Transcript
DUMP BODY SPREADERS INSTALLATION INSTRUCTIONS (Includes PS350 & PS400)
EFFECTIVE 09/2011 Revision A
1330 76TH AVE SW CEDAR RAPIDS, IA 52404-7052 PHONE (319) 363-8281 | FAX (319) 286-3350
www.highwayequipment.com
Copyright 2009 Highway Equipment Company, Inc.
table of C ontents
HI-WAY
Tableheader of Contents
DUMP BODIES
Recommended Installation........................................................................................................................... 3 Hydraulics...................................................................................................................................................... 4 Truck Requirements....................................................................................................................................... 4 Lifting PS350.................................................................................................................................................. 4 PS350 with Underbody Hoist........................................................................................................................ 5 Truck Preparation.............................................................................................................................. 5 Hoist.................................................................................................................................................. 6 Dump Body....................................................................................................................................... 7 Body Props........................................................................................................................................ 8 Decals................................................................................................................................................ 8 Mounting of Body with Telescopic Hoist....................................................................................................... 9 Hinge................................................................................................................................................. 9 Mounting Pads................................................................................................................................ 1 0 Cradle & Hoist Cylinder to Truck..................................................................................................... 1 1 Mounting Dump Body..................................................................................................................... 1 4 Body Props...................................................................................................................................... 1 4 Hoist Cylinder to Dump Body.......................................................................................................... 1 5 Decals.............................................................................................................................................. 1 5 Cab Shield.................................................................................................................................................... 1 6 PS350 with Underbody Hoist Option.............................................................................................. 1 6 Body with Telescopic Hoist Option.................................................................................................. 1 7 Inspection Ladder........................................................................................................................................ 1 8 Storage............................................................................................................................................ 1 8 Body-Up Indicator....................................................................................................................................... 1 8 Side Boards.................................................................................................................................................. 1 8 Mudflaps..................................................................................................................................................... 1 8 Coal Chute................................................................................................................................................... 1 9 Tailgate Air Kit.............................................................................................................................................. 1 9 Lights........................................................................................................................................................... 2 0 Hydraulic Hose............................................................................................................................................ 2 0 Hose Installation Guide............................................................................................................................... 2 0 Frame Mount Reservoir............................................................................................................................... 2 2 Filling Hydraulic System............................................................................................................................... 2 2 Checking Installation................................................................................................................................... 2 2
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Hi-Way
DUMP BODIES
Installation Instructions
Recommended sequence of installation: 1. 2. 3. 4. 5.
Hinge, if applicable Cradle, if applicable Hoist – Underbody or Cylinder Dump Body Body Props
6. 7. 8. 9.
Decals Options* Hydraulics Lights
* – The cab shield may be installed before the dump body is mounted on the truck for easier access. HYDRAULICS Hydraulic System Requirements 20 GPM (76 LPM)
PUMP TYPE
Gear or load sense
PUMP PRESSURE
2200-2500 PSI (151.8-172.5 Bar) operating
CONTROL TYPE
Manual Electric solenoid
FILTRATION RESERVOIR
Return line filter, 10 Micron
RELIEF VALVE
2000 PSI (138 Bar) at pump or control valve
30 gallon (113.5 liter) frame mount with sight gauge
RECOMMENDED HOSE Pressure line Return line Suction line NOTICE!
0-9 GPM (0-34 LPM) 9-20 GPM (34-76 LPM) 20-36 GPM (76-136 LPM) 0-35 GPM (0-132 LPM) 35-57 GPM (132-216 LPM) 0-22 GPM (0-83 LPM) 22-40 GPM (83-151 LPM)
.500 dia 100R1(min) .75 dia. 100R2 1.00 dia. 100R2 1.00 dia. 100R1 1.25 dia. 100R1 1.50 dia. 100R4 2.00 dia. 100R4
Retracting underbody hoist with more pressure than 300 PSI (21 Bar) may cause damage to frame.
UNDERBODY HOIST
Relief valve for retracting Relief valve for extending
100 – 300 PSI (7-21 Bar) 2000 PSI (138 Bar)
PLOWS & ACCESSORIES
Refer to manufacturer’s manual.
