TAILGATE SPREADER INSTALLATION INSTRUCTIONS

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1 SPREADER (Includes Models SA-6C, SA-9 & TGC-18) EFFECTIVE 12/2015 Revision B TH AVE SW CEDAR RAPIDS, IA PHONE (319) FAX (319) Copyright 2009 Highway Equipment Company, Inc.

2 TABLE OF CONTENTS HI-WAY TABLE HEADER OF CONTENTS Table of Contents... 2 Installation Instructions... 3 Hydraulic Reservoir and Filter... 3 Cab Control Valve... 4 Tailgate Baffles... 4 Mounting of Spreader... 5 SA-6C... 5 SA TGC Conveyor Guard (TGC-18 Only)... 8 Spinner Assembly... 8 SA-6C... 8 SA TGC Leveling Mechanism (Except TGC-18) Removing Spinner Assembly Berm Chute SA TGC Hydraulic Hose Hydraulic Hose Maintenance Hose Installation Guide Filling Hydraulic System Electrical Connections Control Panel (TGC-18 Only) Mirror Installation (TGC-18 Only) Checking Installation

3 INSTALLATION HI-WAY INSTALLATION HEADER INSTRUCTIONS Due to the variations in type and model of trucks, dump bodies and PTO assemblies, no one set of instructions will be applicable to all units. The following information is offered as a guide for laying out an individual unit. Considerable latitude is permitted in mounting of parts. The mounting kits contain sufficient parts to allow mounting on most any type of truck. Read the material in this manual carefully before attempting installation. Recommended sequence of installation is as follows: 1. Mounting of pump and pump drive. 2. Installation of cab controls. 3. Mounting of spreader. 4. Installation of hydraulic hose and electrical wiring. 5. Filling hydraulic reservoir and lubrication. 6. Checking for leaks and functioning. CAUTION Be careful when drilling so as to not damage truck frame, gas tank, or any other important components. NOTICE! DO NOT WELD ON VEHICLE FRAME! Such welding can lead to fatigue cracking and must be avoided. NOTICE! DO NOT PUT HOLES INTO TOP OR BOTTOM FLANGES to do so may void truck manufacturer s warranty. When drilling holes in frame member, drill only through vertical web portions. NOTICE! Connect welders ground directly to one of the items being welded anytime an arc welder is used on the vehicle or anything connected to the vehicle. Refer to Manufacturer s instructions. Disconnect electrical components from electrical system when welding on equipment to IMPORTANT! prevent component damage due to power surges or excessive current. HYDRAULIC RESERVOIR AND FILTER (if HECO Supplied) The hydraulic reservoir is mounted on the truck frame on either side. It should be as close to the truck cab as practical and where filler neck is accessible with the suction line being as short as possible. Drill four 7/16 (1.1cm) diameter holes through the frame channel vertical web for the mounting holes for the tank brackets and bolt the reservoir into place. The filter is installed on the tank using a pipe coupling and a close nipple. Use thread sealer as explained in the Hydraulic Hose section under Installation Instructions. The oil must flow through the filter in the direction of the arrow on the filter head casting. After installation, the element should be down and vertical. 3

4 HI-WAY INSTALLATION HEADER INSTRUCTIONS CONTINUED CAB CONTROL VALVE (If HECO Supplied) When selecting a location for the cab control, there are a number of things to consider: 1. Select a suitable location for the operator to adjust the control and to turn it On and Off. 2. Check for clearance with the seat in all positions. 3. Check the transmission gear shift in all gears for clearance with the valve and the valve lever in the On and Off positions. 4. If there are any other controls, such as parking brake, plow and wing controls, check for clearance. 5. Under the cab check for interference with transmission, etc. 6. Check to see that control valve location does not interfere with entering or leaving the cab. CAUTION All holes in the truck cab walls, floor and firewall for control wires, hoses and cables are to be grommetted, plugged and sealed to prevent entrance of engine fumes, dust, dirt, water and noise. BAFFLES Tailgate baffles are furnished to bolt or weld to the inside rear corner of the tailgate. 1. Gather parts needed to install tailgate baffles in truck dump body. 2. Close the tailgate and slide each baffle down until it clears the floor by 1/8 (.3cm). Clamp into position with 1/8 (.3cm) clearance between the baffle and the side of the dump body. 3. Swing the tailgate open approximately 8 (20.3cm) and check clearance between baffles and the floor. At an 8 (20.3cm) gate opening, the leading edge of the baffle should almost touch the floor of the dump body. 4. Trim the top edge of the baffle to suit the dump body and bolt in place using hardware provided. 4

