-7738-124 Printed in U.S.A. ISSUED MAY 1999 ã COPYRIGHT 1999, H.E.I.L...
Page 442 4.30...
Page 443 HEIL PLC HEIL PLC HEIL PLC HEIL PLC INFORMATION INFORMATION INFORMATION INFORMATION Program No. 109-0205 Program No. 109-0205 Program No. 109-0205 Program No. 109-0205 • • • • REAR LOADERS DOVER COMPANY OMRON     2004, Heil Environmental MR-75023-1204...
Page 445 HEIL PROGRAMABLE LOGIC CONTROLER (PLC) MINI PLC VERSION Mini PLC Enclosure Part # 372-1906 Input Side Channel “0” Program # Decal Input LEDs Output LEDs Output Side Channel “10”...
Page 446 NC = terminals that Module Part # 108-7860 are not connected Upper Output Terminals (not used see note below) Lower Terminals EOS screws (not used) Peripheral Port...
Page 447 The Mini PLC component is used in various applications that require two electronic over speeds (EOS). This application is generally found on units using a tandem pump setup. The EOS screws are not activated and are not used. The EOS set points are part of the PLC program.
Page 448 HEIL PLC HAND HELD LOADER PROGRAMER EE Prom “PIN 1” Slot Part # 108-7715-EEP Download Button Upload Button Hand Held Loader Part # 108-7715-HHL EE Prom triangle – must be lined up with “PIN 1” slot when inserted in Hand Held Loader...
Page 449 HEIL MINI PLC PROGRAMMING PROCEDURES Procedures for downloading program using the Hand Held Loader 1.) Install (108-7715-EEP) EE prom into (108-7715-HHL) loader by moving the locking lever up. Make sure you have an EE prom with the correct program. 2.) Place the EE prom into loader with the triangle next to the “PIN 1” location.
Page 452 MINI PLC KIT REAR LOADER O-I-G-A-I 372-1828-006...
Page 454 PRESSURE SWITCH KIT REAR LOADER (O-I-G-A-I) 108-7919-004...
Page 459 SECTION 5 SECTION 5 SECTION 5 SECTION 5 BODY BODY BODY BODY SERVICE MAN SERVICE MANUAL SERVICE MAN SERVICE MAN 2002 UNITS 2002 UNITS 2002 UNITS 2002 UNITS DOVER COMPANY     2004, Heil Environmental MR-75019-404 Industries Ltd.
Page 461 Hydraulic Schematic .......................... 701-8430 Packer Hydraulic Flow Diagrams; Ejector Retract/Extend........................701-8430-1 Ejector Unloading with Tailgate Raised ..................701-8430-8 Ejector Unloading and Blade Back-Off During Slide In ..............701-8430-5 Pneumatic (air) System; Air Supply Kits (272-7464)........................5.19 Printed in U.S.A. ISSUED APRIL 2004 ãCOPYRIGHT 2004, HEIL...
Page 463 FORMULA 4000 NOMENCLATURE Printed in U.S.A. ISSUED MAY 2004 COPYRIGHT 2004, HEIL.
Page 464: Specifications
SPECIFICATIONS Hydraulic Oil Tank ............................24 Gal. Hydraulic Oil System Capacity......................... 36-1/2 Gal. Return Line Oil Filter ........................... 10-Micron Optional In-Tank Oil Filter..........................5-Micron Hydraulic Tank Suction Strainer..................... 140 Mesh Screen Hydraulic Cylinders: Ejector; 11 cu. yd.narrow & 13 cu. yd. std................Telescopic x 65.12” stroke 14 cu.
Page 465 Check wiring, battery cables for wear & proper operation Printed in U.S.A. ISSUED MAY 2004 ãCOPYRIGHT 2004, HEIL...
Page 467 FORMULA 4000 STANDARD HYDRAULIC OILTANK 10 MICRON RETURN LINE FILL CAP OIL FILTER SIGHT GAUGE PRESSURE LINE This is the standard hydraulic oil tank with the 10-micron oil filter. It is normally located on the streetside (left side) of the unit.