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I nstructions installation I nstallation
FLOW REQUIREMENTS
HI-WAY
Installation Instructions Continued
DUMP BODIES
TRUCK REQUIREMENTS Make sure the truck’s CA/CT (Cab to Axle/Cab to Tandem) dimension and Frame Length are correct for the length of the dump body. See Dimensions & Specifications chart to match dump body with truck. Make sure the GAWR (Gross Axle Weight Rating) and GVWR (Gross Vehicle Weight Rating) are adequate to carry the fully loaded dump body. Your Hi-Way dealer can help calculate the weight distribution on each axle and the total loaded vehicle weight. LIFTING PS350
I nstallation I nstructions
55° X MA
DANGER
A
Tailgate must be closed and latch locked before lifting with rear tailgate bolsters. Serious injury or death could occur if tailgate swings open and unit falls.
WARNING
Figure 1 – Lifting Unit Length
Maximum Angle from Vertical
10’ (31 mm) 12’ (37 mm) 13’ (40 mm) 14’ (43 mm) 15’ (46 mm) 16’ (49 mm)
55°
A (Figure 6) Sling Leg Length 99” (25 mm) 113” (29 mm) 120” (30 mm) 126” (32 mm) 132” (34 mm) 138” (35 mm)
CAUTION Do not remove lifting device until dump body is secured to truck.
NOTICE!
Attach a 4-point harness to the front lift hooks and rear corner bolsters as shown in Figure 1
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Use only lifting devices that meet or exceed OSHA standard 1910.184. Never lift equipment over people. Never lift unit with material in the body. Loads may shift or fall if improperly supported, causing injury or damage to the unit.
4
Lift with a maximum 55° angle from vertical to prevent damage to the unit (35° minimum angle from horizontal).
Hi-Way
DUMP BODIES
Installation Instructions Continued
MOUNTING PS350 WITH UNDERBODY HOIST Truck Preparation
3.00 MINIMUM
CAUTION Do not remove lifting devices while test fitting unit on truck. Lifting devices should not be removed until hoist and unit are both secured to truck.
TEST FIT & REMOVE EXCESS FRAME 11 5/8" CENTER OF HINGE PIN TO REAR OF PS FLOOR
41 31/64"
Figure 2 – Truck Modification
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I nstallation I nstructions
1. Measure from front of unit to rear of hinge and add three inches. This is the distance from the cab to the rear of truck frame. 2. Mark this distance on truck frame rail. 3. Test fit hoist sub-frame and dump body to check mark. 4. Remove hoist/unit and cut off excess truck frame.
HI-WAY
Installation Instructions Continued
DUMP BODIES
DANGER
Do not install hoist cylinder at an angle. If the dump body is raised with the cylinder improperly installed, the truck could tip causing serious injury or death.
CAUTION
Do not puncture gas tank or harm any other obstruction when drilling holes.
CAUTION
Do not leave raised body unattended. Do not raise body on unlevel ground. Check for overhead power lines and other obstructions before raising body.
3.00 MINIMUM
NOTICE!
Make sure hoist subframe is square with the truck cab and rails and that the hoist cylinder is centered from side-to-side on the truck chassis.
NOTICE!
DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES—to do so may void truck m a n u fa c t u re r ’s warranty. Drill only through vertical web portions of truck frame, a minimum of 2.00” (5.08 cm) from the top or bottom flanges.
NOTICE!
Do not weld directly to truck frame. Such welding could lead to fatigue cracking and must be avoided.
NOTICE!
Connect arc welder’s ground directly to one of the two items being welded before using welder on anything connected to the vehicle.
90°
90° CAB
I nstallation I nstructions
Hoist
Figure 3 – Hoist Position
LOCATE MOUNT PLATES AT HOIST CROSS SUPPORTS LOCATE REAR MOUNT PLATES UNDER HINGE
2.00 MINIMUM
BOTH SIDES
TRUCK RAIL 2.00 MINIMUM
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.656-10X FIELD DRILL
Figure 4 – Hoist Mounting
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Hi-Way
Installation Instructions Continued
DUMP BODIES
1. Place hoist on truck frame, centered as shown in Figure 3. 2. Center front and center Mounting Plates at ends of hoist cross supports as shown in Figure 4 and mark hole locations. Position rear Mount Plates directly under rear hinge and mark holes. 3. Drill 21/32” (1.67 cm) holes as required. Use existing holes if possible. 4. Install Mounting Plates on truck frame using 5/8” hardware provided. 5. Weld Mounting Plates to hoist sub-frame rails as shown in Figure 4. 6. Attach hydraulic hoses to hoist cylinder ports. Make sure hoist functions properly. Dump Body
2X
Figure 5 – Dump Body Mounting CAUTION
Do not remove lifting device until dump body is completely welded and body props are operational.