5 HI-WAY MOUNTING OF SPREADER CAUTION Stay out from under the spreader while it is supported under the truck body. Serious injury may occur if it falls. Watch out for pinch points between the spreader and the truck body. SA-6C 1. Measure overall width of dump body rub rail and overall width of spreader these dimensions must be the same or spacers must be used to make them the same. (Spacers are not included.) WELD ITEM 5 TO DUMP BODY Parts Needed: ITEM DESCRIPTION QTY 1 Spreader 1 2 Mounting Bracket 2 3 Mounting Rod 2 4 Hairpin 4 5 Anchor Boss 2 6 Mounting Brace 2 1 Figure 1 - SA-6C Mounting Raise and position Spreader (Item 1) as high as possible, usually against the bottom of the tailgate lock, with the motor to the right. Make sure the tailgate and tailgate latch can operate properly with the Spreader installed. 3. Locate a place to attach the mounting brackets on each side as shown in Figure Mark the location of the male bracket holes on each side of the spreader. Drill 17/32 (1.35cm) diameter holes where marked. 5. Bolt one male bracket to each side of the spreader using two (2) 1/2 x 1 1/2 cap screws, lock washers and hex nuts. 6. Place the female brackets (Item 2) in the male brackets and insert mounting rods (Item 3). Using the female brackets as templates, mark the hole locations on the dump body rub rail on each side. Remove mounting rods from brackets and drill 17/32 (1.35cm) diameter holes through dump body where marked. 7. Bolt one female bracket to each side of the dump body using two (2) 1/2 x 1 1/2 cap screws, lock washers and hex nuts. Install the mounting rods (Item 3) through the brackets on both sides and insert hairpins (Item 4). 8. Place one end of the mounting brace (Item 6) on the pin attached to the spreader. Position the mounting bar diagonally as shown in Figure 1 and mark the location of the mounting brace s hole on the dump body. Remove the mounting brace. 9. Weld the anchor boss (Item 5) to the dump body corner post where marked. 10. Replace mounting brace and secure with hairpins (Item 4) on both ends. 11. Repeat steps 8-10 for other side. If there is a gap between the hopper lip and the dump body rear cross member, a spill board of about 3/16 (.5cm) x 2 (5.1cm) steel may be welded to the dump body. This forms a seal at the leading edge of the spreader hopper. It may have to be notched or cut to fit around tailgate latches or other obstructions at the rear of the dump body. 5

