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 Contents HI-WAY Table header of Contents 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 2
I n stallation i n stallation Instructions Hi-Way Installation Instructions Recommended sequence of installation: 1. Hinge, if applicable 6. Decals 2. Cradle, if applicable 7. Options* 3. Hoist Underbody or Cylinder 8. Hydraulics 4. Dump Body 9. Lights 5. Body Props * The cab shield may be installed before the dump body is mounted on the truck for easier access. HYDRAULICS Hydraulic System Requirements FLOW REQUIREMENTS PUMP TYPE 20 GPM (76 LPM) Gear or load sense PUMP PRESSURE CONTROL TYPE FILTRATION RESERVOIR RELIEF VALVE 2200-2500 PSI (151.8-172.5 Bar) operating Manual Electric solenoid Return line filter, 10 Micron 30 gallon (113.5 liter) frame mount with sight gauge 2000 PSI (138 Bar) at pump or control valve RECOMMENDED HOSE Pressure line 0-9 GPM (0-34 LPM).500 dia 100R1(min) 9-20 GPM (34-76 LPM).75 dia. 100R2 20-36 GPM (76-136 LPM) 1.00 dia. 100R2 Return line 0-35 GPM (0-132 LPM) 1.00 dia. 100R1 35-57 GPM (132-216 LPM) 1.25 dia. 100R1 Suction line 0-22 GPM (0-83 LPM) 1.50 dia. 100R4 22-40 GPM (83-151 LPM) 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 100 300 PSI (7-21 Bar) Relief valve for extending 2000 PSI (138 Bar) PLOWS & ACCESSORIES Refer to manufacturer s manual. 3
HI-WAY 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 Installation Instructions Unit Length 55 MAX Figure 1 Lifting Maximum Angle from Vertical A A (Figure 6) Sling Leg Length 99 (25 mm) 10 (31 mm) 12 (37 mm) 113 (29 mm) 13 (40 mm) 120 (30 mm) 55 14 (43 mm) 126 (32 mm) 15 (46 mm) 132 (34 mm) 16 (49 mm) 138 (35 mm) Attach a 4-point harness to the front lift hooks and rear corner bolsters as shown in Figure 1 DANGER 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 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. Do not remove lifting device until dump body is secured to truck. Lift with a maximum 55 angle from vertical to prevent damage to the unit (35 minimum angle from horizontal). 4
I n stallation Instructions Hi-Way MOUNTING PS350 WITH UNDERBODY HOIST Truck Preparation 3.00 MINIMUM 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. 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. 41 31/64" Figure 2 Truck Modification TEST FIT & REMOVE EXCESS FRAME 11 5/8" CENTER OF HINGE PIN TO REAR OF PS FLOOR 5
HI-WAY Hoist 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. Do not puncture gas tank or harm any other obstruction when drilling holes. Do not leave raised body unattended. Do not raise body on unlevel ground. Check for overhead power lines and other obstructions before raising body. Installation Instructions CAB LOCATE MOUNT PLATES AT HOIST CROSS SUPPORTS TRUCK RAIL 3.00 MINIMUM 2.00 MINIMUM 2.00 MINIMUM 90 Figure 3 Hoist Position LOCATE REAR MOUNT PLATES UNDER HINGE.656-10X FIELD DRILL BOTH SIDES Figure 4 Hoist Mounting 90 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. DO NOT PUT HOLES IN TOP OR BOTTOM FLANGES to do so may void truck m a n u f a c t u r e 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. Do not weld directly to truck frame. Such welding could lead to fatigue cracking and must be avoided. Connect arc welder s ground directly to one of the two items being welded before using welder on anything connected to the vehicle. 6
I n stallation Instructions Hi-Way 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 LINE UP ARMS & INSTALL PINS 2X Figure 5 Dump Body Mounting Do not remove lifting device until dump body is completely welded and body props are operational. 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. 7
HI-WAY Body Props DANGER Do not work beneath dump body without body props in place. Serious injury or death could occur from crushing. 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. BODY PROP Installation Instructions 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. 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. 8
I n stallation Instructions Hi-Way MOUNTING OF BODY WITH TELESCOPIC HOIST Hinge Connect arc welder s ground directly to one of the two items being welded before using welder on anything connected to the vehicle. 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. BOTH TRUCK FRAME RAILS DO NOT WELD TO TRUCK FRAME! BOTH TRUCK FRAME RAILS DO NOT WELD TO TRUCK FRAME! 4.50 W/ PADS 5.00 W/O PADS EVEN WITH MOUNT SURFACE 4.00 Figure 7A PS350 Hinge Installation EVEN WITH MOUNT SURFACE 6.00 W/ PADS 6.50 W/O PADS 8.00 Figure 7B PS400 Hinge Installation HINGE BLOCK 5.00 HINGE BUSHING HINGE ANGLE HINGE BLOCK 6.50 HINGE BUSHING HINGE ANGLE 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. 9