CAUTION
Make sure the dump body is securely anchored and will not shift or slide off truck. Periodically check welds and mounting hardware to make sure it is secure.
1. Make sure the hoist sub-frame is properly positioned and attached to the truck frame. 2. Lift dump body onto hoist and position at least 3” (7.62 cm) from the truck cab and centered from side-to-side. Make sure the dump body sills are directly over the sub-frame rails. 3. Weld rear hinge blocks to the dump body sills. 4. Align hoist arm upper pivot holes with dump body hinge holes and insert pins.
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I nstallation I nstructions
LINE UP ARMS & INSTALL PINS
HI-WAY
Installation Instructions Continued
DUMP BODIES
Body Props DANGER
Do not work beneath dump body without body props in place. Serious injury or death could occur from crushing.
CAUTION
Make sure dump body is securely anchored and will not shift or slide off truck. Periodically check welds and mounting hardware to make sure it is secure.
I nstallation I nstructions
BODY PROP
Figure 6 – Body Prop Alignment Place on body props by doing the following: 1. Make sure tailgate latch is open. Raise dump body with hydraulic power. 2. Lift body props and set against tabs as shown in Figure 6. 3. Slowly lower dump body so upper hinge angle of dump body rests on body props. Remove body props by raising dump body enough that body props are free of upper hinge angle. Lower body props and set on sub-frame tabs. Decals Some safety decals are shipped loose and must be installed by the dealer before operation of the PS.
NOTICE!
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Install safety decals as required per “Decals” parts list and illustration in operator’s manual. Install “Danger, Crushing Hazard” decals (PN 96704) on front of both truck frame rails, in clear view. Install “Caution, Operation Safety” (PN 96716) and “Caution, Raised Body” (PN 96715) decals in clear view in truck cab.
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Hi-Way
Installation Instructions Continued
DUMP BODIES
MOUNTING OF BODY WITH TELESCOPIC HOIST Hinge NOTICE!
Connect arc welder’s ground directly to one of the two items being welded before using welder on anything connected to the vehicle.
NOTICE!
Do not exceed 300° F (148° C) at Greaseless Hinge Bushings (optional). Heat can distort Hinge Bushings. Contact Hi-Way Genuine Parts dealer for replacements if Bushings are damaged. EVEN WITH MOUNT SURFACE
HINGE BLOCK
5.00
HINGE BUSHING HINGE ANGLE
BOTH TRUCK FRAME RAILS
DO NOT WELD TO TRUCK FRAME!
4.00
Figure 7A – PS350 Hinge Installation EVEN WITH MOUNT SURFACE
HINGE BLOCK
6.00 W/ PADS 6.50 W/O PADS
6.50
HINGE BUSHING
BOTH TRUCK FRAME RAILS
HINGE ANGLE
DO NOT WELD TO TRUCK FRAME!
8.00
Figure 7B – PS400 Hinge Installation
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I nstallation I nstructions
4.50 W/ PADS 5.00 W/O PADS
1. Measure from front of unit to rear of bottom sill and add 4” (10.16 cm). This is the distance from the cab to the rear of the hinge. 2. Mark this distance on truck frame rail. 3. Test fit unit to make sure there is a minimum of 4” (10.16 cm) clearance between dump body and truck cab as shown in Figure 10. Figure 13 shows position of dump body in respect to hinge/truck frame. 4. Cut truck frame so Hinge Block will be even with rear and level with mounting surface as shown in Figures 7A-7B. 5. Place Hinge Angle in cutout and center from side-toside. 6. Make sure top of Hinge Block will be level with top of Mount Pads (1, Figure 8), or truck frame if mounting directly to frame. 7. Tack weld Hinge Angle to both truck frame rails.