Page 468: Changing The Filter Element
NOTE: Change the filter more often under certain conditions, such as extremely dusty atmosphere or area. Use only HEIL replacement filters , which may be ordered from your local Heil Distributor. The element needs to be changed every 1000 hours or every 6 months or when indicated by the filter monitor light in the chassis cab.
Page 469 4. Check o-ring and gasket and replace if necessary. COVER TORQUE NUTS TO 35 FT./LBS. COVER BYPASS – PART OF ELEMENT – O-RING NOT SERVICED. SPRING ELECTRICAL INDICATOR ELECTRICAL 5-MICRON INDICATOR GASKET ELEMENT GASKET Printed in U.S.A. ISSUED AUGUST 2004 COPYRIGHT 2004, HEIL...
Page 470 5.10 13. Operate the Tailgate – full up and full down. 15. With the packing mechanism in the retracted position, check the tank oil level. If necessary, add recommended oil as required. Printed in U.S.A. ISSUED OCTOBER 2000 COPYRIGHT 2000, H.E.I.L.
Page 473 5.13 SIDE ACCESS DOOR A hinged access door is located on the street side of the unit and provides access to the body area for cleanout purposes. It should never be entered unless the truck engine is stopped and the ignition key removed and the unit is in lock-out/tag-out position.
Page 481: Hydraulic Symbols
5.17 HYDRAULIC SYMBOLS...
Page 482 5.18 HYDRAULIC SYMBOLS...
Page 483 FORMULA 4000 - HYDRAULIC SCHEMATIC TAILGATE CYLINDERS EJECTOR CYLINDER REEVING BLADE SLIDE CYLINDER CYLINDER CYLINDER UNDERBODY VALVE TAILGATE VALVE 701-8430 4/04...
Page 484 EJECTOR EXTEND EJECTOR RETRACT EJECTOR EJECTOR CYLINDER CYLINDER TANK TANK FROM FROM UNDERBODY VALVE UNDERBODY VALVE TANK TANK LEGEND = PUMP PRESSURE = RETURN PRESSURE 701-8430-1...
Page 485 EJECTING LOAD WITH TAILGATE RAISED TAILGATE CYLINDERS EJECTOR CYLINDER TANK FROM PUMP LEGEND = PUMP PRESSURE = RETURN PRESSURE = INTERMEDIATE PRESSURE UNDERBODY VALVE 701-8430-8...
Page 486 EJECTOR UNLOADING & BLADE BACKING OFF DURING SLIDE IN EJECTOR TAILGATE CYLINDER CYLINDERS REEVING BLADE SLIDE CYLINDERS CYLINDERS CYLINDERS UNDERBODY VALVE TAILGATE VALVE LEGEND = PUMP PRESSURE = RETURN PRESSURE = INTERMEDIATE PRESSURE 701-8430-5...
Page 487: Air Filter/ Regulator
5.19 AIR SUPPLY KITS PNEUMATIC DIAGRAMS 272-7464 AIR REGULATOR ADJUSTMENT KNOB. SET @ 80 PSI LIFT KNOB TO UNLOCK, PRESS KNOB TO LOCK ADJUST REGULATOR TO 80 PSI ADJUST REGULATOR TO 80 PSI TRACTOR PROTECTION FILTER/ VALVE REGULATOR ISSUED FEBRUARY 2004 ã...
Page 489 SECTION 6 SECTION 6 SECTION 6 SECTION 6 TAILGATE TAILGATE TAILGATE TAILGATE SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL 2002 UNITS 2002 UNITS 2002 UNITS 2002 UNITS DOVER COMPANY     2004, Heil Environmental MR-75020-404 Industries Ltd.
Page 491: Section 6 - Tailgate
Hydraulic Detent Adjustment for Blade and Slide Spool ................. 6.4 Optional Container Mechanism........................ 6.5 Linkage Adjustment..........................6.7 Slide Shoe Removal ............................ 6.8 Tailgate Props.............................. 6.9 Winch Lubricant Adding Procedure ......................6.10 Printed in U.S.A. ISSUED MAY 2004 ãCOPYRIGHT 2004, HEIL...