6 HI-WAY SA-9 Position the spreader on the floor under the tailgate of the dump body with the motor to the right side. Measure the overall width of the dump body rub rail and the overall width of the spreader these dimensions must be the same or spacers must be used to make them the same. (Spacers are not included.) Figure 2 SA-9 Bracket Mounting 1 Parts Needed: ITEM DESCRIPTION QTY 1 Spreader 1 2 Male Bracket 2 3 Female Bracket 2 4 Mounting Rod 2 5 Hairpin 2 6 Anchor Boss 2 7 Mounting Brace 2 1. Gather parts needed to mount the SA-9 on the truck. 2. Raise and position the spreader as high as possible, usually against the bottom of the tailgate lock. Make sure the tailgate and tailgate latch can operate properly with the spreader installed. 3. Locate a place to attach the mounting brackets on each side as shown in Figure Mark the location of the male bracket (Item 2) holes on both sides of the spreader. Drill 17/32 (1.35cm) diameter holes where marked. 5. Bolt one male bracket (Item 2) to each side of the spreader using two (2) 1/2 x 1 1/2 cap screws, lock washers and hex nuts Place the female brackets (Item 3) in the male brackets and insert mounting rods (Item 4). Using the female brackets as a template, mark the holes on the dump body rub rail on 6 both sides. Remove mounting rods from brackets and drill 1 17/32 (1.35cm) diameter holes where marked. 7. Bolt one female bracket to each side of the dump body using two (2) 1/2 x 1 1/2 cap screws, lock washers and hex nuts. Install the mounting rods (Item 4) through the brackets on 7 both sides and insert hairpins (Item 5) Place one end of the mounting brace (Item 7) on the pin attached to the spreader. Position the mounting bar diagonally as shown in Figure 3 and mark the location of the mounting brace s hole on the dump body. Remove the mounting brace. Figure 3 SA-9 Mounting Brace 9. Weld the anchor boss (Item 6) to the dump body corner post where marked (Figure 3). 10. Replace mounting brace and secure with hairpins (Item 5) on both ends. 11. Repeat steps 8-10 for other side. If there is a gap between the hopper lip and the dump body rear cross member, a spill board of 3/16 (.48cm) x 2 (5.08cm) flat bar or similar may be welded to the dump body. This forms a seal between the dump body and spreader trough. Notching or cutting may be required to fit around tailgate latches or other obstructions at the rear of the dump body. 6

7 TGC-18 HI-WAY Figure 4 - TGC Mounting Bracket Figure 5 - TGC Leveling Mechanism 1. Locate the LH and RH mounting brackets on each side of the dump box. Position the center of the pivot 9 3/4 (10.9cm) below the dump box floor and 1 1/4 (3.18cm) past the rear of the dump box as shown in Figure 4. If the unit will use the spinner attachment, the brackets may have to be mounted further rearward. Drill mounting holes in the dump box and bolt the brackets in place. 2. To locate the stabilizer bar measure down 17 1/2 (44.45cm) from the dump box pivot point and forward 2 1/8 (35.4cm) as shown in Figure 5. Clamp the stabilizer bar to the truck frame when one of the three pivot holes are at the measured location. Mark and drill two 9/16 (1.43cm) holes in the truck frame and attach using 1/2 hardware. See Mounting parts list in operator s manual. 3. To determine the second hole location in the leveling links, measure the distance between the spreader pivot point and the dump body pivot point. This is the X dimension shown in Figure 5. Mark the leveling link the X dimension plus 1/2 (1.27cm) from the center of the single hole and drill 29/32 (2.3cm) diameter hole in all four links. The extra 1/2 (1.27cm) is to allow for settling of the spreader when it is attached. Cut off the remaining material 1 (2.54cm) past the center of the drilled hole. 4. Lift the spreader into place and pin in all three pivot point locations being sure to use the pin locking devices (cotter pin, pin catch) at each location. 5. Carefully raise the dump body through its complete range of movement. Make sure the spreader stays level. If not, adjust the position of the stabilizer bars until it does stay level. If there is a gap between the spreader and the rear of the dump box, install the spill guard belting and belt retainer supplied in the mounting kit. 7

8 HI-WAY CONVEYOR GUARD (TGC-18 ONLY) The conveyor can be set up to discharge out either side. Install the conveyor guard (see Conveyor Idler and Guard parts lists in operator s manual) on the end opposite of the discharge end. The guard will help prevent accidental entanglement with the conveyor. It bolts to four tabs that are welded to the spreader body. SPINNER ASSEMBLY SA-6C The spinner assembly is installed on two brackets near the center of the spreader underneath the trough. (Figure 5) Parts Needed: ITEM DESCRIPTION QTY 1 Spinner Assembly Figure 5 -Spinner Mount Hinge Rod 1 3 Hairpin 2 1. Assemble spinner as shown under Spinner in the parts list section in the operator s manual. 2. Install Spinner Assembly (1) by inserting Hinge Rod (2) as shown in Figure 4 and secure with Hairpin (3) at each end. 3. Vary the spread pattern by sliding the Spinner Assembly on the Hinge Rod. Place Spinner Assembly in desired position and tighten collar set screw. 8