HI-WAY
Installation Instructions Continued
DUMP BODIES
Mounting Pads (Optional) 1. Cover both truck frame rails completely with Mount Pads (1) as shown in Figure 8, from the front of the rear hinge to the rear of the cradle, and cut to length as needed. This will provide even contact with the truck frame and reduce high wear points. 2. Drill or cut Mount Pads to make clearance for rivets, bolts or other obstructions so Pads lay flat. Do not weld Mount Pads directly to truck frame. Such welding could lead to fatigue cracking and must be avoided.
NOTICE!
I nstallation I nstructions
5" MAX FROM CRADLE
2
28 - TYP 22
3 4 5
TYP.
.125
2" MIN
.438 - TYP FIELD DRILL
5" MAX FROM HINGE 1
TRIM RUBBER TO WELD MOUNT ANGLES TO MOUNT PAD'S METAL BASE
SECTION VIEW
Figure 8 – Mounting Pads
Parts needed: ITEM DESCRIPTION 1 Mount Pad 2 Mount Angle 3 Cap Screw – 3/8 x 1-1/4 4 Lock Washer – 3/8 5 Hex Nut – 3/8 AR – As Required
NOTICE!
QTY AR AR AR AR AR
3. Trim rubber from Mount Pads (1) so Mount Angles (2) can be welded on without damaging rubber. 4. Position Mount Angles (2) on Mount Pads (1) as shown in Figure 8 and mark hole locations on truck frame. NOTE: The rear Mount Angle should be no more than 5” (12.7 cm) from the rear hinge and the front Mount Angle should be no more than 5” (12.7 cm) from the cradle.
DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES—to do so may void truck manufacturer’s warranty. Drill only through vertical web portions of truck frame, a minimum of 2.00” (5.08 cm) from the top or bottom flanges.
5. Drill 7/16” (1.11 cm) holes. 6. Install Mount Angles using 3/8” hardware (3, 4 & 5). 7. Weld Mount Angles (2) to metal base of Mount Pads (1) as shown in Figure 8.
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Hi-Way
DUMP BODIES
Installation Instructions Continued
Cradle & Hoist Cylinder to Truck
BODY SIZE 10’ (31 mm) 12’ (37 mm) 13’ (40 mm) 14’ (43 mm) 15’ (46 mm) 16’ (49 mm)
A (Figure 9) (CRADLE FRONT TO HINGE FRONT) 105.635 (27 mm) 129.635 (33 mm) 141.635” (36 mm) 153.635” (39 mm) 165.635” (42 mm) 177.635” (451 cm)
A
QTY 1 2 8 8 8 1 2 2 4 8 8
C
B
D
NOTE: Cradle will extend 1.5” (3.81 cm) beyond front of body headsheet. See Figure 10 for Items 1–5.
CRADLE
See Figure 11 for Items 6-11.
CAB 1. Center Cradle (1) on truck frame rails as shown in Figures 9 & 10, and distance from Figure 9 – Hinge/Cradle Square Hinge according to chart above. 2. Make sure hinge and cradle are square by measuring from center of hinge pins to center of cradle pins as shown in Figure 9. Distance A must equal B and distance C must equal D. 3. Center Angles (2) under Cradle and mark center of eight holes on truck rails. 4. Drill 11/16” (1.75 cm) holes where marked. 5. Attach Angles to truck with 5/8” hardware (3, 4 & 5).
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I nstallation I nstructions
Parts needed: ITEM DESCRIPTION 1 Cradle 2 Angle 3 Cap Screw – 5/8 x 2 GR 8 4 Lock Washer – 5/8 5 Hex Nut – 5/8 GR 8 6 Hoist Cylinder 7 Lower Cap Block 8 Upper Cap Block 9 Grease Zerk 10 Cap Screw – 1/2 x 3-3/4 11 Lock Washer – 1/2
HINGE
HI-WAY
Installation Instructions Continued
NOTICE!
DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES—to do so may void truck manufacturer’s warranty. Drill only through vertical web portions of truck frame, a minimum of 2.00” (5.08 cm) from the top or bottom flanges.
NOTICE!
Make sure Cradle is square with truck cab and rails and Hoist Cylinder (6) will be centered from side-to-side on truck chassis and vertical when dump body is down. See Figures 9 & 11.
NOTICE!
Do not weld directly to truck frame. Such welding could lead to fatigue cracking and must be avoided.