Page 492 Optional Mechanism (Winch, Roll Bar) .....................1400 PSI Tailgate Packer Mechanism Cycle Times (Empty Hopper); Non Regen @ 28 GPM)....................... 22 to 26 Seconds Regen @ 28 GPM........................15 to 17 Seconds Printed in U.S.A. ISSUED MAY 2004 ãCOPYRIGHT 2004, HEIL...
Page 493: Blade Assembly
FORMULA 4000 6.2.1 TAILGATE NOMENCLATURE TAILGATE TAILGATE (SECONDARY) RAISE VALVE CYLINDER SLIDE CYLINDER BLADE CYLINDER SLIDE ASSEMBLY HOPPER TURNBUCKLE ASSEMBLY BLADE ASSEMBLY SLIDE & BLADE CONTROL LEVERS Shown are some of the features of the F4000 tailgate. Printed in U.S.A.
Page 494 Formula 4000 Lubrication Guide DOVER COMPANY Note: 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. REF. NO. LOCATION QTY. INTERVAL Tailgate Hinge Weekly/40 Hours Tailgate Cylinders (2/Cyl.)
Page 495: Hydraulic Schematic
FORMULA 4000 6.2.3 HYDRAULIC SCHEMATIC REEVING BLADE SLIDE CYLINDER CYLINDER CYLINDER FROM UNDER BODY VALVE TAILGATE VALVE RETURN TANK 701-8430 Printed in U.S.A. ISSUED MAY 2004 COPYRIGHT 2004, HEIL...
Page 496 BLADE DOWN SLIDE IN BLADE SLIDE SLIDE CYLINDERS CYLINDERS CYLINDERS FROM FROM PREVIOUS PREVIOUS VALVE VALVE SECTION SECTION TANK TANK TAILGATE VALVE TAILGATE VALVE LEGEND = PUMP PRESSURE = RETURN PRESSURE 701-8430-4...
Page 497 BLADE UP SLIDE OUT BLADE SLIDE SLIDE CYLINDERS CYLINDERS CYLINDERS TAILGATE VALVE TAILGATE VALVE LEGEND = PUMP PRESSURE = RETURN PRESSURE 701-8430-3...
Page 498 TAILGATE RAISE TAILGATE LOWER TAILGATE TAILGATE CYLINDERS CYLINDERS TANK FROM PUMP TANK FROM PUMP UNDERBODY VALVE UNDERBODY VALVE LEGEND = PUMP PRESSURE = RETURN PRESSURE = INTERMEDIATE PRESSURE 701-8430-2...
Page 499 REEVING CYLINDER REEVING CYLINDER LOWERING CONTAINER LOWERING CONTAINER DURING BLADE UP REEVING BLADE SLIDE REEVING CYLINDER CYLINDERS CYLINDERS CYLINDER FROM FROM UNDERBODY UNDERBODY TANK TANK VALVE VALVE TAILGATE CYLINDERS TAILGATE CYLINDERS LEGEND = PUMP PRESSURE = RETURN PRESSURE 701-8430-7...
Page 500 REEVING CYLINDER REEVING CYLINDER RAISING CONTAINER RAISING CONTAINER DURING BLADE DOWN REEVING BLADE SLIDE REEVING CYLINDER CYLINDERS CYLINDERS CYLINDER TANK FROM UNDERBODY VALVE TANK FROM UNDERBODY VALVE TAILGATE CYLINDERS TAILGATE CYLINDER LEGEND = PUMP PRESSURE = RETURN PRESSURE 701-8430-6...
Page 505 FORMULA 4000 TAILGATE (SECONDARY VALVE) LINKAGE MAINTENANCE OF WEAR SURFACES ADJUSTMENT 1. Loosen the jam nut behind the yoke. 2. Screw the yoke OUT to pull levers closer to the unit. 3. Screw the yoke IN to pull levers away from the unit.

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