9 HI-WAY SA-9 Figure 6 Spinner Installation Parts Needed: ITEM DESCRIPTION QTY 1 Spinner Assembly 1 2 Hinge Rod 1 3 Hairpin 2 4 Hairpin 2 5 T-Bolt 1 6 Trough Cover 1 7 1/2 x 1 Capscrew 2 8 1/2 Nut 2 1. Gather parts needed to install spinner assembly onto the SA Slide the hinge pin (Item 2) through the left trough bracket, through the spinner assembly (Item 1) and then through the right trough bracket as shown in Figure 6. Place a washer (Item 3) on each end and then insert the hairpins in both ends (Item 4). 3. The spread pattern can be varied by sliding the spinner assembly sideways on the hinge pin. Place the spinner assembly in the desired position and tighten the T-bolt (Item 5) to lock the spinner assembly to the shaft. 4. The berm chute discharge hole must be covered when using the spinner. Position the trough cover as shown in Figure 7 and attach using two (2) 1/2 x 1 capscrews and lock nuts. Figure 7 - Trough Cover The adjustable spinner baffle can be bolted to the permanent baffle behind the spinner disc to control spread width and direction. 9

10 HI-WAY TGC-18 The spinner assembly is installed by bolting to mounting holes in the left-hand end of the spreader. (Figure 8) A material chute is installed on the lefthand end of the spreader to direct material onto the spinner disc. Install the conveyor guard on the right-hand end of the unit when using the spinner attachment. With the spinner installed, the unit is 7 (17.78cm) deeper and 10 (25.4cm) higher. On some trucks, particularly with tandem axles, clearance between the spinner boom and the tire may be a problem. Check for clearance with the box in all positions. If necessary, move the entire unit further to the rear to gain adequate clearance. Figure 8 - Installing Spinner and Material Chute 10

11 HI-WAY CONTINUED LEVELING MECHANISM (EXCEPT TGC-18) DUMP BODY HINGE LEFT TRUCK FRAME RAIL WELD SOLID BOTH SIDES 6 7 SPINNER MOTOR REMOVED FOR CLARITY. 1 2,3,4 Figure 9 - Leveling Mechanism Parts Needed: ITEM DESCRIPTION QTY 1 Mounting Angle 1 2 Cap Screw 3/8 x 1-1/2 2 3 Lock Washer 3/8 2 4 Hex Nut 3/8 2 5 Frame Bracket 1 6 Linkage Rod 2 7 Hairpin 2 The leveling mechanism may now be mounted. Clamp the Frame Bracket (5) to the outside of the right truck frame rail. The center of the Frame Bracket hole should be exactly 14 (35.6cm) directly below the dump body hinge pin center line as shown in Figure 9. If this is not possible, locate the Frame Bracket hole center as close as possible ahead and/or below this point. Adjust the Mounting Angle (1) to line up withthe Frame Bracket. Install the two Linkage Rods (6), secure with Hairpins (7) and clamp together. Carefully raise the dump body through its complete range of movement. Make sure the spinner stays level throughout the range of movement. Adjust the position of the Mounting Angle and the length of the Linkage as necessary until the spinner stays level. Attach the Frame Bracket to the truck frame after it s properly aligned. Weld the Linkage Rods thoroughly at the lapped joint. Paint the welded area to retard rust formation. 11