NOTICE!
Connect arc welder’s ground directly to one of the two items being welded before using welder on anything connected to the vehicle.
6. Tack weld Cradle to Angles as shown in Figure 10.
I nstallation I nstructions
DUMP BODIES
2X
2X
4" MINIMUM 2X
SECTION CUT AWAY TO SHOW UPPER CYLINDER MOUNT
HOIST CYLINDER CENTERLINE 1
3 4 5 2 .688"-8X FIELD DRILL 1.50 A
Figure 10 – Cradle Installation
Dump Body Install-A Page Rev. A
12
Hi-Way
Installation Instructions Continued SECTION VIEW
DUMP BODIES
90°
TOP VIEW
6
90°
8
90°
11 10 9 7
FRONT VIEW
Figure 11 – Hoist Cylinder Installation
Do not install hoist cylinder at an angle. If dump body is raised with the cylinder improperly installed, the truck could tip causing serious injury or death.
CAUTION
Do not leave raised body unattended. Do not raise body on unlevel ground. Check for overhead power lines and other obstructions before raising body.
CAUTION
Make sure dump body is securely anchored and will not shift or slide off truck. Periodically check welds and mounting hardware to make sure it is secure.
7. Restrain cylinder’s lower and upper trunnion pins together before lifting so cylinder will not extend. Crimped steel banding may be used. 8. Lift Hoist Cylinder (6) with a suitable lifting device, and place in Cradle (1) as shown in Figure 11 with hydraulic ports facing truck cab. Remove trunnion restraints. Place cylinder’s lower trunnion pin in cradle’s cylinder block. 9. Place Lower Cap Blocks (7) over trunnion pins and secure with 1/2” (1.27 cm) hardware (10 & 11). Torque as required. 10. Install Grease Zerks (9). 11. Lean Hoist Cylinder against truck cab to mount dump body and install body props.
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I nstallation I nstructions
DANGER
HI-WAY
DUMP BODIES
Installation Instructions Continued
Mounting Dump Body 1. Make sure there is adequate clearance for the hoist if the cab shield has been installed. See Cab Shield Installation for cutout instructions if necessary. 2. See “Lifting PS350” in Installation Instructions before lifting unit onto truck. 3. Center unit from side-to-side with rear of hinge block 7” (17.8 cm) from rear of dump body as shown in Figure 12.
BOTH SILLS
CAUTION
.313
Do not remove lifting device until hoist cylinder is secured to dump body. 7.0
I nstallation I nstructions
Figure 12 – Mounting Dump Body Body Props CAUTION
Do not remove lifting device until dump body is completely welded and body props are operational.
CAUTION
Make sure dump body is securely anchored and will not shift or slide off truck. Periodically check welds and mounting hardware to make sure it is secure.
DANGER
Do not work beneath dump body without body props in place. Serious injury or death could occur from crushing.
Figure 13 – Install Body Props (1) on cradle with 3/4” hardware (2 & 3). Insert non-threaded end of Latch Pins (5) through Body Props, with bend to inside, and secure with Cotter Pins (6). Place Flange Nut (4) on threaded end of Latch Pin.
Dump Body Install-A Page Rev. A
Parts needed: ITEM DESCRIPTION 1 Body Prop 2 Cap Screw – 3/4 x 5 3 Lock Nut – 3/4 4 Flange Nut – 1/4 5 Latch Pin 6 Cotter Pin
QTY 2 2 2 2 2 2
4
5
1 6
2 3
Figure 13 – Body Prop
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Hi-Way
Installation Instructions Continued
DUMP BODIES
Place on body props by doing the following: 1. Make sure tailgate latch is open. Raise dump body with hydraulic power. 2. Lift body props and place latch pins in slot at front of hinge. 3. Tighten or loosen flange nut to position body prop under bracket as shown in Figure 13. 4. Slowly lower dump body so body props rest inside brackets. Remove body props by raising dump body enough that body props are free of bracket. Pull latch pin from hinge. Lower body props. Hoist Cylinder to Dump Body (Figure 11) 1. 2. 3. 4.
NOTICE!
Do not exceed 300° F at the Hinge Bushings. Heat can distort the Hinge Bushings. Contact Hi-Way Genuine Parts dealer for replacements if Bushings are damaged.