HI-WAY 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. 5" MAX FROM CRADLE 2 3 4 5 28.438 - TYP 22 - TYP 5" MAX FIELD DRILL FROM HINGE Installation Instructions 2" MIN SECTION VIEW Parts needed: ITEM DESCRIPTION QTY 1 Mount Pad AR 2 Mount Angle AR 3 Cap Screw 3/8 x 1-1/4 AR 4 Lock Washer 3/8 AR 5 Hex Nut 3/8 AR AR As Required TYP..125 Figure 8 Mounting Pads 1 TRIM RUBBER TO WELD MOUNT ANGLES TO MOUNT PAD'S METAL BASE 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. 10
I n stallation Instructions Hi-Way Cradle & Hoist Cylinder to Truck BODY SIZE A (Figure 9) (CRADLE FRONT TO HINGE FRONT) 10 (31 mm) 105.635 (27 mm) 12 (37 mm) 129.635 (33 mm) 13 (40 mm) 141.635 (36 mm) 14 (43 mm) 153.635 (39 mm) 15 (46 mm) 165.635 (42 mm) 16 (49 mm) 177.635 (451 cm) HINGE A B Parts needed: ITEM DESCRIPTION QTY 1 Cradle 1 2 Angle 2 3 Cap Screw 5/8 x 2 GR 8 8 4 Lock Washer 5/8 8 5 Hex Nut 5/8 GR 8 8 6 Hoist Cylinder 1 7 Lower Cap Block 2 8 Upper Cap Block 2 9 Grease Zerk 4 10 Cap Screw 1/2 x 3-3/4 8 11 Lock Washer 1/2 8 C 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. 1. Center Cradle (1) on truck frame rails as CAB shown in Figures 9 & 10, and distance from Hinge according to chart above. Figure 9 Hinge/Cradle Square 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). 11
HI-WAY 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. 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. Do not weld directly to truck frame. Such welding could lead to fatigue cracking and must be avoided. 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. Installation Instructions HOIST CYLINDER CENTERLINE 1.50 4" MINIMUM 2 2X 1 3 4 5.688"-8X FIELD DRILL SECTION CUT AWAY TO SHOW UPPER CYLINDER MOUNT Figure 10 Cradle Installation A 2X 2X 12
I n stallation Instructions Hi-Way SECTION VIEW 90 6 8 11 10 9 90 TOP VIEW 90 7 FRONT VIEW Figure 11 Hoist Cylinder Installation DANGER 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. Do not leave raised body unattended. Do not raise body on unlevel ground. Check for overhead power lines and other obstructions before raising body. 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. 13
HI-WAY 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.313 Do not remove lifting device until hoist cylinder is secured to dump body. 7.0 Installation Instructions Body Props Figure 12 Mounting Dump Body DANGER 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. Do not remove lifting device until dump body is completely welded and body props are operational. 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. Do not work beneath dump body without body props in place. Serious injury or death could occur from crushing. Parts needed: ITEM DESCRIPTION QTY 1 Body Prop 2 2 Cap Screw 3/4 x 5 2 3 Lock Nut 3/4 2 4 Flange Nut 1/4 2 5 Latch Pin 2 6 Cotter Pin 2 4 5 1 6 2 3 Figure 13 Body Prop 14
I n stallation Instructions Hi-Way 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. Lift unit and place on body props. 2. Attach hydraulic hoses to Hoist Cylinder ports. 3. Carefully extend cylinder with hydraulic power. Align top trunnion pin in unit s cylinder block. 4. 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. 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 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. 15
HI-WAY 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. PS350 with Underbody Hoist Option C CAB SHIELD C L TRUCK C L MIN. CAB CLEARANCE TOP OF CAB SHIELD SHOULD BE ABOVE TOP OF HEADSHEET Installation Instructions 2-8 A B 16 /22 /30 40 16 22 62.125 18 24 64.125 20 26 66.125 22 28 68.125 24 30 70.125 26 32 72.125 28-74.125 30-76.125 32-78.125 34-80.125 A 304 UNITS ONLY B CAB HEIGHT TOP OF CAB Hoist - 4.0 Figure 14 Cab Shield Installation with Underbody Hoist TRUCK FRAME 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