12 HI-WAY REMOVING SPINNER ASSEMBLY The spinner assembly may be removed entirely, for berming or stockpiling, in the following manner: 1. Uncouple the quick-disconnects on both sides of the spinner assembly and connect them together. This must be done for the hydraulic system to work without the spinner assembly in place. 2. Remove the hairpins from the leveling link if applicable. Remove the leveling link. 3. Loosen the t-bolt and remove the hairpins from each end of the hinge pin. Remove the mounting shaft and the spinner assembly. 4. Store the assembly until needed. BERM CHUTE SA-9 The berm chute is installed at the right or left end of the spreader underneath the trough. (Figure 9) Parts needed: ITEM DESCRIPTION QTY 1 Berm Chute Weldment 1 2 Hairpins 1 3 Control Rod 3 1. Gather parts needed to install berm chute onto the SA When using the berm chute, the opposite discharge opening must be covered. Position the trough cover weldment over the opening and attach as shown previously in Figure 10, using two (2) 1/2 x 1 capscrews and lock nuts. 3. If berming to the right-hand side, the hydraulic hoses attached to the auger motor must be switched so the auger flighting moves material to the right-hand side of the trough. (The Hydraulic System parts list in operator s Figure 10 - Berm Chute Installation manual illustrates proper installation when using the spinner or berming to the left-hand side.) 4. Place the pin, welded to the berm chute (Item 1), through the hole in the bracket on the bottom of the trough. Insert hair pin (Item 2). 5. Install the control rod (Item 3) through the hole in the tab on the side of the trough and insert hairpin. 6. Install the other end of the control rod through the tab on the top of the berm chute and insert hairpin. 12

13 HI-WAY TGC-18 The berm chute is installed at the right or left end of the spreader underneath the trough. (Figure 11) 1. Gather parts needed to install berm chute onto the TGC When using the berm chute, the opposite discharge opening must be covered. Position the trough cover weldment over the opening and attach as shown in Figure If berming to the right-hand side, the hydraulic hoses attached to the auger motor must be switched so the auger flighting moves material to the right-hand side of the trough. (The Hydraulic System parts list in operator s manual illustrates proper installation when using the spinner or berming to the left-hand side.) Figure 11 - Berm Chute Assembly HYDRAULIC HOSE Determine the pressure port of the pump (Figure 12). Install the pressure hose into this port. Connect the suction hose to the opposite port and to the tank outlet on the reservoir. If necessary, use plastic tie straps to support hoses so they will not catch on field obstructions, or contact muffler or moving parts. Use thread sealer on all fittings, except O-ring and JIC adapter, O-ring valves and motors, etc. When using thread sealer, do not put in on the first three threads of the fitting. Too much on the fitting or on the first three threads will force it into the oil stream where it could damage the system. Figure 12 - Hydraulic Pump Assemble the system as shown in the Hydraulic System section undergeneral Operating Procedures in the operator s manual. Place the hose clamps as needed to keep hoses away from hot or moving parts. Do not let hoses hang so low as to be snagged. Do not stretch hoses tight. The Hydraulic Hoses supplied are as follows: Pressure Line - Two wire braid hose, one end fitting crimped on, the other end fitting to be field installed after cutting hose to length. See assembly instructions on the following page. Suction Line - Single spiral wire reinforced to be cut to length. Fittings to be assembled with double hose clamp. All Return Lines - Double cotton braid to be cut to length as necessary. Fittings to be assembled with single hose clamps. 13

14 HI-WAY HYDRAULIC HOSE MAINTENANCE WARNING To prevent serious personal injury testing should be conducted in approved test stands with adequate guards to protect the operator. Hose assemblies in operation should be inspected frequently for leakage, kinking, abrasion, corrosion or any other signs of wear or damage. Worn or damaged hose assemblies should be replaced immediately. Clean Clean assembly by blowing out with clean compressed air. Assemblies may be rinsed out with mineral spirits if the tube stock is compatible with oil, otherwise hot water at 150 F (65.55 C) maximum may be used. STORAGE AND HANDLING Inspect Examine hose assembly internally for cut or bulged tube, obstructions, and cleanliness. For segment style fittings, be sure that the hose butts up against the nipple shoulder; band and retaining ring are properly set and tight, and segments are properly spaced. Check for proper gap between nut and socket or hex and socket. Nuts should swivel freely. Check the layline of the hose to be sure the assembly is not twisted. Cap the ends of the hose with plastic covers to keep clean. Test The hose assembly should be hydrostatically tested at twice the recommended working pressure of the hose. Test pressure should be held for not more than one minute and not less than 30 seconds. When test pressure is reached, visually inspect hose assembly for: 1. Any leaks or signs of weakness. 2. Any movement of the hose fitting in relation to the hose. Any of these defects are cause for rejection. Hose should be stored in a dark, dry atmosphere away from electrical equipment, and the temperature should not exceed 90 F (32 C). 14