8. Solid weld Hinge to dump body (Figure 12) and both sides of truck frame rails (Figure 7) using full fillet welds. 9. Solid weld Cradle to Angles on truck frame rails using full fillet welds (Figure 10). Decals
NOTICE!
Install safety decals as required per “Decals” parts list and illustration in this manual. Install “Danger, Crushing Hazard” decals (PN 96704) on front of both truck frame rails, in clear view. Install “Caution, Operation Safety” (PN 96716) and “Caution, Raised Body” (PN 96715) decals in clear view in truck cab.
Some safety decals are shipped loose and must be installed by the dealer before operation of the spreader.
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Dump Body Install-A Page Rev. A
I nstallation I nstructions
Lift unit and place on body props. Attach hydraulic hoses to Hoist Cylinder ports. Carefully extend cylinder with hydraulic power. Align top trunnion pin in unit’s cylinder block. Place Upper Cap Blocks (8 – Figure 11) over trunnion pins and secure with remaining hardware. Torque as required. 5. Install Grease Zerks (9 – Figure 11). 6. Lower body. 7. Make sure cylinder is completely vertical in all directions when dump body is down (Figure 11). Adjust if necessary.
HI-WAY
Installation Instructions Continued
DUMP BODIES
CAB SHIELD (Optional) Never lift equipment over people. Use a suitable lifting device to lift the cab shield. Loads may shift or fall if improperly supported, causing injury.
CAUTION
PS350 with Underbody Hoist Option CAB SHIELD CL
I nstallation I nstructions
C
TRUCK CL
B A
2-8
TOP OF CAB SHIELD SHOULD BE ABOVE TOP OF HEADSHEET
MIN. CAB CLEARANCE
CAB HEIGHT
304 UNITS ONLY
TOP OF CAB
Hoist - 4.0
TRUCK FRAME
Figure 14 – Cab Shield Installation with Underbody Hoist A 16”/22”/30” 16 18 20 22 24 26 28 30 32 34
Dump Body Install-A Page Rev. A
B 40” 22 24 26 28 30 32 -
62.125 64.125 66.125 68.125 70.125 72.125 74.125 76.125 78.125 80.125
1. Measure cab clearance (cab height + minimum cab clearance) as shown in Figure 14 and match to “B” in chart to find corresponding “A” dimension. 2. Determine offset of cab shield to truck centerline “C” (to clear obstructions such as exhaust stack). NOTE: Side of cab shield should not extend past bolster edge. 3. Lift cab shield by its lift hook, using a crane that meets or exceeds OSHA standards. Test fit by dimension “A”. Make any necessary modifications for proper fit. 4. Clamp cab shield in place, keeping it attached to the crane, and solid fillet weld all seams.
16
Hi-Way
DUMP BODIES
Installation Instructions Continued
Body with Telescopic Hoist Option 15.00 D
MIN. CAB CLEARANCE
CAB SHIELD CL TRUCK CL
TOP OF CAB SHIELD SHOULD BE ABOVE TOP OF HEADSHEET
B A C
CAB HEIGHT
Figure 15 – Cab Shield Installation with Telescopic Hoist PS350
A 56.0 58.0 60.0 62.0 64.0 66.0 68.0 70.0 72.0 74.0 76.0 78.0
B CAB SHIELD SIZE 16”/22”/30” 40” 22.37 20.37 18.37 16.37 14.37 12.37 10.37 8.37 6.37 4.37 2.37 0.37
16.37 14.37 12.37 10.37 8.37 6.37 4.37 2.37 0.37 ----
C CAB SHIELD SIZE 16”/22”/30” 40” 15.88 17.88 19.88 21.88 23.88 25.88 27.88 29.88 31.88 33.88 35.88 37.88
21.88 23.88 25.88 27.88 29.88 31.88 33.88 35.88 37.88 ----
PS400 A 66.0 68.0 70.0 72.0 74.0 76.0 78.0 80.0
B 36 “/ 44” 32.13 30.13 28.13 26.13 24.13 22.13 20.13 18.13
52” 40.13 38.13 36.13 34.13 32.13 30.13 28.13 26.13
C 16” / 22” / 30” 25.88 27.88 29.88 31.88 33.88 35.88 37.88 39.88
40” 31.88 33.88 35.88 37.88 39.88 41.88 43.88 45.88
1. Measure cab clearance (cab height + minimum cab clearance) as shown in Figure 15 and match to “A” in chart to find corresponding “B” dimension. 2. Determine offset of cab shield to truck centerline “D” (to clear obstructions such as exhaust stack).