I n stallation Instructions Hi-Way Body with Telescopic Hoist Option D 15.00 CAB SHIELD C L TRUCK C L MIN. CAB CLEARANCE TOP OF CAB SHIELD SHOULD BE ABOVE TOP OF HEADSHEET B C A CAB HEIGHT Mount pads -.50 TRUCK FRAME Figure 15 Cab Shield Installation with Telescopic Hoist PS350 B C A CAB SHIELD SIZE CAB SHIELD SIZE 16 /22 /30 40 16 /22 /30 40 56.0 22.37 16.37 15.88 21.88 58.0 20.37 14.37 17.88 23.88 60.0 18.37 12.37 19.88 25.88 62.0 16.37 10.37 21.88 27.88 64.0 14.37 8.37 23.88 29.88 66.0 12.37 6.37 25.88 31.88 68.0 10.37 4.37 27.88 33.88 70.0 8.37 2.37 29.88 35.88 72.0 6.37 0.37 31.88 37.88 74.0 4.37 -- 33.88 -- 76.0 2.37 -- 35.88 -- 78.0 0.37 -- 37.88 -- PS400 A B C 36 / 44 52 16 / 22 / 30 40 66.0 32.13 40.13 25.88 31.88 68.0 30.13 38.13 27.88 33.88 70.0 28.13 36.13 29.88 35.88 72.0 26.13 34.13 31.88 37.88 74.0 24.13 32.13 33.88 39.88 76.0 22.13 30.13 35.88 41.88 78.0 20.13 28.13 37.88 43.88 80.0 18.13 26.13 39.88 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. 17
HI-WAY INSPECTION LADDER (Optional) WARNING Empty and lower body, turn off all power, set vehicle brakes, lock engine starting switch and remove keys before entering body. Tag all controls to prohibit operation. Tags should be placed, and later removed, only by person working in body. Ladder is to be used for inspection purposes only. Do not use to enter dump body. 16.00 1.24-2X 1. Position ladder on side of PS as shown in Figure 16. 2. Fillet weld all around the four ladder brackets. Installation Instructions Storage 100.5 52.5 2X Figure 16 Ladder Installation Fold bottom portion of ladder up and lock in place by hooking to top portion with rubber hooks. BODY-UP INDICATOR (Optional).50-2X If ladders are being installed on both sides, they must be offset to comply with 102 max vehicle width regulations (FHWA 49USC31113). 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. 18
I n stallation Instructions Hi-Way COAL CHUTE (Optional) 10.13 NOTE: A tailgate with vertical supports is required for the coal chute modification. 3.00 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 Figure 17 - Coal Chute Modification TAILGATE AIR KIT (Optional) 0.375 Air lines recommended All ports are 0.250-NPTF PORT #4 EXHAUST PORT SHALL BE PLUGGED INLET PRESSURE PORT PORT #2 EXHAUST PORT.625 MOUNTING HOLE REQUIRED OUTLET PRESSURE PORT WHEN KNOB IS DOWN SHALL BE PLUGGED OUTLET PRESSURE PORT WHEN KNOB IS UP 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. Install an air safety control valve, if necessary, into the supply port and connect the line to the valve inlet. Place cable ties as needed to keep air lines away from hot or moving parts. Check for leaks and proper operation. Figure 18 Tailgate Air Valve 19
HI-WAY LIGHTS (Optional) Installation Instructions Parts Needed: ITEM DESCRIPTION QTY The following is only an example. Make sure light installation 1 Red Oval Light 2 complies with all applicable requirements prescribed by FMVSS/ CMVSS 108, state and local regulations. 2 Yellow Oval Light 2 3 Red Round Light 5 See Lights parts list for installation illustration. 4 Oval Grommet 4 5 Round Grommet 5 Mount 3-Light Bar (15) on rear of truck frame as required. 6 Yellow Reflector 2 Mount Junction Box (8, not shown) on truck frame. 7 Red Reflector 4 Install Lights (1, 2 & 3) with Grommets (4 & 5). Route all wiring to 8 Junction Box 1 Lights and secure. Install Compression Fittings (9 11, not shown) 9 Compression Fitting 1 in Junction Box and connect wiring. Protect all wiring looms and connections from corrosion. 10 Compression Fitting 2 11 Compression Fitting 1 NOTE: Backup and license plate lights are not included. 12 Harness 1 13 RH Harness 1 14 LH Harness 1 15 3-Light Bar 1 HYDRAULIC HOSE 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. 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. Figure 19 - Hydraulic Pump Installation 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. 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. 20
I n stallation Instructions 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.) 21
HI-WAY Frame Mount Reservoir TRUCK CAB 3.00 CLEARANCE REQUIRED.562-4X FIELD DRILL 2.00MIN 1 2 3 4 TRUCK FRAME 2.00MIN MOUNT RESERVOIR AS HIGH AS POSSIBLE. SIDE VIEW REAR VIEW Installation Instructions Parts needed: ITEM DESCRIPTION QTY 1 Reservoir 1 2 Cap Screw 1/2x 1-1/2 4 3 Washer 1/2 4 4 Lock Nut 1/2 4 Filling the Hydraulic System Figure 20 Frame Mount Reservoir 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). 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. 22