15 HI-WAY HOSE INSTALLATION GUIDE WRONG RIGHT WRONG RIGHT 1. Use elbows and adapters in the installation to relieve strain on the assembly, and to provide easier and neater installations that are accessible for inspection and maintenance. Remember that metal end fittings cannot be considered as part of the flexible portion of the assembly. 2. Install hose runs to avoid rubbing or abrasion. Clamps are often needed to support long runs of hose or to keep hose away from moving parts. It is important that the clamps be of the correct size. A clamp that is too large will allow the hose to move in the clamp causing abrasion at this point. WRONG RIGHT WRONG RIGHT 3. In straight hose installations allow enough slack in the hose line to provide for changes in length that will occur when pressure is applied. This change in length can be from +2% to -4%. 4. Do not twist hose during installation. This can be determined by the printed layline on the hose. Pressure applied to a twisted hose can cause hose failure or loosening of the connections. WRONG RIGHT WRONG RIGHT 5. Keep hose away from hot parts. High ambient temperature will shorten hose life. If you cannot route it away from the heat source, insulate it. 6. Keep the bend radii of the hose as large as possible to avoid hose collapsing and restriction of flow. Follow catalog specs on minimum bend radii. (Used with the permission of The Weatherhead Company.) 15

16 HI-WAY FILLING HYDRAULIC SYSTEM NOTICE! DO NOT attempt to run pump without first filling hydraulic oil reservoir and opening suction line gate valve, or pump may be ruined. Fill reservoir with hydraulic oil as specified in the Lubricant Specifications section in the operator s manual. Be sure oil is clean, free from dirt, water and other contaminants. Lubricate all points requiring lubrication per Lubrication Chart in the operator s manual. ELECTRICAL CONNECTIONS Connect any electrical control circuits. The supply conductor should be connected to the accessory terminal of the truck ignition switch through a five amp line fuse. All wiring should be approved automotive insulated wire. It should be supported adequately with insulating ties or straps and be located where it won t interfere with any control access, does not contact any moving parts or sharp edges and is kept away from any hydraulic lines or heated parts. All lights and reflectors which are blocked by the spreader must be moved to meet all applicable local, regional or national codes. CONTROL PANEL (TGC-18 ONLY) The control panel is equipped with a conveyor indicator light. The purpose of the indicator light is to be aware when the conveyor is running. The control panel must be mounted in the cab such that the indicator light is clearly visible. The pressure switch that activates the indicator light must be plumbed into the conveyor hydraulic circuit. (See Hydraulic System parts list in operator s manual, item 52) Wire as shown in figure 5. (See Control Panel parts list in operator s manual.) NOTICE! The conveyor must be moving (Indicator light on) whenever the dump box is being raised. Failure to do so will result in the shearing of the leveling link shear pin and possible damage to the conveyor hopper. Figure 5 - Conveyor Indicator Light 16

17 HI-WAY MIRROR INSTALLATION (TGC-18 ONLY) The mirror is used to monitor the material flow into the conveyor. It can be mounted to the left or the right side of the spreader. Bolt the mirror mount to the spreader through the existing hole in the lip of the spreader, and attach mirror (Figure 6). Rotate the mounting weldment and /or adjust mirror so that from the driver s seat the conveyor is visible. Drill a 9/32 (.71cm) diameter hole for the lower mounting hole and secure with the enclosed hardware. Figure 6 - Conveyor Mirror CHECKING INSTALLATION See Initial Start-Up section in operator s manual. 17

18 HI-WAY HEADER NOTES This page is intentionally left blank. 18

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