3. Cut 15” wide by “B” high, offset as required. 4. Lift cab shield by its lift hook, using a crane with a minimum 1,000-pound lifting capacity. Test fit by dimension “C”. Make any necessary modifications for proper fit. 5. Clamp cab shield in place, keeping it attached to the crane, and solid fillet weld all seams.
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I nstallation I nstructions
TRUCK FRAME
Mount pads - .50
HI-WAY
Installation Instructions Continued
DUMP BODIES
INSPECTION LADDER (Optional) Empty and lower body, turn off all power, set vehicle brakes, lock engine starting switch and WARNING remove keys before entering body. Tag all controls to prohibit operation. Tags should be placed, and later removed, only by person working in body. NOTICE!
Ladder is to be used for inspection purposes only. Do not use to enter dump body.
16.00
I nstallation I nstructions
1.24-2X
.50-2X
1. Position ladder on side of PS as shown in Figure 16. 2. Fillet weld all around the four ladder brackets. If ladders are being installed on both sides, they must be offset to comply with 102” max vehicle width regulations (FHWA 49USC31113).
2X 52.5 100.5
Figure 16 – Ladder Installation Storage Fold bottom portion of ladder up and lock in place by hooking to top portion with rubber hooks. BODY-UP INDICATOR (Optional) The Body-Up Indicator has a red light that indicates when the dump body is in the raised position. Install Body-Up Indicator as shown on parts pages in the back of this manual. Make sure switch lines up with elevator bolt when body is down. Adjust bolt so switch is pressed when body is down. Raise body to test Indicator. SIDE BOARDS (Not Supplied) Wood sideboards, not provided, should be cut to length and slipped into channels on both sides of unit. Bolt sideboards in place to avoid bouncing out during operation. MUDFLAPS (Optional) Consult factory.
Dump Body Install-A Page Rev. A
18
Hi-Way
DUMP BODIES
Installation Instructions Continued
COAL CHUTE (Optional)
10.13
3.0010.13
3.00
7.00 14.00
2X
7.00 14.00
2X
1. Cut opening in tailgate and through horizontal rails as shown in Figure 17. 2. Position coal chute on tailgate and fillet weld.
3.01
+.12 14.00 - .00
3.01
+.12 14.00 - .00
Figure 17 - Coal Chute Modification
TAILGATE AIR KIT (Optional) • �0.375 Air lines recommended • All ports are 0.250-NPTF
Mount Tailgate Air Valve with knob in truck cab. Determine air supply source—air manifold block or air tank. Make sure truck air brake system remains secure. Route lines from outlet pressure port on valve to air chamber.
.625 MOUNTING HOLE REQUIRED PORT #4 EXHAUST PORT SHALL BE PLUGGED
Install an air safety control valve, if necessary, into the supply port and connect the line to the valve inlet.
OUTLET PRESSURE PORT WHEN KNOB IS DOWN SHALL BE PLUGGED
Place cable ties as needed to keep air lines away from hot or moving parts. Check for leaks and proper operation.
INLET PRESSURE PORT
PORT #2 EXHAUST PORT
OUTLET PRESSURE PORT WHEN KNOB IS UP
Figure 18 – Tailgate Air Valve
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NOTE: A tailgate with vertical supports is required for the coal chute modification.
I nstallation I nstructions
HI-WAY
Installation Instructions Continued
LIGHTS (Optional) Parts Needed: ITEM DESCRIPTION 1 Red Oval Light 2 Yellow Oval Light 3 Red Round Light 4 Oval Grommet 5 Round Grommet 6 Yellow Reflector 7 Red Reflector 8 Junction Box 9 Compression Fitting 10 Compression Fitting 11 Compression Fitting 12 Harness 13 RH Harness 14 LH Harness 15 3-Light Bar HYDRAULIC HOSE
QTY 2 2 5 4 5 2 4 1 1 2 1 1 1 1 1
DUMP BODIES
The following is only an example. Make sure light installation complies with all applicable requirements prescribed by FMVSS/ CMVSS 108, state and local regulations. See Lights parts list for installation illustration. Mount 3-Light Bar (15) on rear of truck frame as required. Mount Junction Box (8, not shown) on truck frame. Install Lights (1, 2 & 3) with Grommets (4 & 5). Route all wiring to Lights and secure. Install Compression Fittings (9–11, not shown) in Junction Box and connect wiring. Protect all wiring looms and connections from corrosion. NOTE: Backup and license plate lights are not included.
CAUTION
All holes in the truck cab walls, floor and firewall for control wires, hoses and cables are to be grommeted, plugged and sealed to prevent entrance of engine fumes, dust, dirt, water and noise.
CAUTION
If a threaded connection is tightened too tightly, the fitting or housing into which the fitting is placed could be distorted and an unstoppable leak could occur. Determine the pressure port of the pump. Install the pressure hose into this port. Connect the suction hose to the opposite port and to the tank outlet on the reservoir. Use thread sealer on all fittings, except o-ring and JIC adapters, o-ring valves and motors, etc. NOTICE!
Figure 19 - Hydraulic Pump Installation
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20
Do not put thread sealer on the first three threads of the fitting. Too much on the fitting or the first three threads will force it into the oil stream where it could damage the system.
Hi-Way
DUMP BODIES
Installation Instructions Continued
HOSE Installation Guide
WRONG WRONG
RIGHT
RIGHT
WRONG
RIGHT WRONG
RIGHT
3. In straight hose installations allow enough slack in 4. Do not twist hose during installation. This can be the hose line to provide for changes in length that determined by the printed layline on the hose. will occur when pressure is applied. This change in Pressure applied to a twisted hose can cause hose length can be from +2% to -4%. failure or loosening of the connections.
WRONG WRONG
RIGHT
RIGHT
5. Keep hose away from hot parts. High ambient 6. Keep the bend radii of the hose as large as possible temperature will shorten hose life. If you cannot to avoid hose collapsing and restriction of flow. route it away from the heat source, insulate it. Follow catalog specs on minimum bend radii. (Used with the permission of The Weatherhead Company.)
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Dump Body Install-A Page Rev. A
I nstallation I nstructions
1. Use elbows and adapters in the installation to relieve 2. Install hose runs to avoid rubbing or abrasion. strain on the assembly, and to provide easier and Clamps are often needed to support long runs of neater installations that are accessible for inspection hose or to keep hose away from moving parts. It is and maintenance. Remember that metal end fittings important that the clamps be of the correct size. A cannot be considered as part of the flexible portion clamp that is too large will allow the hose to move of the assembly. in the clamp causing abrasion at this point.
HI-WAY
DUMP BODIES
Installation Instructions Continued
Frame Mount Reservoir
TRUCK CAB 3.00 CLEARANCE REQUIRED
.562 - 4X FIELD DRILL
1
2.00MIN
2 3 4
TRUCK FRAME 2.00MIN
I nstallation I nstructions
MOUNT RESERVOIR AS HIGH AS POSSIBLE.
REAR VIEW
SIDE VIEW
Figure 20 – Frame Mount Reservoir
Parts needed: ITEM DESCRIPTION 1 Reservoir 2 Cap Screw – 1/2x 1-1/2 3 Washer – 1/2 4 Lock Nut – 1/2
QTY 1 4 4 4
The 30-gallon (113.5-liter) Frame Mount Reservoir (1) mounts on the right-hand side of the truck frame as shown in Figure 20. Find a suitable location, as high as possible, with a minimum clearance of three inches above the cap. Mark hole locations, making sure they’re at least two inches from the top and bottom of the truck frame rail. Drill 0.562” (9/16”) holes and attach with 1/2” hardware (2, 3 & 4).
Filling the Hydraulic System NOTICE!
Do not attempt to run pump without first filling hydraulic reservoir with oil and opening suction line gate valve or the pump may be ruined.
Fill reservoir with hydraulic oil as specified in the Lubricant Specifications section of this manual. Be sure oil is clean, free from dirt, water, and other contaminants. Lubricate all points requiring lubrication per the Lubrication Chart in this manual. CHECKING INSTALLATION See Initial Start-Up section in the operator’s manual.
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